CLG920D - 922D Service Manual201506001-EN

201506001
Service Manual
CLG920D/922D
Excavator
Applicable type and model: CLG920D/922D Cummins QSB7

Contents
Safety ........................................................... 1-1

Foreword...................................................... 2-1
Structural Function and Maintenance....... 3-1
Parameters................................................... 4-1
Testing and Adjusting ................................ 5-1
Fault Diagnosis ........................................... 6-1
Removal and Installation............................ 7-1
1-1
CLG920D/922D
June 10, 2015
1 Safety
1.1 Safety precautions ......................................................................................... 1-4

Compressed air ................................................................................................... 1-6
High-pressure solution ........................................................................................ 1-7
Safe disposal of waste liquid ............................................................................... 1-8
Precautions for accumulator application ............................................................. 1-8
Asbestos ............................................................................................................. 1-9
Prevention of extruding or cutting-off .................................................................. 1-9
Prevention of burns ........................................................................................... 1-10
Coolant .............................................................................................................. 1-10
Oil ...................................................................................................................... 1-11
Battery ............................................................................................................... 1-11
Protection for fire and explosion ........................................................................ 1-12
Diethyl ether ...................................................................................................... 1-13
Piping, pipe and hose ........................................................................................ 1-13
Fire extinguisher and first aid kit ........................................................................ 1-14
Prevention of injury by thunder .......................................................................... 1-14
Cab protector ..................................................................................................... 1-15
Inner space of cab ............................................................................................. 1-15
Precautions for accessories .............................................................................. 1-16
1.2 Precautions for lifting and matching operations ................................... 1-17
Precautions for operating mobile crane ............................................................. 1-18
Precautions for operating bridge crane ............................................................. 1-18
Selection of rope ............................................................................................... 1-19
1-2
CLG920D/922D
June 10, 2015
1-3
CLG920D/922D
June 10, 2015
Most accidents related to product operation, maintenance and repair result from neglect of basic
safety rules or protective measures. Before such accidents, if we had attached more importance,
the potential accidents could have been avoided. The relevant personnel shall be familiar with the
potential accident dangers, and accept necessary training to obtain certain troubleshooting skills
by using tools. Incorrect operation, lubrication, maintenance and repair shall be of great danger,
and if serious, personnel death may happen. Before reading and understanding the operation,
lubrication, maintenance and repair contents, no operation, lubrication, maintenance or repair shall
be permitted on the machine.
The safety precautions and warnings are all listed in this manual and on the product. If such warn-
ings are ignored, related personnel death may happen.
Any risk is marked with "Sign of Safety Warning" followed by "Signal Terminology", such as
"DANGER", "WARNING" and "NOTICE". "WARNING" identification for safety is as follows:

The meaning of the safety warning symbol is as follows:
Notice! Be careful! For your safety!
The content of danger is interpreted with text or diagram under warning sign. Such operations possibly
leading to damages of the machine all have "NOTICE" or "WARNING" marked on the machine and in this
manual. It is impossible for LiuGong to predict every dangerous working environment, so the warnings in
this manual and on the product are somewhat not exhaustive. If any tool, procedure, method or technique
not specifically recommended by LiuGong is applied, you should make sure of your own or others' safety,
and that no operation, lubrication, maintenance or repair program you have selected would make the
machine damaged or endangered. The instructions, numerical values and illustrations in this manual are
prepared according to the currently latest available data. Due to continuous improvement on the design of
this machine, the details may have changes possibly unavailable in this manual.
For the machine-related latest information or any doubt on the data in this manual, please contact
LiuGong or LiuGong's dealers.
Article 65 of California Suggestions

California considers that exhaust from diesel engines and some of its ingredients can lead to cancer, and
cause birth defects or other harms on reproduction.
Battery posts, battery electrodes and relevant accessories contain lead and lead compounds, which
require washing hands after touch.
1-4
1.1 Safety precautions CLG920D/922D
June 10, 2015
1.1 Safety precautions Do not wear loose clothes, jewelries or long

hair. Because they may be drawn into the
Please read and be familiar with all safety control system or the mobile parts and lead
rules to avoid the occurrence of severe dam- to severe damage or even death.
age or even death.
Only trained and qualified persons are per-
mitted to operate and maintain the machine.
When operating and maintaining the

If you feel uncomfortable, feel sleepy after machine, please wear the helmet, ear cover
taking medicine or have drunk, do not oper- and safety glasses of hard material as well
ate the machine. In the case, it may cause as safety shoes, mask and gloves.
your misjudgement and possibility of acci-
dents. Before maintaining and repairing the
machine, please hang the labels of "Do not
Operate" or similar warnings on the starting
switch or the operation lever.
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1-5
CLG920D/922D 1.1 Safety precautions
June 10, 2015
Goggles, safety glasses or mask can protect

your eyes from the hazards of high-pressure • Make sure all guard plates and covers of
fluid during the maintenance of the battery the machine are fastened to the machine.
and the hazards of flying debris generated • Please ensure that there is no chip, greasy
during the work of the engine and the opera- dirt, tool or other foreign matters irrelevant
tion of tools. Please wear the protection to the machine on the machine, especially
mask when removing spring, elastic parts or on the instrument panel, channel and stair-
add acid to the battery. Please wear the case. Put the scattered things in place,
safety cap and goggles when conducting such as the lunch boxes and tools. Prevent
welding operations or using the welding gun foreign matters from entering the compo-
for cutting. nents of the system when inspecting the
opened oil tanks or water tanks. Please
empty the clothes pockets and move
wrenches and nuts with great care before
removing the cover.
If you work under loud noise, please wear

appropriate hearing protection devices, such
as earmuff or earplug, to avoid damage to
hearing due to loud noise.
• Learn about the gesture singles and the

signal sources at the working site and only
receive the signals from one person.
• Never keep the maintenance and repair
solution in glass containers.
• Please observe relevant laws and regula-
tions when disposing hazardous materials
such as lubricant, fuel, coolant, solution, fil-
ter, battery and other materials.
• When using detergent, be careful. Do not
1-6
Compressed air June 10, 2015
use inflammable materials as detergents, Compressed air

such as diesel or gasoline. It may catch
fire. Compressed air may lead to personal injury.
When using the compressed air for cleaning,
wear the mask, protection suits and shoes. Do
not point the compressed air to others or one-
self. The compressed air may penetrate the skin
and lead to severe injury or even death. The
maximum pressure of the compressed air for
cleaning should be lower than 0.2 MPa.
• Report all necessary repair work in a timely

manner.
• Persons without permission or authoriza-
tion cannot stay onto or around the
machine.
• It is prohibited to modify the machine with-
out LiuGong's consent, and LiuGong will
not be responsible for the aftermath due to
modification.
1-7
June 10, 2015 High-pressure solution
High-pressure solution Even if the pressured liquid is leaked from a

hole as small as a pin hole, it may penetrate
 Warning: the muscles and lead to death. If shot by the
spouted high-pressure oil, please contact a
• When overhauling or replacing the pipes of
doctor and take a medical treatment immedi-
hydraulic system, you shall check the sys-
ately.
tem pressure had been released in order to
prevent from being scalded by high-pres-
sure oil. Hydraulic oil under pressure will
damage your skin severely when it spat-
tered on you.
• Take care when dismantling the hydraulic
pipelines or connectors. When the oil
spouts, the released high-pressure oil may
lead to the continuous movement of the
hoses.
• Please wear safety glasses and leather
gloves when checking for leakages. Do not
use bare hands to check the leakage but
plate or paper plate.
1-8
Safe disposal of waste liquid June 10, 2015
Safe disposal of waste liquid Precautions for accumulator

• Inappropriate disposal of waste liquid will application
endanger environment and ecology.
• The dangerous high-pressure nitrogen is
Please observe local laws and regulations
contained in the accumulator, so read the
when disposing the waste liquid.
following requirements and properly use
• It is mandatory and necessary to collect the
the accumulator.
liquid spattered during the inspection,
• The accumulator must be checked before
maintenance, test, adjustment and repair of
the charging of nitrogen. It is prohibited to
containers. Before opening any fluid cavity
charge the accumulator with air if the accu-
or disassembling the parts containing liq-
mulator does not have a nameplate, or the
uid, the proper container shall be prepared
words of the nameplate are missed and
well firstly. Use proper container when
unable to be identified with the type, or if
draining liquid. Do not use the food or drink
the steel seal marks are incomplete or can-
containers because they may be drunk by
not be read clearly, or if there is defect with
others by mistake.
the body and therefore safe use cannot be
ensured.
• The accumulator can only be charged with
nitrogen. It is prohibited to charge the accu-
mulator with oxygen, compressed air or
other flammable air to avoid explosion.
• Slowly charge the nitrogen into the accu-
mulator so as to avoid the breakage of the
capsule.
• The air valve of the accumulator shall be
mounted upward vertically. The accumula-
tor must be stably fastened to the bracket.
Do not weld to fasten the accumulator.
• Do not drill any hole on the accumulator or
carry open fire or heat sources close to the
accumulator.
• Never conduct any welding operation on
the accumulator.
• Since the accumulator is a high-pressure
container, it must be replaced and repaired
by professional operators.
• Release the air before discarding the waste
accumulator.
1-9
June 10, 2015 Asbestos
Asbestos Prevention of extruding or

If asbestos dust is sucked in, it will endanger cutting-off
your health. This product does not contain
• Do not make your hands, arms or any other
asbestos and LiuGong Machinery Co. Ltd
bodies placed among the moving parts.
recommends using genuine LiuGong spare
E.g. between work implement and cylinder,
parts. If materials that you need to deal with
between machine and working implement.
contain asbestos fiber, please observe the
• When working under the work implement,
following rules:
you shall support the equipment properly.
• Never use compressed gas when cleaning.
Do not support the work implement
Water can be used for descending the dust.
depending on hydraulic cylinder. If control
• You can use the vacuum cleaner with high
mechanism moves or hydraulic oil line
filtering properties.
leaks, work implement will drop. If it is
• Do not grind the materials containing necessary to remove the shield, you must
asbestos dust. fix well the shield after the repair.
• In possible case, the engine shall be oper- • Revolving vane of engine has the risk of
ated in the upstream air. cutting the fingers, so shut down the engine
• Please observe local laws and regulations or keeping a safety distance when repair-
when disposing asbestos. ing.
• Bath your body after contacting with asbes-
tos.
• If necessary, effective protective mask can
be used.
LG856H01304
• Make sure there's no foreign matter in the

vanes of engine fan. Fan vanes will throw
out or cut off the tools and other things that
dropped or pushed in it.
• Unless otherwise stated, any adjustment is
not permitted to be performed when
machine or engine is running.
1-10
Prevention of burns June 10, 2015
• If the repair procedure must be performed Coolant

when machine is running, do not let the
machine stay in an unattended status. At working temperature, the coolant of the
Arrange one operator seated in the seat engine is at high temperature and has pres-
and prepare to shut down the engine at any sure, the radiator and all the pipes con-
times. nected to the radiator contain hot water or
vapor, if you touch them, serious burn would
• Do not use twisted or worn wire rope. Wear
occur.
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 you eyes.
• When knocking object with hammer, please
make sure the flying debris will not hurt oth-
ers.
Prevention of burns
After running for some time, parts of the
machine will be hot and those parts shall be
LG856H01305
inspected or repaired after it is cooled down.
• When checking the coolant level, the

engine shall be shut off and the filler cap
shall be cooled to the extent that it can be
opened by bare hands.
• Slowly loosen the filler cap of cooling sys-
tem to release the pressure.
• Coolant contains alkali which may causing
injury and do not let it contact your skin,
eyes and mouth.
1-11
June 10, 2015 Oil
Oil Battery
Hot oil and parts will cause personnel injury, • Smog discharged from the battery may
and do not let the hot oil and parts contact cause explosion.
your skin. • 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 con-
tact electrolyte.
• You shall wear safety goggles and gloves
when inspecting battery.
LG856H01306
• 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 and cool the filler
cap down until it can be opened by bare
hands. Remove the tank cover slowly to
release the pressure of hydraulic oil tank so
as to prevent from being scalded by hot oil.
• Before disassembling all pipes, connector,
or relevant parts, and release the system
pressure.
1-12
Protection for fire and explosion June 10, 2015
Protection for fire and explo- cleaned completely.

• Accumulated combustible materials such
sion as fuel, lubricant or other scattered materi-
• All fuels, such as most of lubricants and als on the machine shall be cleaned up.
some cooling agent are flammables. • Do not operate the machine near open fire.
• Fuel leaking onto the hot surface or electri- Make sure the battery is far away from
cal elements may cause fire. open fire and sparks, and do not smoke at
• Do not smoke when refilling or within refil- the place of battery charing.
ing area, and in the place storing flamma- • When the machine is started with a jump
bles. method, the (+) cable must be connected to
battery (+) terminal which is connected with
start motor coil, and (-) of external power is
connected with (-) of the starter. If there is
no starter negative terminal, it shall be con-
nected to the engine housing.
• Do not charge the frozen battery to avoid
explosion.
• Clean and tight all the electrode connec-

tors. Daily inspect the wire for looseness or
wear. Before start, tighten the loose power
supply switch, and repair or replace the
worn electric wires.
• Store the fuel, lubricant into containers with
relevant marks to avoid use by non-working
personnel.
• Put the cleaning cloth or other combustible
materials with oil soaked into protective
container, and set it at a safe place.
• Do not perform welding or flame cutting
onto the pipe containing flammable liquid.
Before welding or cutting, the operation
shall be performed until flammable liquid is
1-13
June 10, 2015 Diethyl ether
Diethyl ether Piping, pipe and hose

 Warning: Ether is forbidden for starting • Do not warp or knock the high-pressure
pipe, and do not install the abnormally
machine.
warped or broken pipe or hose onto the
Any attempt of using ether to start the
machine.
engine may cause serious damage of engine
• Repair the loose or damaged pipe and
or personnel injury or even death.
hose of fuel and lubricant pipeline and
hydraulic system in time. Leakage will
cause fire hazard, and if repair or replace-
ment is necessary, please contact the
authorized dealer by LiuGong Machinery
Co., Ltd.
If following problems occur, it shall be replaced:
• Damage or leakage of connector.
• Exterior hose wear or cut and exposed
reinforced steel wires.
• Partial bulge of hose.
• Hose with obvious twisting or flattening.
LG856H01302
• Reinforced hose guide wire is embedded
into the outer layer.
• Misplacement of the end connectors.
Make sure all clamps, guard and heat shield are
installed correctly to prevent shaking or over-
heating by friction with other parts.
When removing the connecting pipe of the com-
pressor, open fire is forbidden, or it will generate
toxic gas, resulting in poisoning.
1-14
Fire extinguisher and first aid kit June 10, 2015
Fire extinguisher and first aid Prevention of injury by thunder

kit Never try to access the machine when there
is lightning near it.
• Be sure to equip fire extinguisher, carefully
If the thunder occurs when you sit in the cab,
read its use instructions, and be sure to
please stay in cab; if you're on the ground,
know how to use it.
please keep away from the machine.
• The construction site must have first-aid kit
in stock. Conduct regular inspection and
add some medicines if necessary.
• You should know how to do when catching
a fire or being injured.
• Select some contacts of phone number
(such as doctor, first-aid center, fire station
and so on) for use in emergency. Paste the
contact list onto specified location to
ensure all staff known the contact informa-
tion and correct communication ways.
Inspect and maintain the fire extinguisher

frequently. Follow the recommended method
of application listed on the instruction panel.
1-15
June 10, 2015 Cab protector
Cab protector Measures in emergency

Use the escape hammer placed in the cab to
Top guard and front guard
break window glass and get out of cab when
The protectors are installed in order to prevent encountering emergency situations.
falling or splashing objects from injuring the
driver under some special circumstances. Be
sure to close the window before doing hazard-
ous work. All personnel except the driver must 1
be away from hazardous zone. Please add TOP

Guard and FRONT Guard when necessary.
2
LG906D01002
2 1. Escape hammer 2. Fire extinguisher (optional)

Inner space of cab
This LiuGong device is equipped with and meet
the industry standard of: "SAE J154" and "ISO
LG906D01001
3411" cab, and standard provided the require-
1. Top guard devices 2. Front guard devices ments to the cab space.
Any refit of cab shall not occupy the specified
space. Installation of added radio, fire extin-
guisher and other devices must make the speci-
fied space kept well. Any object bringing in 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.
1-16
Precautions for accessories June 10, 2015
Precautions for accessories

It shall be installed and commissioned by quali-
fied personnel; the operator shall be trained, and
his/her operation and maintenance shall be per-
formed strictly according to the operation
instructions for accessories.
When installing and using the spare accessory,
please read related instructions, manuals and
informations about the accessories.
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 Liu-
Gong. Using unauthorized accessories will
cause safety issues, do harm on the normal
operation of machine and influence its service
life.
It is forbidden to make any refit on the accesso-
ries without permissions; otherwise you shall
bear the responsibility.
LiuGong Machinery Co., Ltd will not be respon-
sible for the injury, accident and damage of
machine due to using unauthorized accessories.
1-17
CLG920D/922D 1.2 Precautions for lifting and matching operations
June 10, 2015 Precautions for accessories
1.2 Precautions for lifting roper is, the larger the bearing force is. The fol-
lowing figure shows the maximum weights at dif-
and matching operations ferent lifting angles when using two wire ropes
1) One designated personnel sends out cooper- with a bearing force controlled within 9.8kN
ative signal to fully keep the contacts among {1000kg}. If kept vertical, two wire ropes can lift
common operating personnel. The signalman 19.6kN{2000kg} in total; however, when the sus-
shall stay in a safe place where the driver can pension angle of two wire ropes presents 120°,
see easily and understand operating state from the lifting weight becomes 9.8kN{1000kg}. On
the driver seat, and definitely send out signal in the other hand, if lifting angle is 150°, for lifting a
the form specified in advance. The signalman load of 19.6kN{2000kg}, the two wire ropes will
shall stand in front of lifted load and safely guide bear a super force of up to 39.2kN{4000kg}.
lifting operation.
• It is forbidden to stand under lifted load.
• It is forbidden to climb on lifted load.
2) Check sling, etc. before lifting operation.
3) Wear gloves during lifting operation. (Leather
gloves are the best)
4) Visually measure the weight to confirm center
of gravity of lifted load.
5) Use slings suitable for the weight of lifted load
or lifting mode. Load may fall down if too thick
wire ropes are used for lighter load.
6) Try to avoid lifting by single wire rope. Lifted
load may rotate or fall off due to looseness. Use 8) Use a pad to avoid damage of wire ropes
two or multiple wire ropes for lifting in symmetric when installing them on lifted load with edges
mode. and corners. For lifted load which easily slides,
antiskid device shall be used.
 Lifted load may rotate, swing back due to
9) Use genuine eyebolt, and use shackle, etc. to
pull of wire rope or deviate from lifting posi-
fix eyebolt, wire rope, iron chain, etc.
tion if only a single wire rope is used for lift-
10) Hang the wire rope in the central part of
ing, so as to cause dangerous accident,
hook for lifting.
which shall be noted.
If the wire rope is hung on the edge of hook for
7) Lifting angle shall be under 60° in principle.
lifting, the rope may slide and even fall off from
Pay attention to avoiding overlarge lifting angle
the hook when lifting. The central part of hook
between the wire rope and hook when lifting
has maximum strength.
heavy objects (above 25kg).
11) Do not use wire rope in distortion state.
When using more than two wire ropes for lifting
load, the larger the lifting angle of each wire
1-18
1.2 Precautions for lifting and matching operations CLG920D/922D
Precautions for operating mobile crane June 10, 2015
Precautions for operating

mobile crane
Read operation and maintenance manual of
various models carefully in advance to oper-
ate the crane safely.
Precautions for operating

bridge crane
 Heavy objects of above 25kg must be lifted
by the crane.
1) Before operation, check wire rope, brake,
12) The following matters shall be noted during
clutch, controller, slide rail, over-winding protec-
lifting operation.
tor, residual-current circuit breaker against elec-
• Roll up wire rope slowly till it is tightened.
tric shock, crane anti-collision device and power
The hand may be caught easily when
warning lamp to guarantee safety.
touching lifting tools by hands, so do not
2) Follow signal indication during lifting.
hold them, but press them from above.
3) Operate the crane in a safe position.
• Stop rolling up after the wire rope is tight-
4) Always confirm the directions of directional
ened, and confirm the condition of lifted
display panel (east/west/south/north) and opera-
objects away from the ground and contact
tion button.
conditions between slings and padded
5) Do not lift load in a tilted angle or travel when
objects.
the load swings.
• If lifted load is unstable, or wire rope or lift-
6) Do not operate lifting or horizontal and verti-
ing chain is distorted, first lower lifted load,
cal travel at the same time.
and then lift again.
7) Do not use slings to drag.
• Lifted load can not be tilted.
8) Try to lift a little before lifting, and then lift after
13) The following matters shall be noted to
confirming it is safe.
during lowering operation.
9) Take moving route into consideration in
• When lowering lifted load, first stop at 30cm
advance, and lift to a safe height.
above the ground, and then lower it gently.
10) Place control switch on the position not
• Remove slings after confirming the load is
affecting operation or passing.
placed steadily.
11) Do not shake control switch forcefully after
• After clearing the distortion or dirt on wire
operating the crane.
rope and chain used during lifting, place
12) Remember the position of main power
them in designated positions.
switch so as to cut off the power rapidly in emer-
1-19
CLG920D/922D 1.2 Precautions for lifting and matching operations
June 10, 2015 Selection of rope
gency. Selection of rope

13) If the crane stops operating due to power
1) By referring to following table, select most
failure, etc., power switch shall be cut off. In
suitable wire rope according to the weights of
addition, if power switch is disconnected due to
lifting parts.
the start of residual-current circuit against elec-
tric shock, confirm whether relevant machineries
of the switch are in operating states before con- Wire rope
tacting again (Wire rope meeting "Z" standard without plating)
(JIS G35256 6×37-A type)
14) Stop the operation when finding obstacles
around the machine. Diameter of
Permissible load
wire rope
15) After the operation is finished, place the
mm kN t
crane on designated position, and lift the hook to
the height of 2m from the ground. Do not hang 10 8.8 0.9
slings on the hook when placing. 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).
1-20
1.2 Precautions for lifting and matching operations CLG920D/922D
Selection of rope June 10, 2015
2-1
CLG920D/922D
June 10, 2015
2 Foreword
2.1 How to read the Manual .....................................................................2-3

Composition of service manual ........................................................................... 2-3
Other reference manuals ..................................................................................... 2-3
User's Guidance .................................................................................................. 2-3
2.2 Marking of Revised Version ...............................................................2-4
2.3 General Torque Specifications ..........................................................2-5
2.4 Unit conversion table .........................................................................2-9
2.5 Cable Identification Methods ...........................................................2-10
Wire No. ............................................................................................................ 2-10
Wire categories ................................................................................................. 2-11
Color abbreviation codes ................................................................................... 2-11
Wire specifications ............................................................................................ 2-12
Circuit type and color abbreviation code ........................................................... 2-12
2.6 Coating materials .............................................................................2-13
2.7 Weight table .....................................................................................2-14
2.8 Usage specifications for oils ............................................................2-15
2-2
CLG920D/922D
June 10, 2015
2-3
CLG920D/922D 2.1 How to read the Manual
June 10, 2015 Composition of service manual
2.1 How 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 conve-
nient reading, it is divided into technical guide and workshop guide, which is used for reference of relevant
chapters and sections as required.
(1) Technical guide
1) Safety
2) Foreword
3) Structure function and maintenance standards
4) Testing and adjusting
5) Fault diagnosis
(2) Workshop guide
1) Disassembly and assembly
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.
1. Parts catalogue
2. Use and maintenance manual
3. Cummins engine parts manual
User's Guidance
1. Because the influences from area or processing are different of the machine, it shall confirm which
machine is applicable, and what work implements it has.
2. Some accessories and optional parts in the Manual may not be transported to relevant areas, and if neces-
sary, please consult the dealer of LiuGong in this area
3. The materials and technical specifications in the Manual change according to changes, and all information,
diagrams and specifications in the Manual are the latest product information obtained at the time of publi-
cation. The Company reserves the right to change without any notice. If it needs to obtain the latest techni-
cal information, please consult the dealer of LiuGong in this area or Service Department of LiuGong
Excavator Marketing Co., Ltd.
2-4
2.2 Marking of Revised Version CLG920D/922D
User's Guidance June 10, 2015
2.2 Marking of Revised Version

The meaning of version number for service manual of LiuGong is as follows:
2nd version
Publication
month
Publication
year
When the version is revised, the year and month will embody revision date of the version, and the
last numbers will reflect revision times of the Manual. For example, 001 represents the first revi-
sion, 002 represents the second revision, and so on.
2-5
CLG920D/922D 2.3 General Torque Specifications
June 10, 2015 User's Guidance
2.3 General Torque Specifications

Bolts involved in this machine shall be fastened in accordance with the torque requirements speci-
fied in the following table, unless special declaration.
The required tension torque is expressed in kgf.m.
For example, when tightening the bolt or nut with a 1m-long wrench, rotate the end of the wrench
with a force of 12kgf, then it will generate the following torque: 1m×12kgf=12kgf.m. When the same
torque is generated by the 0.25m wrench: 0.25m×kgf= 12kgf.m, the force needed is: 12÷0.25=48kgf.
Bolt Wrench size Torque
No. Description
specification (mm) N.m Kgf·m
Captive bolt of the engine
1 M22-10.9 34 800 80
shock absorber
2 Captive bolt of engine mount M12-8.8 18 90 9
3 Bolt on flywheel housing M12-8.8 18 60 6
Captive bolt of water tank
4 M12-8.8 18 90 9
bracket
5 Captive bolt of fuel tank M16-10.9 24 305 30.5
Captive bolt of hydraulic oil
6 M16-10.9 24 305 30.5
tank
17 Inner
7 Captive bolt of pump M20-10.9 600 60
hexagon
Captive bolt of main control
8 M12-10.9 18 120 12
valve
Captive bolt of swing
9 M20-10.9 30 600 60
reduction gear
14 Inner
10 Captive bolt of swing motor M16-10.9 305 30.5
hexagon
11 Captive bolt of battery M10 30 3
12 Captive bolt of cab M16-8.8 24 225 22.5
Captive bolt of revolving
13 M22-10.9 34 800 80
frame and swing bearing
Captive bolt of underframe
14 M22-10.9 34 800 80
swivel bearing
Captive bolt of the travel
15 M16-10.9 24 305 30.5
reduction gear
16 Captive bolt of sprocket M16-10.9 24 305 30.5
17 Captive bolt of carrier roller M18-10.9 27 415 41.5
18 Captive bolt of track roller M18-8.8 27 310 31
19 Captive bolt of track shoe M20-12.9 30 750 75
20 Captive bolt of guard M18-8.8 27 310 31
Counterweight mounting
21 M30-10.9 46 1850 185
bolt
2-6
2.3 General Torque Specifications CLG920D/922D
Tightening torque of 24° cone O-ring sealed connector
Hose inner Tightening torque

Series Thread size diameter
mm N.m kgf.m
M12×1.5 5 16±1 1.6±0.1
M14×1.5 6.3 16±1 1.6±0.1
M16×1.5 8 26±2 2.6±0.2
M18×1.5 10 37±2 3.7±0.2
M22×1.5 12.5 47±2 4.7±0.2
Light-type
M26×1.5 16 89±4 8.9±0.4
M30×2 19 116±5 11.6±0.5
M36×2 25 137±6 13.7±0.6
M45×2 31.5 226±11 22.6±1.1
M52×2 38 347±16 34.7±1.6
M14X1.5 5 26±2 2.6±0.2
M16X1.5 6.3 42±2 4.2±0.2
M18X1.5 6.3 53±2 5.3±0.2
M20X1.5 8 63±3 6.3±0.3
M22X1.5 10 79±4 7.9±0.4
Heavy type
M24X1.5 12.5 84±4 8.4±0.4
M30X2 16 126±6 12.6±0.6
M36X2 19 179±8 17.9±0.8
M42X2 25 263±12 26.3±1.2
M52X2 31.5 368±17 37.8±1.7
2-7
CLG920D/922D 2.3 General Torque Specifications
Tightening torque of flange-type sealed connector bolt
Bolt Tightening torque

Series Bolt performance
level N.m kgf.m
M8 25.2±1.2 2.52±0.12
M10 52.5±2.5 5.25±0.25
8.8
M12 96.6±4.6 9.66±0.47
M16 220±10 22±1
Light-type
M8 33.6±1.6 3.36±0.16
M10 73.5±3.5 7.35±0.35
10.9
M12 136±6 13.6±0.6
M16 310±15 31±1.5
M8 25.2±1.2 2.52±0.12
M10 52.5±2.5 5.25±0.25
M12 8.8 96.6±4.6 9.66±0.47
M16 220±10 22±1
M20 420±20 42±2
Heavy type
M8 33.6±1.6 3.36±0.16
M10 73.5±3.5 7.35±0.35
M12 10.9 136±6 13.6±0.6
M16 310±15 31±1.5
M20 577±27 57.7±2.7
2-8
2.3 General Torque Specifications CLG920D/922D
Tightening torque of thread angle type sealed connector
Fastening
Carbon steel, alloy steel Aluminum product
material
Tightening torque Tightening torque
Thread size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.875±0.12 / /
G1/4 36±2 3.6±0.2 29.3±2.2 2.93±0.2
G3/8 73.5±4.5 7.3±0.46 49±3 4.9±0.3
G1/2 110±10 11±1.0 55±5 5.5±0.5
G3/4 165±15 16.5±1.5 74±4 7.4±0.4
G1 225±25 22.5±2.5 / /
G1-1/4 275±25 27.5±2.55 / /
G1-1/2 285±15 28.5±1.5 / /
Joint tightening torque
Tightening torque
Thread size
N.m kgf.m
M12 24±2 2.4±0.2
M14 30±2 3.0±0.2
M16 30±2 3.0±0.2
M18 30±2 3.0±0.2
2-9
CLG920D/922D 2.4 Unit conversion table
2.4 Unit 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 0.1097
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 CLG920D/922D
Wire No. June 10, 2015
2.5 Cable Identification Methods

In circuit diagram, identify the wire in combination with wire No., wire categories, color abbrevia-
tion codes and line gauge in order to maintain. For example:
Indicates heat-resistant, lower-voltage wire for automobiles, red, with

the number of 108 and a diameter of 50.0 mm2.
Wire gauge (note: the ones with no marked wire gauge are all
0.85mm2)
Color abbreviation codes
Wire categories
Wire No.
LG922E930E02002
Wire No.
wire No. refers to digital code for identifying wire with three Arabic numbers in accordance with
certain rules.
2-11
CLG920D/922D 2.5 Cable Identification Methods
June 10, 2015 Wire categories
Wire categories
The wire categories selected for engineering machinery are AEX, AV, AVS, AVSS, and QVR in gen-
eral. For applicable range of temperature environment of various wires, see following table.
Heat
S/N Wire type Wire name Description
resistance
Low voltage wire for road Cooper core PVC for
1 QVR ≤70°C
vehicles insulation
Thin-wall insulated low The thickness of insulation
2 AVSS ≤80°C
voltage wire for vehicles layer is 0.30~0.40mm
Thin-wall insulated low The thickness of insulation
3 AVS ≤80°C
voltage wire for vehicles layer is 0.50~0.70mm
Insulated low voltage wire for The thickness of insulation
4 AV ≤80°C
vehicles layer is 0.60~2.0mm
Heat-resisting low voltage Heat resistance and
5 AEX ≤110°C
wire for vehicles cross-linking polyethylene
Color abbreviation codes
Color Abbreviation Color Abbreviation

BLACK BK BLUE BU
GREY GY GREEN GN
RED RD YELLOW YL
BROWN BR PINK PK
VIOLET VT ORANGE OR
WHITE WH LIGHT BLUE LTBU
RED/GREEN RD/GN YELLOW/BLUE YL/BU
Remark: the code composed of two colors indicates double-color wire

For example: "RD/GN" shows red-green wire.
2-12
2.5 Cable Identification Methods CLG920D/922D
Wire specifications June 10, 2015
Wire specifications
For allowable and voltage drop of AV wire, and for AVS, AVSS, and QVR with approximate perfor-
mances, execute uniformly according to following table.
Ambient
30°C 40°C 50°C 60°C 70°C
temperature
Allowable
current/voltage A mV/m A mV/m A mV/m A mV/m A mV/m
drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal
sectional 15 103 176 92 157 80 137 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 80 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37
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
2-13
CLG920D/922D 2.6 Coating materials
June 10, 2015 Circuit type and color abbreviation code
2.6 Coating materials
Name Specifications Main features and purposes

1277 Thread fastening • Features: anaerobic and fast air drying
1277
sealant • Purposes: used for parts not frequently removed
1243 Thread fastening • Used for removable parts that is speed sensor in
1243
sealant general.
• Features: rust protection for a long time
Long-term antirust LONG#2 light
• Purposes: used for mounting face of main pump,
agent yellow
sensor, hydraulic fitting, etc.
Molybdenum disulfide
2# • Lubrications for swing bearing and work implement pin
lithium grease 2#
• Features: strong ability of cleaning
Efficient cleaning agent
1755 • Purposes: used for main pump, swing motor and travel
1755
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
Anaerobic pipe thread medium (sealing oil, air, vapor, water) pipeline cone/
1567
sealant taper thread
• Purposes: used for water temperature sensor and oil
pressure sensor
Cleaning agent for
electromechanical HD-10 • Used for cleaning oil pipe connectors, etc.
equipment
Diesel engine sealant 1515 • Used for mounting face of diesel engine flange
• Used for waterproof of start motor and assembling
Polyurethane sealant 1924
clearance
Mobilux EP None • Used for rust protection of cover hinge
2-14
2.7 Weight table CLG920D/922D
Circuit type and color abbreviation code June 10, 2015
2.7 Weight 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.
Components Weight (kg)

Engine as (excluding coolant and engine oil) 496
Engine (excluding coolant and engine oil) 432
Hydraulic pump 127
Radiator as (excluding coolant, engine oil and fuel) 160
Hydraulic oil tank (without hydraulic oil) 176
Fuel tank (without fuel) 191
Revolving frame 1882
Cab 552
Cab seat 46
Counter weight 4300
Main control valve 200
Swing motor and reduction gear 217
Travel motor and reduction gear 275
Center connector 34.8
Boom 1616
Arm 792
Boom cylinder as 173
Arm cylinder as 270
Bucket cylinder as 161
Track as (single side) 1405
Track frame as 2711
Idler as 142
Swing bearing 317
Idler tensioner 180
Carrier roller 18
Sprocket 56
Track roller 34.7
2-15
CLG920D/922D 2.8 Usage specifications for oils
June 10, 2015 Circuit type and color abbreviation code
2.8 Usage specifications for oils

Time interval of oil change and approximate of filling capacity (QSB7 engine)
Oil change interval

Category Approximate filling volume (L)
(working hours)
Engine oil 500 24L
Gear oil of swing reduction gear 1000 3.4L
Gear oil of travel reduction gear 1000 (5.5L×2)L
Hydraulic oil 2000 Oil tank 210 L (system 330 L)
Fuel 420L
Cooling system 2000 25L
Technical specification of oil (QSB7 engine)
Fuel
Parts Oil specification Ambient temperature
category
Bucket, swing Molybdenum disulfide
-20~40°C (-4~104°F)
Lubricant
bearing of arm and lithium grease 2# ★
boom, and swiveling
gear EP2 or RO2 -20~40°C (-4~104°F)
5W-40 (APICI-4) -35~40°C (-31~104°F)
Engine crankcase,
Diesel engine
fuel injection pump 10W-30 (APICI-4) -30~30°C (-22~86°F)
oil
and regulator
15W-40 (APICI-4) ★ -25~40°C (-13~104°F)
0# ★ Above 4°C (above 39.2°F)
-10# Above -5°C (above 23°F)
Diesel fuel -20# Above -14°C (above 6.8°F)
-30# Above -29°C (above -20.2°F)
-50# Above -44°C (above -47.2°F)
Anti-freeze (100% stock
anti-freeze solution) and water with -30~40°C (-22~104°F)
proportion of 42:58
Swing reduction
SAE85W-140 (API GL-4) -20~45°C (-4~113°F)
gear
Gear oil
Travel reduction
SAE80W-90 (API GL-4) -20~45°C (-4~113°F)
gear
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)
2-16
2.8 Usage specifications for oils CLG920D/922D
Circuit type and color abbreviation code June 10, 2015
The oil marked with ★ is the oil filled when the machine is transported out of the factory.
Caution:
1. The oil of the same specification but different brands cannot be used together. If another brand of oil is to
be used, please clean the system first.
2. The lubricant should be changed in a timely manner. Even though the oil is very clean, yet it may deteri-
orate if it is placed for a long time.
3. The selection of fuel should depend on the lowest temperature of the place where the machine is used.
4. Except oil specifications in above table, when using the oil purchased in the market, please contact with
dealers of LiuGong
3-1
CLG920D/922D
June 10, 2015
3 Structural 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, inter-cooler and fuel cooler ............... 3-3
3.2 Undercarriage system ................................................................................... 3-5
3.2.1 Track frame and tensioner ........................................................................ 3-5
3.2.2 Idler ........................................................................................................... 3-6
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
3.3 Hydraulic system .......................................................................................... 3-14
3.3.1 Layout of hydraulic device ....................................................................... 3-14
3.3.2 Hydraulic elements .................................................................................. 3-16
3.3.3 Hydraulic working principle .................................................................... 3-145
3.4 Work implement ........................................................................................ 3-183
3.4.1 Sizes of components ............................................................................. 3-183
3.4.2 Arm part ................................................................................................. 3-186
3.4.3 Bucket part ............................................................................................ 3-188
3.5 A/C system ................................................................................................. 3-190
3.5.1 Layout of A/C pipeline .......................................................................... 3-190
3.6 Electrical system ....................................................................................... 3-191
3.6.1 Engine control ....................................................................................... 3-191
3.6.2 Display system ...................................................................................... 3-193
3.6.3 Electrical control system ....................................................................... 3-221
3-2
CLG920D/922D
June 10, 2015
3-3
CLG920D/922D 3.1 Power system
June 10, 2015 3.1.1 Diesel engine related parts
3.1 Power system 3.1.2 Water radiator, hydraulic

3.1.1 Diesel engine related oil cooler, inter-cooler and fuel
parts cooler
4
2
1
3
1 2
LG922E930E03001 LG922D03001
9
3
8
6 2 4
7
4 LG922D03002
LG922E930E03002
1. Left rear engine support

2. Fan side engine shock absorber
3. Rear engine support-rh
4. Flywheel housing side engine shock absorber
5. Muffler 6. Front engine support-lh
7. Front engine support-rh 8. Coupling
9.Main pump flange
3-4
3.1 Power system CLG920D/922D
3.1.2 Water radiator, hydraulic oil cooler, inter-cooler and fuel cooler June 10, 2015
8 10 9
11
7
6 12
5
13
LG922D03003
1. Intercooler hydraulic oil radiator

2. Water radiator 3. Hydraulic oil cooler
4. Reservoir tank 5. Shroud
6. Fan 7. Fan shield
8. Intercooler steel pipe
9. Intercooler steel pipe
10. Vent pipe 11. Water radiator inlet pipe
12. Hose 13. Water radiator outlet pipe
3-5
CLG920D/922D 3.2 Undercarriage system
June 10, 2015 3.2.1 Track frame and tensioner
3.2 Undercarriage system

3.2.1 Track frame and tensioner
9
1 2 3 4
8
7 6 5
LG922E930E03006
1. Idler 2. Track frame 3. Carrier roller 4. Sprocket 5. Track roller

6. Track 7. Tensioner
Judgment standards Count

No. Item ermea
Standard size Permissible limit sure
Free Installation Installation Installation Installation
length length load length load Replac
7 Tensioner
ement
- 840mm 144.2KN - -
3-6
3.2 Undercarriage system CLG920D/922D
3.2.2 Idler June 10, 2015
Unit: mm
Judgment standards
No. Item Standard Countermeasure
Tolerance Repair limit
size
Track +3
Vertical 110 115 Surfacing repair
frame +1
8 width of idler
plate 0 Surfacing repair
Idler 108 105
-1 or replacement
Track +3
Horizontal 240 245 Surfacing repair
frame +1
9 width of idler
plate 0 Surfacing repair
Idler 238 235
-1 or replacement
3.2.2 Idler
8
5
6
2
1
LG922E930E03007
3-7
June 10, 2015 3.2.2 Idler
Unit: mm
Count
No. Check items Standard erme
asure
Outer diameter of Standard size Repair size
1
bulge 538 ——
Outer diameter of
2 500 488
wheel face
Thickness of wheel Surfac
3 19 —— ing or
face
replac
Difference of wheel
4 19 25 ement
faces
5 Overall width 158 ——
6 Width of wheel face 37 ——
Standard Tolerance Standard Limit
Clearance between size Shaft Hole clearance clearance
7
shaft and bushing -0.25 +0.164
75 0.176-0.514 ——
-0.35 -0.074
Repla
Standard Tolerance Standard Interferenc cing
Interference between size Shaft Hole interference e limit bushi
8 ng
idler and bushing +0.153 +0.030
63 0.023-0153 ——
+0.053 0
Standard value Clearance limit
9 Idler axial clearance
0.5-1.0 ——
3-8
3.2.3 Carrier roller June 10, 2015
3.2.3 Carrier roller
5 3
4
6
1
LG922E930E03008
3-9
June 10, 2015 3.2.3 Carrier roller
Unit: mm
Count
No. Check items Standard ermea
sure
1
bulge 140 ——
Outer diameter of
2 120 106
wheel face
Thickness of wheel
3 45.5 ——
face
4 Width of wheel face 22.5 15.5
5 Bulge width 81 ——
Standard Tolerance Standard Limit Repla
size clearance clearance cemen
Clearance between Shaft Hole
6 t
shaft and bushing -0.170 +0.301
47.5 0.338-0.491 ——
-0.190 -0.168
Standard Tolerance Standard Interferenc
Interference size interference e limit
7 between carrier Shaft Hole
roller and bushing +0.061 +0
53 0.16-0.101 ——
+0.016 -0.040
Axial clearance of Standard value Clearance limit
8
carrier roller 0.44-0.76 ——
3-10
3.2.4 Track roller June 10, 2015
3.2.4 Track roller

LG922E930E03009
3-11
June 10, 2015 3.2.4 Track roller
Unit: mm
Count
No. Check items Standard ermea
sure

1
flange 185 ——
Outer diameter of
2 150 138
wheel face Repla
Thickness of wheel cemen
3 38.5 32.5
face t
4 Overall width 220 ——
5 Width of wheel face 46.5 ——
6 Flange width 23.5 ——
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
7
shaft and bushing
-0.215 +0.195
60 0.215-0.510 ——
-0.315 0
Standard Tolerance Standard Interferenc Repla

Interference size interference e limit cing
8 between track roller Shaft Hole
bushin
and bushing +0.10 +0 g
73 0.05-016 ——
+0.05 -0.06
Clearance between Standard value Clearance limit
bushing and neck
9 strap (the sum of
clearances on both 0.3-1.2 ——
sides)
3-12
3.2.5 Sprocket June 10, 2015
3.2.5 Sprocket
$
$
LG922E930E03010
Unit: mm
No. Check items Standard Countermeasure
1 Wear loss on sprocket Repair limit: 6
Standard size Repair limit Replacement
2 Width of sprocket
68 63
3-13
June 10, 2015 3.2.6 Track
3.2.6 Track

LG922E930E03011
Unit: mm
No. Check items Standard Countermeasure
Caterpillar track Standard size Repair limit
1
pitch 190 193
2 Height of track link 106 97
Height of track shoe Surfacing or
3 26 16
rib replacement
4 20
Length of track shoe
5 14
top
6 19
3-14
3.3 Hydraulic system CLG920D/922D
3.3.1 Layout of hydraulic device June 10, 2015
3.3 Hydraulic system

3.3.1 Layout of hydraulic device
1. Bucket cylinder 9. Return oil filter

2. Arm cylinder 10. Main control valve
3. Boom cylinder 11. Left travel motor & reduction gear
4. Swing motor & reduction gear 12. Bypass valve block
5. Right travel motor & reduction gear; 13. Center connector
6. Main pump 14. Hand pilot valve-rh
7. Accumulator 15. Hand pilot valve-lh
8. Breather valve 16. Foot pilot valve
LG922E930E03012
3-15
CLG920D/922D 3.3 Hydraulic system
June 10, 2015 3.3.1 Layout of hydraulic device
8 9 10 11 13
12
14
15
6
16
2
4
LG922D03004
3-16
3.3.2 Hydraulic elements June 10, 2015
3.3.2 Hydraulic elements

3.3.2.1 Main pump as
Structure and function of main pump as
3 3
2 2
4
Pi1 Pi2
a4
1
Psv
B3
D1
B1
a3
a1 a2
P3
P1 P2 LG922E930E03014
Structure of main pump assembly:

1-Drive shaft 2- Adjusting nut for minimum flow 3- Main pump regulator
4-Electric proportional pressure-reducing valve Pi1-P1 pump pilot oil port
Pi2-P2 pump pilot oil port Psv - Main pump servo port
a1, a2, a3, a4 - Pressure ports B1- Main pump suction port
B3- Pilot pump suction port Dr - Housing return oil.
Main pump as is composed of the main pump (pumps P1 and P2) and a pilot pump (pump P3). The
main 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.
3-17
June 10, 2015 3.3.2 Hydraulic elements
(1) Main pump (pumps P1 and P2)

Specifications of main pump
Displacement (cm3/rev) 115×2

Pressure Rated 34.3
MPa Max. 39.2
Rotate speed Rated 1950
r/min Max. 2700
Weight kg 120
Category Antiwear hydraulic oil
Temperature
-20~+95C
range
Hydraulic oil Viscosity range 10~200cSt (mm2/s)
Nominal dimension of oil return line:
Recommended 10m
strainer Suction line 80 ~ 150 mesh filter
screen
Structure and working principle of main pump

The main pump is directly driven by the engine via a coupling, and the pilot gear pump is connected behind
the pump P2 in series, is indirectly driven by the drive shaft and rotates at the same speed to the main
pump during working.
1 2
5 4
LG922E930E03015
Main pump
1- P2 pump governor, 2- P1 pump governor, 3- key shaft, 4- P1 pump, 5- P2 pump
3-18
The figure below shows the structural diagram of the main pump as, and the numbers in () behind
concerned parts in the figure below shall prevail.
Structure drawing of main oil pump
LG922E930E03016
3-19
Parts list of main pump

S/N in the S/N in the S/N in the
Part name Part name Part name
figure figure figure
530 Auxiliary tilt pin 313 Valve plate (R) 719 O-ring
Auxiliary
30 325 Cover 724 O-ring
swashplate
Auxiliary cylinder
13 401 Hex bolt 725 O-ring
(R)
111 Drive shaft 406 Hex bolt 727 O-ring
123 Roller bearing 407 Hex bolt 728 O-ring
124 Needle bearing 466 VP plug 732 O-ring
127 Bearing washer 468 VP plug 774 Oil seal ring
Protective
141 Cylinder body 490 Embedded plug 789
washer
Protective
151 Piston 531 Tilt pin 792
washer
152 Shoe 532 Servo piston 802 Hex nut
153 Pressing plate 11 Auxiliary piston 808 Hex nut
Spherical
156 3 Gear pump 824 Retainer ring
bushing
157 Cylinder spring 534 Stopper (L) 825 Fixed ring
211 Skid shoe plate 535 Stopper (S) 885 Valve plate pin
212 Swashplate 542 Washer 886 Spring pin
214 Tilt bushing 544 Washer 901 Eyebolt
Tilt plate support Inner hexagon
251 548 Feedback pin 953
platform locating screw
Positioning
261 Seal cover (F) 702 O-ring 954
screw
271 Pump housing 710 O-ring 981 Nameplate
312 Valve cap (R) 717 O-ring 983 Rivet
The main pump is composed of two plunger principles of the two pumps P1 and P2 are the
pumps, namely pump P1 and pump P2, which same, the pump P1 will be described as an
are connected via a spline joint (114). The example.
engine rotation is delivered to the drive shaft F The pump P1 is roughly composed of a rotating
(111) at the front to simultaneously drive the two mechanism for driving the pump to rotate, a
pumps. The oil suction port and oil discharge swashplate mechanism for adjusting output
port are converged at the connection (namely capacity and a valve cap mechanism for alter-
valve block (312)) of the two pumps, and the nately making oil suction and output actions.
pump P1 and pump P2 share one suction port. The rotating mechanism is composed of a drive
Because the structure principles and working shaft F (111), a cylinder body (141), shoes (151,
3-20
152), a plate (153), a spherical cylinder liner piston installed in the cylinder body rotates
(156), a shim (158) and a cylinder spring (157). along with the cylinder body while making recip-
Both ends of the drive shaft are supported by rocating linkage in relative to the cylinder.
bearings (123, 124). The shoes are installed on Therefore, for a single piston, when the cylinder
the piston to form a ball joint, the thrust gener- body rotates by one turn, the piston moves away
ated by load pressure is also reduced, and there from the valve plate (oil suction stroke). When
is one housing on the shoe (211) to lightly adjust the cylinder body rotates by 180°, the stroke is
oil pressure balance. To make auxiliary mecha- completed. When the cylinder body continues to
nism of the shoes act smoothly on the support rotate by another 180°, the piston moves
plate, the shoes are pressed on the support towards the valve plate (oil discharge stroke).
plate by the oil pressure spring via the pressure When the tile angle of the swashplate is zero,
plate and the spherical cylinder liner. Likewise, the swashplate neither makes stroke movement,
the cylinder body is also pressed on the valve nor discharges oil.
plate (313) by the cylinder spring.
The swashplate mechanism is composed of a 4. Main pump regulator
swashplate (212), a shoe (211), a swashplate Overview
support platform (251), a tilt cylinder liner (214),
The main pump adjuster is installed on the main
a tilt pin (531) and a servo cylinder (532). The
pump and is composed of the following three
cylindrical section of the swashplate formed at
control mechanisms.
the opposite side of shoe action face is sup-
(a) Power control
ported on the swashplate support platform. Oil
As the own pump output pressure P1 and the
pressure controlled by a adjuster makes an aux-
opposite pump output pressure P2 rise, the
iliary piston to move from side to side under the
pump tilt angle (output flow) automatically
guidance of oil pressure chambers at both sides
decreases so as to limit the input torque below a
of the auxiliary piston. At the moment, the
certain value. (The input power is constant if the
swashplate swings on the swashplate support
speed is constant.)
platform by means of the ball section of the tilt
For a tandem type double pump, because the
pin to change the tilt angle ().
total power type that the load pressures and
The valve cap mechanism is composed of a
actions of pumps P1 and P2 are added, the
valve block (312), a valve plate (313) and a
adjuster of each pump is controlled to be the
valve plate pin (885). The valve plate with two
same tile angle (output flow) in the power control
melon-shaped holes is installed on the valve
state.
block and is used for supplying and recovering
Therefore, the overload of a prime motor is auto-
oil to and from the cylinder block. Oil switched
matically prevented in the power control state no
by the oil valve is connected to an external pipe
matter how many the loads of the pumps P1 and
via the valve block.
P2 are.
When the drive shaft is driven by the motor, the
(b) Power switching control
cylinder body also rotates by means of the
spline joint. When the swashplate is tilting, the The power setting value is switched by changing
3-21
the power switching command pressure Pf, that is, the current value of the electric proportional pressure-
reducing valve. The power switching pressure Pf (secondary pressure of electric proportional pressure-
reducing valve) is guided into the power control section of the adjuster of each pump respectively via the
internal passage of the pump and is switched into the setting value of respective same power.
Because the output power of the pump can be changed freely via this mechanism, the optimal power can
be obtained in the cooperative working state.
(c) Flow control
The tilt angle (output flow) of the pump can be freely controlled by changing pilot pressure Pi. Control ways
include the positive flow control (positive control) way in which the output flow Q increases as the pilot pres-
sure Pi increases and the negative flow control (negative control) way in which the output flow Q decreases
as the pilot pressure Pi increases. This adjuster adopts the negative flow control way.
Unnecessary power is not consumed because the pump only outputs necessary flow when the command
pilot pressure of necessary correspondent flow during working via this mechanism.
This adjuster has the above three control mechanism functions. When all controls are combined, priority is
given to the small tilt (small flow) command through machine calculation described below.
3-22
Structure of adjuster
Adjuster section diagram
LG922E930E03017
S/N Part name S/N Part name

412 Bolt 733 O-ring
413 Bolt 734 O-ring
436 Bolt 735 O-ring
438 Bolt 753 O-ring
496 Plug 755 O-ring
708 O-ring 756 O-ring
722 O-ring 763 O-ring
724 O-ring 801 Nut
725 O-ring 802 Nut
728 O-ring 814 Ring washer
730 O-ring 858 Ring washer
732 O-ring 924 Bolt
3-23
Principle of adjuster (2) (613) is embedded in the slotted section of

the pilot plunger (643), the lever (2) (613)
rotates around section B (fixed via fulcrum bush-
ing (614) and pin (876)) as a fulcrum through the
movement of the pilot plunger (643). On the
other hand, because the pin (897) fixed on the
feedback rod (611) is protruding at the major-
hole section (section C) of the lever (2) (613),
the pin (897) moves rightwards as the lever (2)
(613) rotates. Moreover, because the U-shaped
slot section (section D) at the top end of the
feedback rod (611) is embedded in a feedback
Adjuster circuit diagram
in (548) fixed on the tilt pin (531) making the
pump swashplate (212) swing, the feedback rod
(611) rotates around the section D as a fulcrum
(1) Flow control through the movement of the pin (897). On the
As shown in the figure below, the output flow of other hand, the spool (652) on the feedback rod
the pump can be freely controlled according to (611) is connected together via the pin (874),
the pilot pressure Pi. the spool (652) moves rightwards as the feed-
back rod (611) rotates.
If the spool (652) moves, the output pressure P1
is communicated with the interface Cl via the
spool (652) and is guided into the major-diame-
ter chamber of the servo piston (532). The out-
Output flow
put pressure P1 is usually guided into the minor-

diameter section of the servo piston (532), so
the servo piston (532) moves rightwards through
area difference so as to decrease the tilt angle.
Q If the servo piston (532) moves rightwards, sec-
tion D also moves rightwards. Because a left-
Pilot pressure Pi ward pulling force usually acts on the spool due
to a return spring (654) installed on the spool
(652), the pin (897) is pushed towards the
① Flow decrease action major-hole section (section C) of the lever (2)
When the pilot pressure Pi increases, the pilot (613). Therefore, the section D moves right-
plunger (643) moves rightwards and stays still in wards, the feedback rod (611) rotates around
the position where the pretightening force and the section C as a fulcrum, and the spool (652)
the hydraulic force of the pilot spring (646) are also moves leftwards. The opening section
balanced. Because a pin (875) fixed on a lever between the valve bushing (651) and the spool
3-24
(652) is slowly closed through this movement, and the servo piston (532) stays still in the fully closed posi-
tion.
② Flow increase action
When the pilot pressure Pi decreases, the pilot plunger (643) moves leftwards through the pretightening
force of the pilot spring (646), and the lever (2) (613) rotates around the section B as a fulcrum through this
movement. The pin (897) is pushed towards the major-hole section (section C) of the lever (2) (613) via the
spool (652), pin (874) and feedback rod (611) through the return spring (654), the feedback rod (611)
rotates around the section D as a fulcrum as the lever (2) (613) rotates, and the spool (652) moves left-
wards.
When the spool (652) moves, because the interface Cl and the oil tank interface are communicated, the
pressure in the major-diameter chamber of the servo piston is released, the servo piston (532) moves left-
wards through the output pressure P1 of the minor-diameter section, and the flow increases.
The section D also moves leftwards as the servo piston (532) moves, the feedback rod (611) rotates
around the section C as a fulcrum, and the spool (652) moves rightwards. The opening section between
the spool (652) and the valve bushing (651) continues to move until it is closed, and it stays still in the fully
closed position.
(2) Power control

As shown in the figure below, when the load pressure increases, the pump tilt angle decreases, and the
overload of the prime motor is prevented.
Output flow
Output pressure (P1 +P2)
The action of power control is the same to that of flow control and is briefly described below.
(For detailed actions of each part, refer to flow control item.)
① Overload prevention action
If the own pump output pressure P1 rises or the opposite pump output pressure P2 rises, because P1 and
3-25
P2 act on the step section of the compensation crum along with the rotation of the lever (1)
plunger (621), the compensation rod (623) is (612), so the spool (652) moves leftwards.
pushed rightwards and moves to the position Because the interface Cl is communicated with
where the pretightening forces and hydraulic the oil tank interface, the pressure in the major-
forces of external spring (625) and internal diameter section of the servo piston (532) is
spring (626) are balanced. The movement of the released, so the servo piston (532) moves left-
compensation rod (623) is transmitted to the wards, and the pump output flow increases.
lever (1) (612) via the pin (875), and the lever (1) The movement of the servo piston (532) is
(612) rotates around the pin (876) (section E) transmitted to the spool (652) via the feedback
fixed on the housing (601) as a center. Because mechanism, and the opening section between
the major-hole section (section F) of the lever the spool (652) and the valve bushing (651) con-
(1) (612) is protruding out by the pin (897) fixed tinues to move until it is closed.
on the feedback rod (611), the feedback rod
(611) rotates around the section D as a fulcrum (3) Priority mechanism of small tilt (small flow)
along with the rotation of the lever (1) (612), and command
the spool (652) moves rightwards.
As previously mentioned, although the tilt com-
If the spool (652) moves, the output pressure P1 mands of flow control and power control are
is guided into the major-diameter section of the transmitted to the feedback rod (611) and the
servo piston via the interface Cl, the servo pis- spool (652) via the major-hole sections (section
ton (532) moves rightwards, so that the output C and section F) of the lever (1) (612) and the
flow of the pump decreases, and the overload of lever (2) (613), because the section C and sec-
the prime motor is prevented. tion F are structures protruding in major hole
The movement of the servo piston (532) is (φ9) by the pin (φ5), it is only in contact with the
transmitted to the feedback rod (611) via the pin (897) at the small tilt side, and the holeφ9 of
section D, so the feedback rod (611) rotates the rod at the large tilt command state side is
around the section F as a fulcrum, and the spool free without being in contact with the pin (897).
(652) moves leftwards at the moment. The The command at the small tilt side of flow con-
opening section between the spool (652) and trol and power control has priority through this
the valve bushing (651) moves until it is closed, mechanical selection mechanism.
and the servo piston (532) stays still in the posi-
tion where the opening section is fully closed.
② Flow recovery action
If the own pump output pressure P1 rises or the
opposite pump output pressure P2 decreases,
the compensation rod (623) is pushed back
through the external spring (625) and the inter-
nal spring (626), so the lever (1) (612) rotates
around the section E as a center. The feedback
rod (611) rotates around the section D as a ful-
3-26
(4) Power switching control (power decrease Adjustment by adjuster

control) The maximum and minimum flow can be
As shown in the figure below, the setting power adjusted through the adjusting screws (953 and
of the pump can be freely controlled through 954) at the pump body side, power control char-
power switching pressure Pf. acteristics can be adjusted by using the adjust-
ing screw (C) (628) and adjusting wheel (C)
(627) of this adjuster, and flow control character-
istics can be adjusted by using the inner hexa-
gon locating screw (924).
(1) Adjustment of maximum flow (pump body
Output flow
side)
Loosen the hex nut (808) and then tighten (or
loosen) the locating screw (954) for adjustment.
Only the maximum flow other than other control
Q
characteristics changes.
If the power switching pressure Pf increases, the

compensation rod (623) moves rightwards by
means of the pin (898) and the compensation
Output flow
plunger (621), just like the overload control

action for preventing power control described
above, and the power setting decreases when
the pump tilt angle decreases. On the contrary, Q
if the power switching pressure Pf decreases,
the power setting increases. Pilot pressure Pi
(2) Adjustment of minimum flow (pump body

side)
loosen) the inner hexagon locating screw (953)
for adjustment. The adjustment is the same as
that of the maximum flow. Although other control
characteristics will not change, if the locating
screw is tightened too much, the power required
in the case of maximum output pressure (over-
flow) could rise, which should thus be noted.
3-27
Output flow
Output flow
Q Q
Pilot pressure Pi Output pressure (P1 +P2)
(3) Adjustment of input power ② Adjustment of internal spring

As this adjuster is in the concurrent total power Loosen the hex nut (802) and then tighten (or
manner, please adjust the adjusting screws (C) loosen) the adjusting wheel (C) (627) for adjust-
(628) and adjusting wheels (C) (627) of P1 and ment. When the adjusting wheel (C) (627) is
P2 by the same amount when changing power tightened, the flow shows an increase manner
settings. In addition, adjusted pressure changes as shown in the figure below, and thus the input
refer to the values when both the pumps are power also increases.
pressurized simultaneously.
① Adjustment of outer spring
Loosen the locknut (630) and then tighten (or
loosen) the adjusting screw (C) (628) for adjust-
ment. When the adjusting screw (C) (628) is
Output flow
tightened, the control curve moves to the right

and input power shows an increase manner as
shown in the figure below. In addition, when the
adjusting screw (C) (628) is turned by N circles,
Q
the internal spring (626) is also tightened along
with the turning, and thus settings will change;
therefore, turn the adjusting wheel (C) (627) in
the opposite direction by N×A circles to return
the inner spring back.
(A is the return rate)
3-28
(4) Adjustment of flow control characteristics

loosen) the inner hexagon locating screw (924)
for adjustment.
When the inner hexagon locating screw (924) is
tightened, the control curve moves to the right
as shown in the figure below.
Output flow
Pilot pressure Pi
3-29
Cause and handling of adjuster fault

If poor action is caused by the adjuster, refer to section "Removal and installation" for removal and
inspection.
When
prime motor
is overload
Exert the load on monomer

of each pump, and
separately check whether
front pump and rear pump is
abnormal
Both two pumps are abnormal
Check whether
current value I of
power switch
order is abnormal
Single pump is abnormal No
Check whether power
switch pressure (pf) is
too low, namely check Replace electro-hydraulic
Yes proportional pressure-reducing
high frequency valve
disturbance current of
amplifier
No
Jamming of
compensating
plunger (621) and Yes Removal.Cleaning
compensating lever
(623)
No
Jamming of Yes Removal.Cleaning

pin (898)
3-30
Fall short of
maximum flow
Yes
Confirm whether
pilot pressure is
normal
No
Jamming of pilot
plunger (643)
Yes Removal.Cleaning
No
Jamming of Yes Removal.Cleaning

spool (652)
LG922E930E03028
2) Electric proportional pressure-reducing is Pf inversely proportional to input current.

valve Main pump maintenance references
An electric proportional pressure-reducing valve When the abrasion loss of each part exceeds
is used to change the control curve (P-Q curve) the following references, replacement or re-
of the main pump (P1 and P2) and provide the adjustment is needed. But a part must be
main pump with the control curve suitable for replaced when it has obvious damage in
various working conditions. Its input pressure is appearance.
Psv (i.e. pilot pressure), and its output pressure
Standard Maintenance
Check items Treatment
size (mm) limit (mm)
Space clearance (D-d) inside piston Change the piston or
0.039 0.067
and cylinder cylinder
Looseness (δ) of clearance section Change the piston and
0~0.1 0.3
between piston and shoe shoe assembly parts.
Change the piston and
Thickness of shoe (t) 4.9 4.7
shoe assembly parts.
Change the cylinder
Free height (L) of cylinder spring 41.1 40.3
spring.
Assembly height of plate and spherical Change the plate or
23.0 22.0
bushing (H-h) spherical bushing.
3-31
D
d
δ
t
LG922E930E03029 LG922E930E03031
Space clearance inside piston and cylinder Looseness of clearance section between
body: D-d plunger ball head and shoe: δ
Thickness of shoe: t
H
h
/
LG922E930E03030
Free height of cylinder body spring: L LG922E930E03032
Assembly height of plate and spherical bushing

(H-h)
3-32
Maintenance standards of cylinder, valve pilot oil.

block and swashplate (shoe plate). Pilot pump specifications
Cylinder body Finish to Model ZX10LGRZ1

(Sliding necessary 3-Z(Ra=0.8)
section) roughness Displacement (cm3/r) 10
Swashplate Set pressure (MPa) 0.2
(Shoe plate) 3.9 0

Standard Rotation speed (r/min) 600~2500
Cylinder body face
Roughness 0.4-Z (Ra=0.1) Suction side pressure
roughness 0.05~-0.01
on each below (abrading) (MPa)
(corrected
surface value) Rotation direction of
(sliding Clockwise
shaft (from drive shaft)
section)
Weight (kg) 1.5
(2) Pilot pump
Pilot pump construction
Pilot pump (P3 pump) is a quantitative type
pump and provides the hydraulic system with
A3
B3
A3
a3 a3
LG922E930E03033
3-33
14 4 2
14 18
B3
19
A3
10
11 20
a3
15 6 5
7
1 3 12
13 17 19
8 9 16
LG922E930E03034
Section view of pilot pump

1 Front cover 12 Locknut
2 Gear housing 13 VP oil plug
3 Drive gear 14 O-ring
4 Driven gear 15 Angular seal
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
3-34
Principle of pilot pump 3.3.2.2 Main control valve

Specifications
$
Specification
Item
s
KMX15RB/
D Model
B45004B
Standard flow 300L/min
1
Working pressure of main relief
31.8 0
valve
᧛ѱ⋯⌫
MPa
720$,13803
1
% Pressurization pressure of
LG922E930E03035
33.3 0
main relief valve
MPa
Diagram of pilot pump hydraulic circuit Boom cylinder
The housing comprises a front housing (1) and a large cavity
and small
gear housing (2), with a pair of drive gear (3) 36.3±0.5MPa
cavity, bucket
and driven gear (4) installed inside as well as a cylinder small
relief valve used for setting output pressure. cavity
The relief valve comprises a strainer (5), a cone Oil port
setting Arm cylinder
valve (7), a valve seat (6), a spring (8), a ring pressure of large cavity
37.2±0.5 MPa
(9), an adjusting screw (10) and a locknut (11). relief valve and small
cavity
To prevent oil from leaking outside, an angular
seal (14) and an O-ring (13) are installed on the Bucket
cylinder big 35.3±0.5 MPa
front housing (1). cavity
Backup 19.6±0.5MPa
Working principle
The oil sucked via oil suction port B3 is drained Working oil temperature -20~90°C
by the driving and driven gears through the dis- Maximum pressure of oil
0.3MPa
charge oil port A3. Discharged oil is kept at set- leakage
ting pressure through the relief valve.

Redundant discharged oil is discharged from the
oil leakage port Dr of the main pump housing by
means of the relief valve.
3-35
External view
XBtr (PTa)
g4 g5 g6
S5
+S6,
S4
U4
XAtr
LG922E930E03036
3-36
TRAVEL RIGHT
XBtr Btr CP1 Atr XAtr
LCs SWING
XAs Bs As XBs
SWING PRIORITY Xb2 CCb Dr1

Psp BOOM2 (XAb2)
(XAo) LCo OPTION

(XBo)
(Bo) (Ao)
+Dr,
LCa ARM1 XBa1

XAa1 Ba
Dr3
(Head) (Pis)
BYPASS CUT 2
N2 N1
XBp2 (BYPASS CUT 1) (XBp1)
NR2 NR1
VIEW A
LG922E930E03037
3-37
(XBp1) XBa2
Dr3
CCo (P5)
Dr6 Pns
Dr7
PnA2
CCk
XAa2
XBk
PCk
XBp2
VIEW B
LG922E930E03038
3-38
XAtr
PU
MR
XBs XAtL
Dr6 Pns
XAb2 XBb1
AbR
XAK
(XBO)
A
AoR AkR
XBa1 XBa2
AR
DU
Dr3
PnA2 Dr7
AaR
(XBp1)
NR1
B
LG922E930E03039
3-39
(P0) PG
Px
TRAVEL STRAIGHT CMR2
Pz
CMR1
(PTa)
AtL
Py
TRAVEL LEFT
C2
XAtL XBtL
BtL
CRb
BOOM1 XAb1
PbL
LCb
XBb1 Bb
(Rod)
Ab
(Head)
BUCKET PCk
LCk
XAk Bk
Ak (Rod)
(Head)
LCAT2
ARM2
CRa LCAP2 XBk
XBa2 R2
XAa2
PaL
Aa
(Rod)
LG922E930E03040
3-40
XBtr
(PTa)
XAs
XBtL Dr2
Psp Pns Dr6
BbR
XAb1 BoR
(XAo)
BkR PCk
XBk
XAa1
XAa2 BaR
Dr7 PnA2
NR2
XBp2
LG922E930E03041
3-41
The interfaces of the main control valve are as

follows
Connector
Symbols Interface name
dimension
G-1 R2 Backup
(P0)
G-3/4 (P3)
(P5)
XAtr Foot (reversing) pilot interface-rh

XBtr Foot (advancing) pilot interface-rh
(XAo) (Backup pilot interface)
(XBo) (Backup pilot interface)
XAk Bucket (excavation) pilot interface
XBk Bucket (unloading) pilot interface
XAb1 Boom 1 (rising) pilot interface
XBb1 Boom 1 (lowering) pilot interface
G-3/8 XAa2 Arm 2 (stretching) pilot interface
XBa2 Arm 2 (retraction) pilot interface
XAtL Foot (reversing) pilot interface-lh
XBtL Foot (advancing) pilot interface-lh
XAs Rotation (left rotation) pilot interface
XBs Rotation (right rotation) pilot interface
XAa1 Arm 1 (stretching) pilot interface
XBa1 Arm 1 (retraction) pilot interface
Dr1 Oil leakage interface
3-42
Px Signal interface for work implements

Py Signal interface for travel
Pz Pilot pressure for pressurization of main relief valve
PG Pilot pressure source interface
N1 Negative control signal pressure interface (boom 1 side)
N2 Negative control signal pressure interface (arm 1 side)
Pns Rotary logic control valve pilot interface
PCk Bucket (excavation) stroke limiting pilot interface
PnA2 Arm 2 logic control valve pilot interface
G-1/4 Dr2 Oil leakage interface
PaL Lock valve pilot interface (arm piston rod side)
PbL Lock valve pilot interface (boom piston head side)
(XBp1) Backup
XBp2 Backup
XAb2 Boom flow merging (lifting) pilot interface pressure
Psp Rotation priority pilot interface
M12 R1 Return interface
Atr Right travel motor interface (reversing)

Btr Right travel motor interface (advancing)
(Ao) Backup interfaces
(Bo) Backup interfaces
Ak Interface (excavation) at bucket cylinder piston head side
Bk Interface (unloading) at bucket cylinder piston rod side
Ab Interface (lifting) at boom cylinder piston head side
Bb Interface (lowering) at boom cylinder piston rod side
M10
AtL Left travel motor interface (reversing)
BtL Left travel motor interface (advancing)
As Swing motor interface (left rotation)
Bs Swing motor interface (right rotation)
Aa Interface (extension) at arm cylinder piston rod side
Ba Interface (retraction) at arm cylinder piston head side
P1 Pump interface (P1 side)
P2 Pump interface (P2 side)
The interfaces in () are valve blocks in gen-
eral.
3-43
Structure diagram
101 159 541 542543 166 151 168 151168 151 168
550
PG 156
2-156
NTS93
(PTa)
SECTION N-N
N
RT42
XAtL XBtL
XBb1
RB47
XAb1
PCk
RK45
XAk
XBk
RAG46
XBa2 XAa2
CCo CCk
514 521 561 551 551 561 521 514 SECTION A-A
LG922E930E03042
3-44
B A 273x10
153
(Po)
XAtr 561
TRAVEL TRAVEL
RIGHT MR STRAIGHT
C 273x12
C
XBs XAtL
SWING 252
TRAVEL
LEFT
D
D
Dr6 Pns
XAb2 XBb1
977
BOOM2 BOOM1
978x2
(SWING PRIORITY)
E E
AbR
XAk
(XBo)
OPTION BUCKET
F AoR F
AkR
XBa1 XBa2
ARM1 ARM2
AR
G G
(XBp1)
PnA2 Dr7
252
(BYPASS CUT 1)
AaR
O O
H BYPASS CUT 2 NR1 H
B
LG922E930E03043
3-45
153 561
102
P2 (P3) R1
975 975
XBtr XAtr
RT42
975
XAs XBs
RS45
975
RBG43
Psp XAb2
RSP41
975
RY40
(XAo) (XBo)
975 975
RA45
XAa1 XBa1
975
XBp2 (XBp1)
NN90
NN90
975 975
SECTION B-B
165 165 165
LG922E930E03044
3-46
AaR
602
XBa2
(XBp1)
Dr3
SECTION O-O
274x4
CCo
Dr6 (P5)
Pns
Dr7
CCk PnA2
P P
210
153 561
(P5)
SECTION P-P
XAa2
XBk
273x12 273x10
XBp2 PCk
LG922E930E03045
3-47
154
164
TRAVEL RIGHT TRAVEL STRAIGHT 201
201
336 336
332 XAtr 332
335 323
321 335
320 322
332
332 MR
261
261
308
163 601
301
Pz
165
512
163 Atr 522
511 553
521
551 CP1
561 CMR1 562
165 562
163
163 Btr
CMR2
163 553
522
512
159
264
159
204 264
XBtr (PTa)
204
SECTION C-C
164
154
LG922E930E03046
3-48
201
201 SWING TRAVEL LEFT 336

336 332
332 XBs XAtL 335
335 321
328
320
320 332
261
332
261 301
305
161
163
163 AtL
As
254
511
521
C2
551
561
BtL
251
Bs
165
Dr2
264
XAs XBtL 264
204
204 163 163 SECTION D-D
LG922E930E03047
3-49
202
336 BOOM2 BOOM1 201
332 XAb2 XBb1 336
332
339
327 335
328
326
320
AbR 602
332
332 261
261 L
L
161 158
511 Dr1
521 PbL
523
CCb CRb 552
551 561
561 513
165 511
307 521
LCb
163
Xb2
551
551 561
561
Bb
311
161
303
261
264
332 XAb1
BbR 602
326
163 204
329
339
332
336
Psp 158
202
SECTION E-E
SWING
PRIORITY
LG922E930E03048
3-50
259
164
201 201
336
336 OPTION BUCKET
332
332 (XBo) XAk
335 335
321 321
320 320
602
332 AkR 332
AoR
261 261
604 304
163
209
971x4
165 Ak
309
163 (Ao)
163
511 511
521 521
LCo
LCk
551
551
561
561
(Bo)
Bk
163
165
971x4
209
163
602
264
264
604 (XAo) 206
BkR 211
204 BoR XBk
164 SECTION F-F 561
154 258
PCk LG922E930E03049
3-51
201
201 336
336 ARM1 ARM2 332
332 XBa1 XBa2 335
335
328 323
320 320
257 Dr3
332
332 AR
261
261
306
L L
158
163
165 513
162 523
152 CRa 561
165 552
162 251
152
(Pis)
302
511
521
LCa
551 LCAT2 256
561
551
163 Ba 561
R2 521
511
165
163
264 XAa2 264
602
BaR XAa1 204
205 SECTION G-G
LG922E930E03050
3-52
SECTION L-L
610 162 152 158 154 164 164 154 158 152 162 164 154 610 162 152
N2 N1
NR2 NR1
BYPASS CUT 2 (BYPASS CUT 1)
XBp2
(XBp1)
203 333 331372 373337331 262 310 165 165 310 163 262 331 337373372331333 203
SECTION H-H
LG922E930E03051
3-53
Parts list of main control valve

101 Valve body A 258 Plunger 335 Stop block
102 Valve body B 259 Plunger 336 Bolt with a liner
151 Plunger 261 O-ring 337 Stop block
152 Plunger 262 O-ring 339 Stop block
153 Plunger 264 O-ring 372 Spring
154 Plunger 273 Hex bolt 373 Spring
156 Orifice plug 274 Hex bolt 511 Cone valve
158 Plug 301 Travel spool 512 Cone valve
159 Plug 302 Arm 1 spool pair 513 Cone valve
161 O-ring 303 Boom spool 1 pair 514 Cone valve
162 O-ring 304 Bucket spool 521 Spring
163 O-ring 305 Swing spool 522 Spring
164 O-ring 306 Spool of arm 2 523 Spring
165 O-ring 307 Spool of boom 2 541 Steel ball
Straight travel
166 O-ring 308 542 Spring seat
spool pair
168 O-ring 309 Backup spool 543 Spring
Bypass stop
201 Spring cover 310 550 Plunger
spool
Rotary pressure
202 Spring cover 311 gradient control 551 Plunger
valve spool
203 Spring cover 320 Spring 552 Plunger
204 Spool cover 321 Spring 553 Plunger
205 Spool cover 322 Spring 561 O-ring
206 Spool cover 323 Spring 562 O-ring
209 Flange 326 Spring 601 Main relief valve
210 Plate 327 Spring 602 Interface relief valve
211 Plunger 328 Spring 604 Interface relief valve
Negative control
251 Logic control valve 329 Spring 610
relief valve
The lock valve
252 330 Spring 971 Hex bolt
selector pair
Rotary logic valve
254 331 Spring seat 975 Hex bolt
gp
3-54
256 Arm 2 logic valve gp 332 Spring seat 977 Nameplate

Arm regeneration
257 333 Bolt with a liner 978 Rivet
stop valve pair
Main control valve hydraulic circuit
Travel (rh) Straight travel
Travel (lh)
Swing
Swing
priority
Boom 1
Boom 2
Backup Bucket
Arm 1 Arm 2
Bypass stop
Hydraulic Circuit Diagram

LG922E930E03052
Figure4
3-55
Working principle
1. When the spool is in the neutral position
[Main circuit]
When all spool are in neutral state, the working oil fed from the hydraulic pump (front) flows into the pump
interface P1, is guided to the main passage (1) and returns to the working oil tank from the return interface
(R1) by the neutral bypass (2) (natural M neutral M-shaped slide valve function) of each spool of linear
travel (308), left travel (301), boom 1(303), bucket (304) and arm (306).
The signals of the negative control relief valve (610) at the boom 1 side are transmitted into the hydraulic
pump adjuster at the P1 side from the interface N1 to control the pump output flow as the minimum flow.
The working oil fed from the hydraulic pump (back) flows into the pump interface P2, is guided to the main
passage (3), and returns to the working oil tank from the return interface (R1) by the neutral bypass (2)
(neutral M-shaped slide valve function) of each spool of flowing into the right travel (301), rotation (305),
boom flow merging (boom 2: 307), backup (309) and arm 1 (302).
In addition, the signals of the negative control relief valve (610) at the arm 1 side are transmitted into the
hydraulic pump adjuster at the P2 side from the interface N2 to control the pump output flow as the mini-
mum flow.
Whichever out of the 9 main spools is switched, the neutral bypass (2) will be immediately closed. The sig-
nal pressure at the interface N1 or N2 in the negative control circuit is the tank pressure, and controls the
pump output flow as the maximum flow.
3-56
1
2
LG922E930E03053
Figure5
3-57
(2) Travel
[Pilot circuit]
When the left or right travel spool is switched, the side passage is closed, and thus the pressure at the
interface Py (signal interface for travel) rises.
[Main circuit]
When the pilot interface XBtL for the left travel spool (301) is pressurized, the neutral bypass (2) at the arm
1 side is closed, and the working oil fed from the hydraulic pump (front) is fed into the left travel motor from
the interface BtL.
Similarly, when the pilot interface XBtr for the right travel spool (301) is pressurized, the neutral bypass (2)
at the arm 1 side is closed, and the working oil fed from the hydraulic pump (back) is fed into the right travel
motor from the interface Btr.
On the other hand, the return oil respectively from the left and right travel motors passes through the left
(right) travel spool from the interface AtL (Atr), and then returns to the working oil tank from the return oil
interface (R1).
When the travel on the opposite side (pressurizing the pilot interfaces XAtr and XAtL) is operated, the pro-
cess is the same as the above.
Travel motor
Figure6
3-58
(3) Bucket arm

1. During the arm extending operation
[Pilot circuit]
When the arm 2 spool (306) is switched, the side passage is closed, and thus the pressure at the interface
Px (signal interface for work implements) rises.
[Main circuit]
During the arm extending operation, pilot pressure oil is fed into the interfaces XAa1 and XAa2. When pilot
pressure oil is applied to both sides of the interfaces XAa1 and XAa2, the arm 1 and arm 2 spools are
respectively switched to the left of the Figure 6, and thus the working oil flowing into P2 is guided to the
neutral bypass (2) through the main passage (3). By switching the arm 1 spool (302), the neutral bypass is
cut off, and thus the working oil flowing into the parallel passage pushes open the cone valve (511) of the
check valve, flows into the arm 1 spool (302) from the U-shaped passage, then flows into the periphery of
the arm 1 spool (302) and arm 2 spool (306), and is fed into the arm cylinder piston rod side from the inter-
face Aa.
On the other hand, the working oil flowing into the interface P1 is fed into the neutral bypass (2) through the
main passage (1). By switching the arm 2 spool (306), the neutral bypass is cut off. Thus the working oil
flowing into the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve gp,
while the working oil flowing into the neutral bypass pushes open the cone valve (511) of the check valve.
They both flow into the arm 2 spool (306) from the U-shaped passage, then merge with the interface Aa
from the internal passage of the arm 2 spool (306), and are fed into the arm cylinder piston rod side (R).
The return oil from the arm cylinder piston head side (H) through the interface Ba flows to the respective
tank oil circuit of the arm 1 and arm 2, and returns to the working oil tank from the tank interface (R1).
3-59
R H
256
511
Aa
XBa 2
XBa 2
XB a1
XA a1
Ba
(Pis) 511
LG922E930E03055
Figure7
3-60
2. During the arm retracting operation On the other hand, the return oil from the arm
[Pilot circuit] cylinder piston rod side (R) makes the working
When the arm 2 spool (306) is switched, the oil with increasing pressure return to the inter-
side passage is closed, and thus the pressure at face Aa through the self weight of the arms etc.
the interface Px (signal interface for work imple- The working oil having returned to the interface
ments) rises. Meanwhile, pressure oil is fed into Aa flows into the spool from a hole on the
the interface PaL, and the release signal of the periphery of the arm 1 spool (302); only under
lock valve selector pair (252) is sent over. low load, it will push open the cone valve (302-
317) inside the spool and merge with the inter-
[Main circuit]
face Ba from a hole on the spool. This is called
During the arm retracting operation, pilot pres-
the arm regeneration function.
sure oil is fed into the interfaces XBa1 and
If the pressure at the arm cylinder piston head
XBa2. When pilot pressure oil is applied to both
side and in the U-shaped passage rises, the arm
sides of the interfaces XBa1 and XBa2, the arm
regeneration stop spool (257-211) is switched to
1 and arm 2 spools are respectively switched to
the left of Figure 9, and is closed through the
the right of Figure 8. Thus the working oil flowing
back pressure of the cone valve (302-317)
into P2 is guided to the neutral bypass (2)
inside the spool simultaneously. Thus the arm
through the main passage (3). By switching the
regeneration function is released. The return oil
arm 1 spool (302), the neutral bypass is cut off.
from the arm cylinder piston rod side (R) flows
Thus the working oil flowing into the parallel
into the spool from the hole (a) on the periphery
passage pushes open the cone valve (511) of
of the arm 1 spool (302), then flows to the arm
the check valve, flows into the bucket spool
regeneration stop valve pair (257) from the hole
(302) from the U-shaped passage, then flows
(c) on the periphery of the arm 1 spool (302),
into the periphery of the arm (302), and is fed
and returns to the working oil tank through the
into the bucket cylinder piston head side (H)
tank interface (R1).
from the interface Ba.
On the one hand, the working oil flowing into the
interface P1 is guided to the neutral bypass (2)
through the main passage (1). By switching the
arm 2 spool (306), the neutral bypass is cut off,
and thus the working oil flowing into the parallel
passage pushes open the logic cone valve (256-
101) of the arm 2 logic valve gp, while the work-
ing oil flowing into the neutral bypass pushes
open the cone valve (511) of the check valve.
They both flow into the arm 2 spool (306) from
the U-shaped passage, then merge with the
interface Ba from the internal passage of the
arm 2 spool (306), and are fed into the arm cyl-
inder piston head side (H).
3-61
Small load
Dead weight
of arm
LG922E930E03056
Figure8
3-62
When the pressure on the side of arm cylinder piston head (H) rises
LG922E930E03057
Figure9
3-63
(4) Boom
① During boom lifting operation
[Pilot circuit]
When the boom 1 spool (303) is switched, the side passage is closed, and thus the pressure at the inter-
face Px (signal interface for work implements) rises.
[Main circuit]
During the boom lifting operation, pilot pressure oil is fed into the interface XAb1, and the boom 1 spool
(303) moves to the left of Figure 10. The working oil flowing into the interface P1 is guided to the neutral
bypass (2) by means of the main passage (1). By switching the boom 1 spool (303), the neutral bypass is
cut off, and thus the working oil flowing into the parallel passage pushes open the cone valve (511) of the
check valve, flows into the boom 1 spool (303) from the U-shaped passage, then flows into the periphery of
the boom 1 spool (303), and is fed into the boom cylinder piston head side (H) from the interface Ab.
Meanwhile, pilot pressure oil is also fed into the interface XAb2, and the boom 2 spool (307) moves to the
right of Figure 10. As the neutral bypass is cut off by switching the boom 2 spool (307), thus the working oil
from P2 flowing into the parallel passage flows into the boom 2 spool (307) by means of the U-shaped pas-
sage, then pushes open the cone valve (511) of the check valve, and is fed into the boom cylinder piston
head side (H) after merging with the interface Ab. This is called the boom flow merging function.
On the other hand, the return oil from the boom cylinder piston rod side (R) flows into the periphery of the
boom 1 spool (303) from the interface Bb, and returns to the working oil tank from the tank interface (R1).
3-64
H R
511
Ab
Bb
XA b1
XAb 2
511
LG922E930E03058
Figure10
3-65
② During boom lowering operation

[Pilot circuit]
When the boom 1 spool (303) is switched, the side passage is closed, and thus the pressure at the inter-
face Px (signal interface for work implements) rises. Meanwhile, pressure oil is fed into the interface PbL,
and the release signal of the lock valve selector pair (252) is sent over.
[Main circuit]
During the boom lowering operation, pilot pressure oil is fed into the interface XBb1, and the boom 1 spool
moves to the right of Figure 10. The working oil flowing into the interface P1 is guided to the neutral bypass
(2) by means of the main passage (1). By switching the boom 1 spool (303), the neutral bypass is cut off.
Thus the working oil flowing into the parallel passage pushes open the cone valve (511) of the check valve,
flows into the boom 1 spool (303) from the U-shaped passage, then flows into the periphery of the boom 1
spool (303), and is fed into the boom cylinder piston rod side (R) from the interface Bb.
On the other hand, the return oil from the boom cylinder piston head side (H) passes through the hole (a)
and periphery of the boom 1 spool (303).
The return oil makes pressure rise through the self weight of the booms. To maintain sufficient pressure,
the cone valve (303-317) inside the spool is pushed towards the right of Figure 11 by means of the internal
spool passage, and the return oil flows out of the spool. This pressure oil acts as the working oil for the
boom lowering operation and is again fed into the boom cylinder piston rod side (R), which is called the
boom regeneration function. Part of the return oil flowing into the internal spool passage from the hole (a)
returns to the working oil tank by means of the hole (b).
3-66
H R
511
Ab Bb
XBb1
(c) (b) (a) (303-317)

LG922E930E03059
Figure11
3-67
(5) Bucket
① During bucket excavation operation
[Pilot circuit]
When the bucket spool (304) is switched, the side passage is closed, and thus the pressure at the interface
Px (signal interface for work implements) rises. Meanwhile, pressure oil is also fed into the interface XBp2.
[Main circuit]
During the bucket excavation operation, pilot pressure oil is supplied into the interface XAk, and the bucket
spool (304) moves to the right of Figure 11. The working oil flowing into the interface P1 is guided to the
neutral bypass (2) by means of the main passage (1). By switching the bucket spool (304), the neutral
bypass is cut off. Thus the working oil flowing into the parallel passage pushes open the cone valve (511)
of the check valve, flows into the bucket spool (304) from the U-shaped passage, then flows into the
periphery of the bucket spool (304), and is fed into the bucket cylinder piston head side (H) from the inter-
face Ak.
On the other hand, the return oil from the bucket cylinder piston rod side (R) flows into the interface Bk, and
then flows to the tank interface (R1) from the periphery of the spool to return to the working oil tank.
During the simultaneous boom lifting and bucket excavation operation, pilot pressure oil is fed into the
interface Pck, and thus the stroke of the bucket spool is not only be limited within the full stroke but in a
halfway position. Thus the passage of the bucket cylinder is throttled, and working oil also flows into the
boom 1 spool (303) from the bucket spool (304). Therefore, the boom lifting operation takes priority.
3-68
H R
AK BK
XA K
PCK
LG922E930E03060
Figure12
3-69
② During bucket unloading operation (304), the neutral bypass is cut off. Thus the
[Pilot circuit] working oil flowing into the parallel passage
pushes open the cone valve (511) of the check
When the bucket spool (304) is switched, the
valve, flows into the bucket spool (304) from the
side passage is closed, and thus the pressure at
U-shaped passage, then flows into the periphery
the interface Px (signal interface for work imple-
of the bucket spool (304), and is fed into the
ments) rises. Meanwhile, pilot pressure oil is
bucket cylinder piston rod side (R) from the
also fed into the interface XBp2.
interface Bk.
[Main circuit]
On the other hand, the return oil from the bucket
During the boom lifting operation, pilot pressure
cylinder piston head side (H) flows into the inter-
oil is fed into the interface XBk, and the bucket 1
face Ak, and then flows to the tank interface
spool (304) moves to the left of Figure 12. The
(R1) from the periphery of the spool to return to
working oil flowing into the interface P1 is
the working oil tank.
guided to the neutral bypass (2) by means of the
main passage (1). By switching the bucket spool
H R
AK BK
XBK
LG922E930E03061
Figure13
3-70
(6) Swing switching the rotary spool (305). So working oil

① During individual swing flowing in the parallel passage pushes open the
logic cone valve (2540-101) of the rotary logic
[Pilot circuit]
valve gp, flows in the rotary spool (305) via the
When the swing spool (305) is switched, the
U-shaped passage, then flows into the periphery
side passage is closed, and thus the pressure at
of the rotary spool (305) and is supplied to the
the interface Px (signal interface for work imple-
swing motor via the interface As (or interface
ments) rises.
Bs).
[Main circuit]
On the other hand, return oil from the swing
During individual rotation, pilot pressure oil is
motor flows in from the interface Bs (or interface
supplied into the interface XAs (or interface
As), flows into the oil tank interface (R1) via the
XBs) to switch the rotary spool (305). The work-
periphery of the spool and then returns to the
ing oil flowing into the interface P2 is guided to
working oil tank.
the neutral bypass (2) by means of the main
passage (3). The neutral bypass is cut off by
XB S XA S
As Bs
(254-101)
Swing Motor LG922E930E03062
Figure14
3-71
② Swing priority function Because the opening area of the rotary priority
[Pilot circuit] spool decreases by switching the rotary priority
spool (311), working oil from the spool (302) of
Pilot pressure oil is supplied into the interface
the arm 1 also flows back the rotary spool (305)
Psp to switch the rotary priority spool (311).
so that rotation takes priority.
[Main circuit]
Psp
LG922E930E03063
Figure15
3-72
(7) Backup main passage (3). The neutral bypass is cut off
The backup spool is used for controlling various by switching the standby spool (309). Thus the
additional devices. working oil flowing in the parallel passage
① Optional operation pushes open the cone valve (511) of the check
valve, flows in the standby spool (309) via the U-
[Pilot circuit]
shaped passage, then flows into the periphery of
When the standby spool (309) is switched, the
the standby spool (309) and is supplied to the
bypass is closed, so the pressure of the inter-
additional devices via the interface Ao (or inter-
face Px (signal interface for working device)
face Bo).
rises.
On the other hand, return oil from the additional
[Main circuit]
devices flows in from the interface Bo (or inter-
When the standby spool is operated, pilot pres- face Ao), flows into the oil tank interface (R1) via
sure oil is supplied into the interface XAo (or the periphery of the spool and then returns to
interface XBo) to switch the standby spool (309). the working oil tank.
The working oil flowing into the interface P2 is
guided to the neutral bypass (2) by means of the
XB o XAo
Ao Bo
LG922E930E03064
Figure16
3-73
② Backup flow merging

To merge standby flow, pilot pressure oil is also supplied to the interface XBp1 to switch the bypass stop
spool (310). The working oil flowing into the interface P1 is guided to the neutral bypass (2) by means of
the main passage (1). The neutral bypass is cut off by switching the bypass stop spool (310), so that work-
ing oil pushes open the cone valve (514) of the check valve and merges with the flow in the standby spool
(309) via the internal passage and the U-shaped passage.
(8) Linear travel
When the travel spool (301) is operated together with other spools.
The condition where the travel spool (301) and the rotary spool (305) are simultaneously operated is
described below. (When pilot pressure oil is supplied to the interfaces XAtL, XAtr and XAs)
[Pilot circuit]
The side passage of right travel and left travel spool (301) and the side passage of the rotary spool at the
downstream side are closed, pilot pressure oil from the interface PG is supplied to the interface PTa, and
the linear travel spool (308) is switched.
[Main circuit]
When the linear travel spool (308) is switched, the right travel and left travel spool (301) is preferentially
communicated with the interface P2, the parallel passage of the rotary spool, boom 2 standby spool, arm 1
oil passage/boom 1 bucket and arm 2 oil passage is preferentially communicated with the interface P1, so
that working oil supplied from the interface P2 mainly flows into the interface AtL and the interface Atr and
is evenly supplied to two travel motors.
On the other hand, working oil supplied from the interface P1 is also supplied to the swing motor via the
interface As.
When the pressure oil in the interface P2 is lower than that of the interface P1, one part of working oil sup-
plied from the interface P1 is supplied to the P2 side. So the rapid decrease of travel speed can be pre-
vented.
3-74
P1 P2
PTa
LG922E930E03065
Figure17
3-75
(9) Function of lock valve When the boom 1 spool (303) is neutral, the
The lock valve selector pair (252) is installed spool (252-511) inside the lock valve selector
among the arm cylinder piston rod side (R), the pair is kept in the position as shown in Figure 18
arm 1 spool (302) and the arm 2 spool (306) to by the pretightening force of the spring (252-
reduce the internal leakage of the spool caused 321) and is pressed in the valve seat of the
by cylinder pressure. valve bushing (252-541) inside the lock valve
Likewise, a lock valve selector pair (252) is also selector pair.
installed between the boom cylinder piston head In this position, working oil at the boom cylinder
side (H) and the boom 1 spool (303) to reduce piston head side (H) flows in from hole (a), flows
the internal leakage of the spool caused by cyl- across the periphery of the spool (252-511) of
inder pressure. the lock valve selector pair and presses the
① Spool neutral state valve seat of valve body of the cone valve (513)
at hole (b) so as to reduce internal leakage.
The condition where the boom 1 spool (303) is
selected is shown below. (The condition of arm
2 spool (306) is also the same.)
(252-321)
(252-511)
(252-541)
(b)
513
(a)
LG922E930E03066
Figure18
3-76
② During boom lowering operation ton head side (H) does not flow into the spring
When the boom is operated to lower, pilot pres- chamber (RH). In addition, oil in the cavity of
sure oil is supplied into the interface PbL and the spring chamber (RH) flows into the leakage oil
interface XBb1. The spool (252-511) inside the circuit via the hole (b). Therefore, the cone valve
lock valve selector pair moves to the upper side (513) is jacked through the pressure at the
of Figure 18 through pilot pressure oil. The hole boom cylinder piston head side (H), and the
(a) is first cut off through the movement of the function of the lock valve selector pair (252) is
spool (252-511) inside the lock valve selector released.
pair, and working oil from the boom cylinder pis-
(252-511)
Dr
(RH)
(b)
513
(a)
PbL
XBb1
LG922E930E03067
Figure19
③ When the boom is operated to lift
During the boom lifting operation, pilot pressure
oil is fed into the interface XAb1. The cone valve
(513) is pushed open through oil flowing in via
the boom 1 spool (303), so working oil flows into
the interface Ab.
3-77
(10) Function of main relief valve periphery of the cone valve (611) and across the
The main relief valve is installed on the valve holes in the valve bushing (103).
body A (101) and has the following functions: ③ The pressure inside the cavity (a) drops due
① Working oil fills the cavity of chamber (a) by to the opening of the cone valve (611), and the
means of the holes in the valve seat (541) and valve plunger (512) is opened. Therefore, work-
small holes in the valve plunger (512) through ing oil in the passage (P) directly flows into the
the passage (P), and the valve plunger (512) is low pressure passage (R).
pressed against the valve seat (541) to form reli- 3. When pressure oil above 3MPa is supplied into
able seal. the interface Pz, the pressure oil pushes the
② When the pressure inside the passage (P) plunger (614) to move leftwards to change the
exceeds the pretightening force of the spring setting load of the spring (621), and the pres-
(621), the cone valve is opened, so working oil sure starts to rise.
flows into the low pressure passage (R) from the
541 611 621
R
PZ
(a) 103
512 614
LG922E930E03068
Figure20
3-78
(11) Function of interface relief valve ① Function as a relief valve

The interface relief valve is installed between 1) Working oil fills the cavity of chamber (B) via
the cylinder interface and the low pressure pas- hole (A) of the plunger (301) and presses the
sage. Besides the function as a relief valve, the valve plunger (511) against the valve seat (541),
interface relief valve also has the function as a and the valve seat (541) is pressed against the
check valve for preventing cavitation and replen- valve seat of the valve body to form reliable
ishing oil. seal.
B
A
R
301
511 541
LG922E930E03069
Figure21
3-79
B
A
301 R
511 541
LG922E930E03070
Figure22
3-80
2) When the pressure inside the passage (P) exceeds the elastic force of the spring (621), the cone valve
is opened, so working oil flows into the low pressure passage (R) from the periphery of the cone valve
(611) and across the hole (C).
621
611
LG922E930E03071
Figure23
3-81
R
621
611
LG922E930E03072
Figure24
3-82
3) The pressure inside the cavity of chamber (B) drops due to the opening of the cone valve (611), and the
valve plunger (511) is opened. Therefore, working oil in the passage (P) directly flows into the low pressure
passage (R).
511 611
LG922E930E03073
Figure25
3-83
R
511 611
LG922E930E03074
Figure26
3-84
② Function as a check valve for preventing cavitation and replenishing oil

When the passage (P) generates negative pressure, working oil is supplied from the passage (R). When
the pressure of the passage (R) is higher than the pressure of the passage (P), the valve seat (541) moves
rightwards. Therefore, working oil is guided into the passage (P) from the passage (R) through the periph-
ery of the valve seat (541) so as to prevent cavitation.
541
LG922E930E03075
Figure27
3-85
541
LG922E930E03076
Figure28
3-86
(12) Function of negative control relief valve

The negative control relief valve is installed
between the most downstream of the neutral by- R 511 321
pass and the low pressure passage. The func-
tion of the negative control relief valve is shown
below.
① If the pressure of the interface P is smaller
than the setting pressure of the spring (321), the
cone valve (511) is in the state shown in Figure P
29. The pressure bearing section φB of the cone (c)
valve (511) is canceled by the section φA of
LG922E930E03078
damping rod (512), and the pressure bearing
area is φB-φA at the moment. Working oil in the Figure30
interface P flows to (R) through the orifice (c). Through the above change, the relationship
between the flow Q of working oil flowing from
the interface P to the low pressure passage (R)
R 511 321 and the pressure change is shown in Figure 31.
Pressure
P B
512 A
(c)
LG922E930E03077
Figure29
Flow
② When the pressure of the interface P is
LG922E930E03079
greater than the setting pressure of the spring
(321) as shown in Figure 30, the cone valve Figure31
(511) is opened, and working oil in the interface
P flows to the low pressure passage (R) through
the periphery of the cone valve (511).
3-87
Maintenance references
Part name Inspection item Judgment references Treatment

1) Valve holes in the valve body and spool
slide section, especially spool shoulder
related to pressure maintenance, is
damaged.
2) The O-ring contact face between the
spool cover and the spring cover is
Presence of damaged.
Valve
scratches, bruises, Replacement
body 3) The interface seal in contact with O-ring is
rust and corrosion
damaged.
4) The seal of each relief valve of main
interfaces is damaged.
5) The seals of plunger and plug are
damaged.
6) Other damages affecting normal function
Replace
Presence of
When there are bruises caused by jamming (especially the
scratches, bruises,
of sliding on the periphery section in contact
rust and corrosion
with the seal)
O-rings and seals at
Sliding section is damaged Replacement
both ends
Spool
Insert the spool into
the valve hole, and
observe the condition O-ring is damaged or the spool acts Repair or
where the spool unsmoothly replacement
rotates while moves
to make travel.
Each spring is
The spring is damaged Replacement
damaged
Each cone valve is The cone valve is damaged and cannot be Repair or
damaged fully sealed replacement
Cone Install the spool of
valve each check valve into
the valve hole of the Normal, no need
It isn’t jammed and can act easily and freely
valve body, and of treatment
observe its action
condition
Whether the spring,
spring holder, plunger
Around
and cover are rusted, Part has significant damages Replacement
spring
deformed and
fractured.
3-88
Repair or
Oil leakage Oil leakage
Around the replacement
sealing Whether the seal
section of plate is rusted, The seal plate is rusted, corroded and Repair or
the spool corroded and deformed. replacement
deformed.
1) Main Whether there is rust
Relief and fracture on There is rust and fracture on appearance Replacement
Valves appearance.
2) Contact face of the The contact face of the valve seat is
Replacement
Interface valve seat damaged.
relief valve The contact face of
The contact face of the spool is damaged Replacement
3) each spool
Negative Abnormal spring Abnormal spring Replacement
control O-rings, snap rings
relief valve Replace all of them in principle Replacement
and seals
3-89
3.3.2.3 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 resis-
tance, multiple accesses, mutual noninterference for rotating 360°, simple connection, safety, reliability,
etc.
Structure
The structure of the center joint is shown in the figure below.
10
14
X2 X1
6
B1
8
B2
12
7 A1 2
1
4 A2
3
13 11
X
A2
B2
A1
B1
LG922E930E03080
3-90
Parts List X1: travel motor-lh high-speed/low-speed

switching port P
S/N Name S/N Name X2: travel motor-rh high-speed/low-speed
Center connector switching port P
1 BOLT M10×25 8
body A1: travel motor-lh port A
2 Washer 10 9 Bushing
B1: travel motor-lh B port
3 Cover 10 Dust ring
A2: travel motor-rh A port
O-ring
4 11 Plug B2: travel motor-rh B port
98.02×3.53
5 Retainer 60 12 Seal ring L: left and right travel motor oil drain port
6 Spindle 13 O-ring 17.8×2.4
7 Retainer ring 14 O-ring 89.6 X 5.3 Working principle
Center swivel joint is composed of revolving
body, revolving shaft, 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
X2 X1 installed on upper part (or upper part) of vehicle
body, which can rotate 360° freely. Slot annular
B1 grooves on revolving shaft with the same num-
B2
ber of oil line, and hydraulic oil entering into oil
A1
A2 inlet of revolving body connects with radial hole
on revolving shaft through oil groove on revolv-
ing body, and supplies travel motor. Because
L
LG922E930E03081 the annular grooves on revolving body and
revolving shaft are closed, no matter whether
revolving body or revolving shaft rotates along
X with vehicle body, the mutually corresponding oil
A2
port is always independent and smooth, which
guarantees normal flowing of hydraulic oil. See
details in following figure
B2
L
A1 B1
LG922E930E03082
3-91
Working Schematic Diagram of Central

Swivel Joint
Body port
Shaft port
Fault analysis
Fault
S/N Fault cause Countermeasures
phenomenon
1. Dust impurities enter the
1. Take dust-prevention measures for
neck to damage neck seal;
base machine
2. The connection is subject to
Oil leakage of 2. The products must meet installation
1 external force during
neck part requirements when being connected
installation, causing single side
and installed;
abrasion of the seal to lead to
3. Replace sealing part.
oil leakage.
Oil leakage at Loosening of fastening bolt or
2 the place of damage and aging of seal at Retighten the bolt, and replace the seal.
cover the place of cover.
Hydraulic pipeline fitting
Oil leakage of oil Replace with new hydraulic pipeline
3 connecting with oil port is
port fitting
damaged.
3-92
3.3.2.4 Explosion-proof valve

The hose bursting-proof valve is optional and its schematic diagram is as follows:
2 2
3
4
5
5
1 2
LG922E930E03084
1- Adjustable throttle valve 2- Throttle valve

3- Relief valve 4- Spool 5- Check valve 6- Strainer
3-93
If the hose bursting-proof valve is selected, it is directly installed on the cylinder (large boom cylinder cavity
and small boom cylinder cavity) to prevent the control cylinder from suddenly dropping without the action of
gravity after hose bursting to cause accidents.
During normal working, oil enters the cylinder through the check valve (5). During reverse action, oil needs
to cooperate with the pilot signal to enter the control port of the balanced valve (4) through the check valve
(5) at the lower right corner so as to open the balanced valve. Oil flows out of bursting preventing valve
through balanced valve (4).
After the hose bursts suddenly, hydraulic oil in the hydraulic cylinder cannot pass through the valve due to
the blocking of the spool 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.
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 pres-
sure 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) can-
not 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.

The safety pressure of the relief valve (3) is used for protecting the cylinder from being damaged.
Do not adjust without permission. After adjustment for specific reasons, please restore to the fac-
tory setting pressure.
3-94
3.3.2.5 Hand pilot valve trol two working devices, left pilot controls rota-
tion and arm, and right pilot controls bucket and
Specifications
boom.
First side
Maximum pressure is 6.9 MPa
pressure Working principle
Secondary
0~4.4 (maximum control pressure)
side
MPa
pressure
Allowable
backpress Maximum 0.3 Mpa P T
ure
Rated flow
20L/min
rate
Operating
±19°
angle
Mass 1.9kg
In order to obtain well
responsiveness, appropriate
3 1 4 2
pipeline is the one with inner
diameter as φ8 and length as
Pipeline LG922E930E03086
about 3m. In addition, return oil
shall not be affected by other Schematic diagram of hand pilot valve
backpressures and directly enter 1, 2, 3, 4-Oil inlet and outlet ports
into tank.
P-Pilot pressure oil port
Structure T-Pilot oil return port
1 2
3
1 4
9
5
8
6
14
2 15
7
16 17 13 12 10
LG922E930E03085 LG922E930E03087
Overall structure of hand pilot valve Structural schematic diagram of hand pilot valve
1-Control lever 2-Pilot valve 1-Presser plate 2-Push rod
The hand pilot control valve is composed of a 3 - Spring 4-Force transmission rod
control lever (1) and a pilot valve (2). It can con- 5-Spring holder 6-Pressure regulating spring
3-95
7-Reset spring 8-Return cavity the control lever generates a certain displace-
9-Return passage 10-Oil inlet passage ment.
When the pilot lever slightly swings to a small
11-Valve rod 12 Oil port
angle under non-operative state, the pressure
13-Oil inlet cavity 14-Return passage
adjusting spring (6) will also make the valve rod
15-Oil inlet passage 17 - Oil port
(11) move downwards slightly, and the main
When the control lever pulled rightwards, the valve control valve rod also generates one small
presser plate (1) tilts rightwards. The presser displacement. At the moment, the main valve
plate (1) pushes the push rod (2) downwards, it will output small-flow pressure oil, and this pres-
brings the spring holder (5) to overcome the pre- sure oil will make the working cylinder or motor
tightening forces of the pressure adjusting act slowly. However, when the pilot lever sud-
spring (6) and return spring (7) to move down- denly swings by a large angle, the pressure
wards. The valve rod (11) also moves down- adjusting spring (6) will also make the valve rod
wards under the action of force of the spring (6). (11) move downwards quickly, the main control
The oil inlet passage (10) is opened. Pilot oil valve rod will quickly generate one large dis-
flows from the oil inlet cavity (13) to the port of placement to output large-flow pressure oil, so
the main valve control valve rod through the that the working cylinder or motor quickly acts.
passage (10) and via the oil port (12). Pilot pres- Therefore, the action speed of the cylinder or
sure oil makes the main control spool move, and motor is related to the control angle of the pilot
corresponding actuating mechanism under con- control lever.
trol acts to operate or rotate.
The controllability depends on the action sensi-
Pilot oil at the another port of the main valve tivity of the cylinder and motor. The timely action
control valve rod returns to the oil port (17), and of the cylinder and motor needs pilot pressure
the return passage (14) is opened and the oil oil to timely reach the main control valve rod end
inlet passage (15) is closed because the push and timely make the main control valve rod act
rod is not pressed by the presser plate. Pilot oil timely. The pilot lever swings in the non-opera-
returned to the oil port (17) enters the return tive state, and only the pressure adjusting spring
cavity through the return passage (14) and (6) makes the valve rod (11) move downwards.
returns to the system oil tank via the hand pilot Actually, the downward movement of the valve
valve. rod (11) firstly makes the push rod (2), the
Therefore, the control lever generates one spring (3) and the force transmission rod (4)
angle, the pressure adjusting spring (6) is com- move downwards, and then, the spring (3) and
pressed and pretightened, the pressure adjust- the pressure adjusting spring (6) act together to
ing spring (6) will also make the valve rod (11) make the valve rod (11) move downwards.
move downwards, the oil inlet passage (10) is Therefore, the conduction speed of pilot pres-
opened, pilot pressure oil reaches one end of sure oil is closely related to these two springs,
the main valve control valve rod through the oil i.e. the controllability is closely related to these
inlet passage (10), and thus, the angle of the two springs.
main valve control valve rod corresponding to When the lever is released, the return spring (7)
3-96
makes the control lever return to the natural non-operative state.

Maintenance references
Check items Maintenance limit Treatment Remarks

If one of them
When the lever is
is reached, Conditions:
neutral: above 1000 cm³/
Leakage the pilot valve
min Primary pressure 2.94 MPa
volume needs to be
During working: above Oil viscosity 23mm²/s
replaced with
2000 cm³/min
a new one.
The sliding section is Replace the In the aspect of leakage, the left
abraded by 10 μm more pilot valve condition is predicted to be roughly the
Slide valve
than the non-sliding with a new same to the condition with the above
section. one. leakage.

The head is abraded by
Push rod Replacement
more than 1 mm.
PP
Abrasion of The amount of clearance

operating between the disk (302) of When shaking (clearance) is generated
section operating section and the Replacement due to the looseness of the tightening
(amount of joint section (301) is section, etc., adjustment is needed.
clearance) more than 2 mm.
Abnormal sounds,
irregular vibrations, too Replace the
Stability of low primary pressure, pilot valve
action etc. are generated during with a new
working and cannot be one.
restored after treatment.
Note 1) Although seals such as O-rings are expected to be replaced after removal, it is ok to reuse
them after being confirmed to be undamaged.
3-97
3.3.2.6 Foot pilot valve Structure
Specifications The overall structure of the foot pilot valve is

First side Maximum pressure 6.9 MPa (70 shown in the figure below
pressure kgf/cm2)
Secondary Maximum control pressure 0~4.4
side
pressure MPa (0~44.8 kgf/m2)
Allowable 1
backpressur Maximum 0.3 MPa (3kgf/m2)
e
Rated flow
10L/min 2
rate T
Operating
±12.4° P
angle
Mass 6.3kg
To obtain good responsibility, a LG922E930E03089
pipeline with about φ8 inner
diameter and 3 m length is External structure of foot pilot valve
Pipeline
selected. Return oil shall not be 1-Pedal 2-Pilot valve
affected by other backpressure
and directly enter into tank. T- Return port P- Oil inlet
To prevent the slide valve from The foot pilot valve is composed of a pedal (1)
being jammed due to and a pilot valve (2). Two control pedals respec-
Oil filter uncleanness, please set oil filter
with above 40 meshes at the P tively control the left and right travel motors and
port interface. share return port T and oil inlet port P.
3-98
Working principle 13-Pedal 14-Pressure regulating spring

The schematic diagram of the foot pilot valve is 15 - Oil port T-Oil joint
as follows P-Oil joint
A hydraulic damping device is arranged inside
this valve. When the machine is operated to
1 move forwards or backwards and the road is
bumpy, machine vibration is easily caused, so
the driver’s operation must be affected, and the
2
P driver cannot operate well to make the machine
vibrate more severely to form a vicious circle.
T
The controllability of foot pilot valve without this
device is poor, and the driver always has no
choice but to stop the machine to eliminate
machine vibration.
LG922E930E03090
The hydraulic damper is composed of a spring
(2), a spring (3), a spring cavity (4), a steel ball
1-Pedal 2-Pilot valve
(5) and a damping piston (6); and the pressure-
T-Oil joint P-Oil joint
reducing valve is composed of a spring holder
(7), a spring (14) and a spool (9).
13 1 When the travel pedal presses leftwards as
shown in the figure, the cam adjusting gp (11)
11 2 tilts to press the push rod (12) downwards, the
3 push rod (12) moves downwards to drive the
12
4 damping piston (6) and the spring valve seat (7)
6 to overcome the resistance applied by the
5 hydraulic damper and the elastic forces of the
7 T
springs (8) and (14) to move downwards, and
8 14
the pressure adjusting spring (14) forces the
9 P spool (9) to move downwards so the oil port (10)
10 15
LG922E930E03091 is communicated with the oil inlet joint P. When
the oil port (10) is communicated with the oil
Internal structure of foot pilot valve
inlet joint P, pilot pressure oil enters along the oil
1-Push rod 2 - Spring
inlet joint P, reaches the travel control valve rod
3 - Spring 4-Spring cavity control port through the oil port (10), and pushes
5-Steel ball 6-Damping piston the travel control valve rod so that high pressure
7-Spring holder 8-Reset spring oil from the main pump flows across the travel
9- Spool 10 - Oil port control valve rod to the travel motor. The travel
motor rotates to drive the mechanical travel to
11-Cam adjusting gp 12-Push rod
move.
3-99
The travel control valve rod makes low pressure amount between the port P and the oil port (10),
oil at the other end flow back the oil port (15) of i.e. damping of communication between the port
the foot pilot valve, the pressure adjusting spring P and the oil port (10) decreases, the pressure
is not stressed due to the action of the return drop from the port P to the oil port (10)
spring, the spool is also in the upper position, decreases, and the pressure of the oil port (10)
and the oil port (15) is communicated with the is ensured to be unchanged, even when the
return interface T at the moment. Low pressure pressure of the oil inlet joint P has decreased.
oil enters to the oil port (15) enters the return
cavity along the oil port (15) and returns to the
system oil tank from the return interface T.
To make sure the mechanical travel moves sta-
bly, pilot oil reaching the travel control valve rod
control port needs to be stable, i.e. oil pressure
coming out of the oil port (10) needs to be sta-
ble, which is realized by the pressure-reducing
valve composed of the spring holder (7), the
spring (14) and the spool (9).
When the oil pressure of the oil inlet joint P
rises, the pressure of the oil port (10) will also
rise within a short period of time. Because the oil
pressure of the oil port (10) rises, the force mak-
ing the spool (9) move upwards increases, so
the pressure adjusting spring pushes the spool
(9) upwards to reduce the communication
amount between the port P and the oil port (10).
Because the communication amount between
the port P and the oil port (10) is reduced, damp-
ing increases, i.e. the pressure drop from the
port P to the oil port (10) increases, and the
pressure of the oil port (10) is ensured to be
unchanged, even when the pressure of the oil
inlet joint P has rised. When the pressure of the
oil inlet interface P decreases, the pressure of
the oil port (10) will also decrease within a short
period of time. Because the oil pressure of the
oil port (10) decreases, the force making the
spool (9) move upwards decreases, so the pres-
sure adjusting spring pushes the spool (9)
downwards to increase the communication
3-100
Fault causes and countermeasures repair, please refer to the cause and counter-
It is not easy to locate the fault. Problem points measure columns in the table.
to be considered in several aspects are listed in
the table below. Because this valve is difficult to
Symptom Reasons Treatment
Insufficient primary pressure Ensure primary pressure
The elastic force of the spring
(324) for setting secondary Replace with new product
pressure has been weakened.
Low secondary pressure The clearance between the
Replace slide valve and valve
slide valve and the valve body
body gp
has been abnormally large.
Remove, assemble and replace
Control parts are loose
control parts
Sliding parts are jammed Repair jammed parts
Variation in oil circuit pressure Directly return the return oil to
Unstable secondary pressure of oil tank the oil tank
Operate repeatedly for several
Air in the pipeline
times to exhaust air
Too high oil tank oil circuit Directly return the filling oil to
High secondary pressure pressure the oil tank
Sliding parts are jammed Repair jammed section
Air remained in the plunger Operate repeatedly for several
chamber times to exhaust air
Sliding parts are jammed Repair jammed section
The elastic force of the buffering
spring (336.337) has been Replace with new product
weakened.
The clearance between the
Ineffective buffering buffering plunger (224) and the Replace the buffering plunger
buffering housing has been and buffering hosing gp
abnormally large.
Check the check valve section
Poor action of check valve
after disassembly.
The damping hole of the
buffering plunger has been Replace the buffering plunger
abnormally large.
Sliding parts are jammed Repair jammed parts
Heavy buffering moment The damping hole of the
Replace or repair the buffering
buffering plunger has been
plunger
blocked
3-101
3.3.2.7 Cushion valve

Exterior drawing
LG922E930E03092
3-102
Structure
1 2 3 4 5 6 7(2) 8 9 10 11 12 13 14 15
LG922E930E03093
1-Plug 6-Throttle 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
5- O-Ring 10- Spool 15-Spring
3-103
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 7. Throttle valve

2. Orifice 5. Spool
3. Check valve 6 Check valve
3-104
Working principle
The buffering valve has two functions, and its working principle will be respectively described below.
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 prop-
erty, 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 prevent-
ing 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.
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 sig-
nal drives the spool 5 of the buffering valve to move rightwards. The port F is communicated with the port
T.
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.
3-105
3.3.2.9 Travel motor & reduction gear

Travel motor & reduction gear includes two sections: travel hydraulic motor (hereinafter referred to
as travel motor) and reduction gear, which will be described below respectively.
(1) Travel motor
Travel motor specification
Item Unit GM35VL motor part

Motor stroke volume (high volume /
cm³/rev. 113/75
low volume)
Rated pressure Mpa 32.2
Parking brake torque N·m 398
Parking brake release pressure MPa 0.6
Common 0.2
Allowable oil discharge pressure MPa
Impact 0.7
3-106
Basic Structure and Schematic Diagram

1. The basic structure of the motor
Hydraulic circuit
Reduction gear
Hydro-motor
Brake valve
Parking brake
2-speed switching
mechanism
Control valve
Hydraulic pump
LG922E930E03205
3-107
13 20 25 7 8 15 6 38 102 3 34 19 33 43
37
9
30
35
22 132
12 149
23 193
5 161
17 162
4 103
1 106
21 107
31 105
2 108
171 111
157 104
115 151
116 397
112 A
398
27 110
379 114
29 139 135 113 109 150 399 341 301 357 355 366 383 145
LG922E930E03206
3-108
324
220
326 201
336 206
325
219
357 202
B
355 203
323
205
327 204
330 210
337 217
326 209
343 211
42 208
LG922E930E03207
3-109
Details of Parts
S/N Name S/N Name S/N Name S/N Name

Reduction gear
A 27 O-ring 115 Friction plate 381 Plunger
assembly
A Shaft gp 29 O-ring 116 Matching plate 324 Plug
A Shaft assembly 30 O-ring 132 Oil seal 325 Spring seat
2 Shaft 33 Plug 135 O-ring 326 Plug
3 Fixed flange 35 Hex screw 139 O-ring 327 Valve
19 Hex screw 36 Steel ball 149 Deep groove 328 Spring

ball bearing
34 Fixed pin 42 Dowel pin 150 Deep groove 330 Spring
ball bearing
37 Washer 43 O-ring 167 Hinge 336 O-ring
B RV- Gear as B Motor as 171 Dowel pin 337 O-ring
Drawings of
A RV - Gear set A cylinder & 193 Spring 346 Hex plug
plunger
4 RV gear A A Drawing of C Relief valve 352 Hex plug
plunger
Drawing of
5 RV gear B A Plunger as A 354 Hex screw
valve
9 Camshaft 105 Plunger 201 Valve 355 O-ring
12 Shim 106 Shoe 202 Valve bushing 357 Hex plug
Spring stop
22 Cone bearing 104 Cylinder body 203 dog 358 O-ring
23 Needle bearing 107 Thrust plate 204 Plug 359 O-ring

Propelling steel
C Support gear gp 108 205 Snap ring 363 Valve rod
ball
7 Support gear 110 Washer 206 Spring 366 Spring
D Floating seal gp 111 Shaft bushing 208 O-ring 368 Steel ball
31 Floating seal ring 114 Spring 209 O-ring 379 Filter
1 Hub 145 Elastic snap 210 O-ring 380 Plug

ring for holes
6 Axle gear 151 Rolling needle 211 Supporting ring 382 Plug
8 Cover B Plunger as 217 Supporting ring 383 O-ring
13 Washer 161 Plunger 219 O-ring 384 O-ring
Connecting
15 162 Shoe 220 Plunger seal 385 Steel ball
sleeve
Control valve
17 Pin 102 Drive shaft D 397 Strainer
as
Elastic snap ring Rear cover
20 103 Swashplate A 398 Hex plug
for holes flange gp
Rear cover
21 Angle bearing 109 Thrust plate A 399 Nameplate
flange gp
Spring backup Rear cover
25 112 Plunger 301 341 Plain pin
ring used on rod flange
113 Spring 323 Valve rod 343 Bolt
3-110
[Note] Reduction gear

① The assembly in the Component Column Working principle
should be an integral assembly in principle, and The reduction gear consists of a spur gearing
treated as one component. (hereinafter referred to as the first reduction
② KIT and ASS'Y in the Component Column gears) and a differential gearing with epicycloid
can be dismantled into single components, but, tooth profile (hereinafter referred to as the sec-
in principle, it should be treated as one compo- ond reduction gears). The purpose of the reduc-
nent, just like a set of components and assem- tion gear is to convert the hydraulic motor’s
blies. high-speed rotary movement into a low speed
③ Distinction is to show the available range of and high torque one to rotate the hub [1] (hous-
complementary components. ing).
A: Available components (JIS components or

exchangeable components from the manufac- Spur Gear
Crank Shaft
turers)
B: Available components (Single components
supplied by our company)
C: Available components (If any component
needs to be replaced, our company will provide
Shaft
the assembly or KIT.)
E: Assembly offered conditionally (When any
component needs to be replaced, a single com-
ponent can be supplied with a precondition that Input GEER
the specified clearance needs to be adjusted.) LG922E930E03208
F: Assembly offered conditionally (When any Description of Reduction Gear Motion

component needs to be replaced, an assembly 1. First reduction gears
or KIT can be supplied with a precondition that The rotary movement of the hydraulic motor is
the specified clearance needs to be adjusted.) transferred to the input sun gear splined to the
X: Unavailable components (Any single compo- shaft [102]. Then, the 3 planetary spur gears
nent cannot be provided but assembly or KIT) engage the input sun gear, resulting in a decel-
④ The number in the Adjustment Symbol Col- erated rotation.
umn means that a component whose clearance In this case, the reduction ratio of the first reduc-
needs to be adjusted when replaced. tion gears is shown below;
i1=
i1 = reduction ratio of the first reducer
Zi= tooth number of the sun gear
Zs= Number of teeth of the planetary spur gears
3-111
reduction ratio of the second reduction gears is

Spur Gear shown below;
Needie Beanng
rolation i2
ecconlric
i2 = Reduction ratio of the second reduction
ralation B gears ZR = Number of teeth of the RV gears A
A
and BZP = Number of needle-sharp teeth
Therefore, when the shaft of the hydraulic motor
makes a turn. The rotational speed of the input
shaft is as follows;
ecconlric motion RV Gear B
i=i1*i2
RV Gear A LG922E930E03209
i1 = Reduction ratio of the first reduction gears
2. Second reduction gears
i2 = Reduction ratio of the second reduction
① The 3 planetary spur gears are respectively
gears
splined to the crankshaft [9] to transfer the
torque from the first reduction gears to the sec- i
ond reduction gears. When the crankshaft [9] is
rotated, its eccentric A and eccentric B perform
eccentric motion (orbital motion) while rotating.
1 Hub
Affect by the eccentric A and B and needle roller Pin
bearing installed on the eccentric A and B Only Rv Gear A or B
transfer the eccentric motion of eccentric A and
Crank Shaft
B into the RV cycloidal gear A and B.
350° 350°
24
Then, the RV cycloid gears A and B move 24
2 3
eccentrically, together with the planetary gears
and the crankshaft, in the same direction and at
the same speed.
② The eccentric movement of RV cycloid gears
crank shaft one rev crank shaft one rev
A and B allows the tooth surfaces of RV cycloid LG922E930E03210
gears A and B of ZR and their meshing needle-

sharp teeth of ZP to change their meshing posi-
Hydraulic motor (brake valve)
tions while rolling.
Function
When RV cycloid gears A and B make a return
1) Function of hydraulic motor
of eccentric rotary movement, the needle-sharp
teeth will move the difference of number of teeth The hydraulic motor is called swashplate axial
[(ZP-ZR) / ZP] between ZR (number of revolu- piston motor. Act on changing the oil pressure
tion teeth) and ZP (number of needle-sharp from the pump into rotary motion.
teeth) in the same direction. therefore, then the 2) Function of hydraulic brake valve
3-112
(1) The hydraulic brake valve can overcome the plunger [105]. The pressure oil into one side of
inertial force due to the inertia of the vehicle the cylinder [104] will push the plunger (4 or 5),
body when the running motor is stopped, result- respectively, resulting in F (Fkg = Pkg/
ing in smooth braking, so that the motor can be cm2×Acm2). This force is applied to the swash
stopped smoothly. plate [103]. Since there is an α angle of the
(2) It can avoid cavitation of the hydraulic motor, swash plate with the axis of the motor rotating
just like a check valve. shaft, the force can be divided into the compo-
(3) It can control the volatility of the hydraulic nent forces F2 and F3. The radial component
motor brake pressure, just like a release valve, (F3) of the two component forces applies a dif-
and avoid cavitation. ferent torque (T = F3 × ri) to Y1-Y2. The resul-
3) Function of parking brake tant torque of these torques [T = Σ (F3 × ri), as a
The parking brake is integrated into the hydrau- running torque, allows the cylinder to rotate
lic motor. The parking brake can prevent the through the plunger. The cylinder is splined to
excavator from slipping or sliding through the the motor shaft, so that the moment of rotation
friction brake mechanism when the excavator is can be transferred to the motor shaft.
parked on a slope.
112
301
104 105 D C D
328 323
C
a b
109
102
Y1 103
F3
F3
327
D F3
Drain B A
F3 P
F3
F3
LG922E930E03212
Y2
LG922E930E03211
2. Brake valve
Principle and Instructions of Operation 2-1) When operating (with brake released)
1. Hydro-motor The pressure oil provided by Port A pushes the
The pressure oil from the hydraulic pump enters valve [327] open and flows into Port C on the
into the rear flange [301] of the hydraulic motor, suction side of the hydraulic motor to rotate the
and then flows into the cylinder [104] from the hydraulic motor. Meanwhile, the pressure oil
plate [109] through the brake valve mechanism. flows through the pipe (a) through the orifice of
The oil pressure is only injected into the side the valve element [323] and flows into the cham-
which connects the top dead center and the bot- ber (b), and then acts on the end face of the
tom dead center (Y1-Y2) of the stroke of the valve element, producing a force which can
3-113
push the valve element (in the neutral state due pressure oil in Chamber D.
to the spring [328] force) left. As a result, the pressure oil in Chamber D flows
Once moved, the valve element will pass the to the chamber (c) with a lower pressure. There-
slot, resulting in a clearance (passageway) fore, the pressure in Chamber D can be con-
between the valve element and the rear flange. trolled, thus avoiding cavitation of the chamber
Through this passageway and, Port D of the (c). When the plunger [381] reaching the end of
return oil line of the hydraulic motor will be linked the stroke, the pressures in the chamber (g) and
to Port B in the other direction. Return oil flows the chamber (f) rise. As a result, the valve [201]
into the tank, so that the hydraulic motor can be on the left side will be closed again, resulting in
rotated. pressure rise of Port D. As a result, the valve
Also, due to the sliding movement of the ele- [201] on the right side will be pushed open. The
ment of the valve [323], the pressure oil flows oil in Port D will flow into Port c at a pressure
into Port P and Port S. The oil into Port P allows higher than the set overflow pressure of the
the plunger [112] of the parking brake to move, excavator. Thus, the pressure of Port D can be
thereby releasing the parking brake force (for controlled through two stages, so that the
more information, see the Parking Brake sec- hydraulic motor can be stopped smoothly.
tion.). 2-3) When self-propelled
If the oil pressure is provided by Port B, the When the excavator traveling down along a
valve element [323] and the valve [327] move slope, its traveling speed will be higher than that
left and right reversely, so that the hydraulic corresponding to the oil volume supplied by the
motor is rotated reversely. oil hydraulic pump, and this is called a self-pro-
2-2) When stopping, stalling (with brake acti- pelled speed (overspeed).
vated) When self-propelled, the oil pressure will disap-
When traveling, if the pressure oil from Port A is pear, just like when stopped. As a result, the
stopped, the oil pressure disappears. As a brake valve operates in the same way when
result, the valve element [323] moved left will stopped to pressurize the return circuit of the
return right (neutral state) through the stopper hydraulic motor, resulting in a backpressure
[325] due to the spring [128] force. Meanwhile, which decelerates the hydraulic motor rotating
the pressure oil from Port A is stopped, but the due to inertia to fit the oil supply of the pump to
hydraulic motor will continue to rotate due to control the motor speed.
inertia. However, the oil discharged from the
hydraulic motor allows the oil pressure in Pipe D
to rise. The pressurized oil flows into the cham-
ber (g) from the chamber (f) through the hole of
the valve [201] on the left side. The oil into the
chamber (g) will allow the plunger [308] to move
to the right shown in the figure, so that the pres-
sure will not rise. During this period, the valve
[201] on the left side is pushed open by the
3-114
3. Parking brake [115] on the main shaft [2] of the reduction gear,
resulting in a frictional force which stops the
rotating cylinder [114] and keeps the brake
116 torque of the main shaft of the hydraulic motor of
α 115
104
397.9N • m (40.6kgf • m). Further, the anti-inver-
sion oil-circuit design is used to ensure smooth
112
operation of the whole process above.
13
LG922E930E03213
3-1) When traveling

When the brake valve providing pressure oil, the
element [323] of the brake valve of the hydraulic
motor will move, so that the passageway to the
parking brake will be opened. The hydraulic oil
flows into the cylinder chamber (a) which is
composed of the main shaft [2] and the plunger
[112] of the reduction gear.
When the oil pressure reaches more than 0.6
MPa (6kgf/cm2), the pressure is greater than the
spring [113] force. The plunger [112] will move
to the side of the rear flange [101] accordingly.
Due to movement of the plunger [112] toward
the engagement piece [116], the thrust to friction
plate [115] will disappear. As a result, the friction
plate in the cylinder [104] of the hydraulic motor
can move freely and the braking force applied to
the cylinder [104] can be released.
3-2) When stopping
With the pressure oil from the brake valve cut
off, when the pressure in the cylinder chamber
(a) is reduced to 0.6MPa (6kgf/cm²) or less, due
to the spring [113] force, the plunger [112] will
be restored, thus pushing the engagement piece
[116] in the free state to engage the friction plate
3-115
4. Description of 2-speed switch when braking

At low speed
When Port D has no control pressure provided, the valve element [363] will be moved upward by the spring
[366] force and the hydraulic pressures of Port A and Port B, and the hydraulic oil of Port C will be blocked,
so that the oil in Chamber P will pass through the element [363] and flow out through the discharge outlet.
Thus, the inclination angle of the swash plate [103] maximizes, so that the motor will be rotated at low
speed.
Pilot Press.
P
A B 366
363
2
103 Y
161
C a
Drain
LG922E930E03214
3-116
At high speed plate until the upper of the swash plate clings to
The control pressure provided by Pipe D the Y surface. Then, the inclination angle (θ2) of
reaches 3.4MPa, which is greater than the the swash plate [103] becomes small, so that
spring [366] force, so that the valve element will the volume displacement of the hydraulic motor
be pushed downward. The pressure oil of Port C minimizes. As a result, the hydraulic motor will
flows into Chamber P through the valve element be rotated at high speed.
[363], and the piston [161] will push the swash
Pilot Press.
P
A B 366
363 b
2
161
103
C a
Drain
LG922E930E03215
3-117
Faults and Actions:
Unable to Without The set adjustment

Set it to the correct position
start pressure pressure is excessively low
Check if there is work other

The pump has failed
than traveling and repair
the pump if action of other
parts is abnormal
Steering control Check if spool works

valve has failed normally and repair it if
necessary.
With pressure The brake valve fails Replace the corresponding

parts if the spool, valve, etc.
are damaged due to burn.
The hydraulic motor has

Check the hydraulic oil and
failed
replace with new hydraulic
oil or motor if the oil
deteriorates.
Replace the motor with

Reduction gear is damaged reduction gear
Overloading appears Lighten the load
Oil leakage At the joint The joint surface is Correct with oil stone,
surface damaged abrasive cloth, etc.
The bolts are loose Check after tightening
At the housing Whether the joint pipe Tightening

is loose
Damage resulting Replace the motor

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

Wear on vibration surface
seal with reduction gear
Replace the motor

The O-ring is not in place
with reduction gear
From the The bolts are loose Tightening

hydraulic motor
The O-ring is damaged Replace the O-ring
Correct with oil stone,

Damage on seal surface
abrasive cloth, etc.
3-118
Poor volume efficiency of Replace the motor with

Brake fails on a slope hydraulic motor reduction gear
Internal leakage of brake

valve increases Replace the brake valve (replace the
rear placed flange)
Parking brake valve is out

of work
The spring is damaged Replace the spring
Brake friction plate is worn Replace the friction plate and

mesh plate
The temperature of the reduction Gear oil is insufficient Refill to the specified amount
gear housing surface is
excessively high
Replace the motor with

The bearing is worn
reduction gear
Hydraulic oil leaks into the

Replace the oil seal
reduction gear
Leftwards and rightwards Taking place under low
snaking symptoms pressure status
Different oil inlet volume at the Repair the hydraulic pump
left and right sides
Different motor displacement at the Replace the motor with
left and right sides reduction gear
Taking place under high

pressure status
Different oil inlet volume at the Repair the hydraulic pump and
left and right sides the control valve
Different motor displacement at the Replace the motor with
left and right sides reduction gear
Different brake valve actions at the Replace the brake valve and the
left and right sides rear placed flange
The set adjustment pressure of the Set correct pressure or
left or the right control valve is
replace the relief valve
excessively low
Abnormal sound Hydraulic motor or reduction gear Replace the motor with
is damaged reduction gear
The oil supply pipe vibrates Perform tightening
LG922E930E03217
3-119
3.3.2.10 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
Specifications of swing motor
Theoretical capacity, cm3 129.2

Relief valve pressure, MPa 25.5
Maximum speed, r/min 1850
Theoretical output torque, N.m 525
Brake torque, N.m 874
Brake release pressure, Mpa 3.4
Weight, kg 54
Structure of swing motor
Section of hydraulic motor
LG922E930E03116
3-120
Parts list of swing motor

10 Piston 301 H2 housing
20 H2 valve body assembly 351 H2 piston
31 Time delay valve 355 H2 spring
33 Hexagon socket head cap bolt 390 Nameplate
51 Relief valve 391 Pin
80 Seal kit 400 Anti-reversing valve
100 Valve body 401 Hex screw
101 Drive shaft 443 Rolling bearing
111 Cylinder 444 Rolling bearing
114 Spring pressure plate 452 Pin
123 Fixed plate 469 Plug
124 Swashplate 712 Brake spring
131 Valve fixing plate 742 Brake plate
151 Plug 743 Spacer
161 O-ring 983 Plug
162 O-ring 984 Plug
163 O-ring 985 Plug
171 Hexagon socket head cap bolt
3-121
Working principle of swing motor
POD
F1
F2
F
a a
4
2 5 1
3
LG922E930E03117
Schematic diagram of swing motor plungers inside the cylinder body, the rotating
1-Thrust plate 2- Plunger moment will be successively transmitted to the
3-Shoe 4-Swash plate cylinder drive shaft through several plungers
5-Cylinder body connected to the high pressure oil port. When
the direction of oil flow is opposite, the direction
When high pressure oil enters the cylinder body
of the cylinder is also opposite.
cavity through the oil port (a) (inlet of the oil dis-
tribution plate 1), hydraulic pressure acting on
the plunger generates axial force F. Pressure F
acts on the shoe (3) through the plunger (2), and
the shoe (3) acts on the swashplate (4) through
hydrostatic support. Force F1 vertically acts on
the swashplate (4), and force F2 vertically acts
on the cylinder center. Force F2 is transmitted to
the cylinder body (5) through the plunger and
causes rotation movement around the cylinder
body. Because there are (9) equally arranged
3-122
① Control valve
Air suction preventing check valve
LG922E930E03118
Working principle of air suction preventing check

valve
1-Control valve
2-Oil replenishing line
3-Oil replenishing 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 con-
stant value. A small buffering piston is arranged
in the relief valve, 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.
3-123
③ Braking of swing motor
101
111
712 1
702
301
742
743
LG922E930E03119
Braking process of swing motor
1-Hydraulic oil cavity 101-Drive shaft 712-Brake spring

2-Hydraulic oil acting force 111-Cylinder body 742-Friction plate
3-Spring acting force 301-Housing 743-Release plate
702-Brake plunger
3-124
The cylinder body (111) is connected with the Looseness Replace

drive shaft (101) through one gear, and the fric- (δ) between the
plunger and plunger
tion plate (742) is connected with the outer side 0 0.3
shoe and
of the cylinder body through one gear. When the riveting shoe
brake spring (712) acts on the friction plate 742 section gp.
through the release plate (743) and the brake Replace
the
plunger (702), friction force is generated
Thickness of plunger
between every two of the friction plate, housing, 5.5 5.3
shoe (t) and
release plate and brake piston. This friction shoe
gp.
force acts on the drive shaft to exert braking
Thickness of Replace
action on it. 2.0 1.8
friction plate it.
On the other hand, when the unlock pressure
enters the cavity formed between the brake
plunger and the housing, the hydraulic oil pres-
sure overcomes the spring force to make the
brake plunger move; the friction plate and the
D
d
housing are separated to release the brake.
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
LG922E930E03109
shall be replaced in advanced without limitations
of this standard. Clearance (D-d)
Part replacement standard
Replacem
Standar ent Handlin
Item d size recommen g
(mm) ded value method
(mm)
δ
Clearance Replace
between the
plunger and 0.027 0.052 plunger
cylinder or
bore (D-d) cylinder.
LG922E930E03110
3-125
Looseness (δ) between plunger and shoe
LG922E930E03111
Thickness of shoe (t)
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
Roughness
Part Standard
requiring
name roughness
trimming
0.8-Z(Ra=0.2)
Shoe 3-Z(Ra=0.8)
(Grinding)
Shoe 0.4-Z(Ra=0.1)
3-Z(Ra=0.8)
plate (Grinding)
1.6-Z(Ra=0.4)
Cylinder 12.5-Z(Ra=3.2)
(Grinding)
Valve 0.8-Z(Ra=0.2)
6.3-Z(Ra=1.6)
plate (Grinding)
3-126
Remarks)
1. The roughness of each rotation meshing surface is controlled to be lower than the standard
roughness through grinding.
2. When the spherical meshing section between the plate spring and cylinder is rough, the com-
plete set of gp shall be replaced.
1. Reduction gear
Structure of reduction gear
The reduction gear is composed of double planetary gears.
The tooth number of each gear is shown in the table below, and the total drive ratio is 20.01. I.e. the rotat-
ing speed of the hydraulic motor is transmitted to the output shaft in 1/20.01. The output shaft is consistent
with the rotating direction of the output shaft.
Planet Transmi
Sun Ring
ary ssion
gear gear
pinion ratio
First i1=4.765
17 23 64
level
Seco
nd 20 21 64 i2=4.2
level
Total
trans i1×i2=20.
missi
on 01
ratio
3-127
Sectional Drawing of Reduction Gear
LG922E930E03120
Parts list of reduction gear

Hexagon socket head
102 Valve body D2 283 #1 pin B 904
cap bolt
104 Rear shaft cover E 284 Push plate E 905 O-ring
201 Drive shaft B 390 Nameplate 909 Pin
202 Gear ring E 391 Pin 910 Pin
#2 planetary gear
203 402 Roller bearing 912 Snap ring
D
204 #2 sun gear D 403 Locating plug 913 Snap ring
#1 planetary gear
210 601 Hex bolt 915 Bearing seal ring
D
Hexagon socket
211 #1 sun gear D 602 922 Plug
head cap bolt
230 #2 bracket D 801 Oil seal 925 Exhaust valve
231 #1 bracket D 802 O-ring 926 Grease fitting
282 #2 pin B 903 Plug 930 Hex screw
3-128
Maintenance references of reduction gear
Maintenance
Part Check Treatment
references
When the size of
Sun gear single pitting
Pitting corrosion and dents on tooth corrosion and dent
Planetary pinion Replacement
surface is above φ1 mm or
Internal gear ring occupied 5% of
total area.
Replacement
(Notice: Replace
them when the
Damaged or
Oil seal Lip surface is damaged or abraded reduction gear is
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
Replacement
visible range.
Support bearing (Notice: Do not
2. Check whether dust caused by
(front side) of drive Abnormal condition reuse bearing
excessive abrasion exists in gear
shaft extracted from the
oil.
shaft.)
3. Check whether excessive
abrasion dust is adhered between
the roller and the cage.
4. Check whether it can smoothly
rotated by hand.
Check whether the race surface and
Drive shaft bearing Have pitting
roller of the bearing have pitting Replacement
(rear side) corrosion
corrosion
Slide bearing section Check whether planetary gear No.2
Looseness above
of planetary gear and pin No.2 of carrier gp No.2 are Replacement
0.5
No.2 loose in the peripheral direction.
Check whether the sliding face zone
Have obvious
Side plate type with the sun gear No.2 has obvious Replacement
bruises
bruises.
Needle bearing set
Have pitting
and pin No.1 for Check whether the rotation face has
corrosion and Replacement
supporting planetary pitting corrosion and abrasion.
abrasion
gear No.1
This reduction gear has few parts and adopts the design method that the life of each section is bal-
anced, 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
3-129
pay special attention to them.

3-130
List of parts to be replaced simultaneously

Parts to be replaced simultaneously
20 40 20 23 28 91 21 23 28 28 28 28
Part No. 401 282 403 909
1 2 3 0 6 0 0 1 3 4 5 7
No2 Planetary
Thrust washer
Braking self-
Braking self-
Carrier No.1
Thrust plate
Thrust plate
No2 Carrier
Part
Drive shaft
gear No.1
Pin gauge
Spring pin
Spring pin
Side plate
Planetary
aligning r
Pin No.1
No2 Pin
aligning
No. Part
gear
name
Drive
201 — ○ ○
shaft
Braking
self-
401 aligning △ — △
roller
bearing
Braking
self-
402 aligning △ △ —
Parts to be replaced simultaneously
roller
bearing
No2
203 Planeta — △ ○ △ ○
ry gear
No2
230
Carrier △ — ○ △ ○
282 No2 Pin △ △ — △ ○

Thrust
286
washer △ △ ○ — ○
Spring
910
pin △ △ ○ △ —
Planeta
210 ry gear — △ ○ △ △ △ △ ○
No.1
Carrier
231
No.1 △ — ○ △ △ △ △ ○
Pin
283
No.1 △ △ — △ △ △ △ ○
Thrust
284
plate △ △ ○ — △ △ △ ○
Side
285
plate △ △ ○ △ — △ △ ○
Thrust
287
plate △ △ ○ △ △ — △ ○
Pin
403
gauge △ △ ○ △ △ △ — ○
Spring
909
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.
3-131
Cause and treatment of reduction gear fault

Fault state Reasons Treatment
Overload Lighten the load
Inlet pressure
Damage of Replace
of swing
reduction gear reduction gear
motor rises
Parking brake of Confirm pressure

swing motor is not relief and check
released the brake part
Confirm relief of
command
pressure
3-132
No rise of inlet pressure

of swing motor
Swing motor has Motor axle Replace swing

noise damage motor
Damage of Replace reduc-
reduction gear tion gear
Swing motor has Abnormal pump, Confirm abnormal

no noise valve, etc. parts and dispose
3-133
Forget to apply liquid

Remove and apply again
seal filling material
Joint surface is loosened

Oil leakage from Remove, apply again and
because the bolt is not
junction surface screwed with looseness, etc. assemble as specified
The joint surface Replace parts

is damaged and components
Oil leakage Oil seal has Replace oil seal when

from the shaft been damaged removing reduction gear
3-134
Housing temperature Confirm the oil

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

Replace reduc-
ing, etc. have
tion gear
been damaged
3-135
3.3.2.11 Cylinder
Basic functions
Hydraulic cylinder is one kind of hydraulic actu-
ating mechanism, and it converts hydraulic
energy supplied by hydraulic pump into huge lin-
ear 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 8 9
huge linear motion and movement.
The structural diagram of the cylinder is
shown below: LG922E930E03126
Structural diagram of arm cylinder
1 2
3 5 6 7
4
LG922E930E03125
10
Structural diagram of boom cylinder LG922E930E03127
Structure diagram of bucket cylinder

1-The port of a small oil chamber
2-The port of a large oil chamber
3-Boom cylinder 4-Cylinder body
5- Piston rod 6-Cushion collar
7-Piston 8-Arm cylinder
9-Cushion collar 10-Bucket cylinder
3-136
Working principle Cushioning process:

Cushioning of boom and bucket cylinder
8 10
1
3 3
11 6
LG922E930E03128
Working principle of cylinder LG922E930E03129
3-Boom cylinder 8-Arm cylinder Cushioning device of boom and bucket cylinder
10-Bucket cylinder 1-The port of a small oil chamber
Cylinder extension: pressure oil enters the large 6-Cushion collar 11-Passage
cavity, return oil enters the small cavity, pres- When the boom and bucket cylinder extends out
sure oil acts on the big end of the piston, and the and the cushion collar (6) approaches to the end
piston moves towards the rod cavity so that the of the extension stroke, the through-flow area of
piston rod extends out. the passage (11) decreases, so that the dis-
Cylinder retraction: pressure oil enters the small placement of the cylinder decreases, and the
cavity, return oil enters the large cavity, pres- movement speed of the piston slows down and
sure oil acts on the rod end of the piston, and reaches the stroke end slowly. The boom and
the piston moves towards the no-rod cavity so bucket cylinder is only cushioned during exten-
that the piston rod retracts. sion.
3-137
Arm cylinder cushioning:
12
9
LG922E930E03130
Cushioning device of boom and bucket cylinder

2-The port of a large oil chamber
9-Cushion collar 12-Passage
The extension of the arm cylinder is same to the boom and bucket cylinder, as described above. When the
arm cylinder retracts and the cushion collar (9) approaches to the end of the extension stroke, the through-
flow area of the passage (12) decreases, so that the displacement of the cylinder decreases, and the
movement speed of the piston slows down and reaches the stroke end slowly. The arm cylinder is cush-
ioned during extension and retraction.
3-138
Precautions on loading and handling

1) Hydraulic cylinder must be transported horizontally, and placed on wood block, and it is better to use
original packaging if possible.
2) Impact, collision, etc. are not allowed during the process of storage and transportation. The surface of
exposed piston rod and other assembly must be protected properly.
3) Use soft strap in case of damaging surface coating.
4) Strap distribution shall make lifting stable. Use balance device if necessary. The center of gravity of cyl-
inder can be confirmed by test.
Precautions for use

1) In order to guarantee hydraulic cylinder operates normally, working medium in hydraulic cylinder must
be filled. The cleanliness of the medium must meet NAS level 8 as the minimum limit requirement. If anti-
rust oil needs to be mixed in working oil, 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 compression of air will cause seal burn-out, leakage generated
inside the hydraulic cylinder cannot maintain the load, etc., and there is a possibility of major acci-
dents.
For air exhaust of hydraulic cylinder, please refer to "Air exhaust of each device" in "Testing and Adjusting"
chapter.
3-139
Periodic maintenance
Lubricant shall be applied on hydraulic cylinder, such as swing shaft, articulated point, pin, etc. periodically
to prevent rust and unsmooth operation. After a new system is put into operation, periodic check is indis-
pensible, the following points must be noted during check:
① Check oil port for leakage.
② Check piston rod for damage.
③ Frequently eliminate dirt, water, dust, grease, etc. on piston rod. However, do not clean dust ring and
sealing parts with water, and please use waste cotton yarn or cloth to wipe. Under the occasion of placing
more than one week, please apply anti-rust oil on the surface of piston rod.
④ Periodically check sealing performance of hydraulic cylinder, especially the joint between piston rod and
cylinder head for leakage.
⑤ 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.
3-140
3.3.2.12 Hydraulic oil tank as

Structure
1 23 4 5 6 7 8 9 1012 1314 11 12 10 17
13
14
15
16
（2）
19 20 18
LG922D03006
Exterior drawing of hydraulic oil tank

1- Hydraulic oil tank 8 - Spring 15- Oil suction strainer
2- Bolt 9-Spring holder 16- O-Ring
3-Washer 10- O-Ring 17-Dipstick
4-Washer 11-Breather 18- Pressure cap
5-Cover 12-Cover 19-Plug
6-Magnet 13- Screw 35 20- O-Ring
7- Oil return filter element 14- Nut
3-141
XI X V
I II
VI
VII
III IV
LG922D03007
Distribution diagram of oil ports in tank body
I - Oil filler IV - Oil suction port Ⅶ - Pilot return port

II - Leakage oil return port in V-Dipstick position X-Back pressure oil return port
pump VI-Leakage oil return port in swing XI - Oil cooler oil return port
III - Oil drain port motor
3-142
① Oil return filter ③ Air filter

Return oil filter is composed of a return oil filter The gas exchange system of hydraulic system is
element ⑦ and a bypass valve ⑥ , the return oil mainly composed of Oil tank and air filter. Air fil-
filter element ⑦ can filter out particles with over- ter, the air duct, prevent the hydraulic oil tank
all size greater than 10 μm in oil so the oil keeps pressure raising or dropping in the following situ-
certain cleanliness. The bypass valve ⑥ plays ation: the movement of oil tank leads to the
the action of protecting the return oil filter ele- pressure change in hydraulic oil tank, the tem-
perature change leads to the pressure change in
ment ⑦ . When the filter element works for a
hydraulic oil tank
period of time and there are too may oil pollut-
ants on its surface, the liquid resistance passing ④ Level gauge
through the return oil filter element ⑦ will Its function is mainly to reflect the oil level in the
increase, the bypass valve ⑥ will be opened tank and the oil range for the system. As shown
during liquid resistance pressure setting, oil in the figure, a safety oil level refers to the sys-
directly returns to the oil tank ⑧ without filtering, tem oil level that is above the red line, and the
so that the damage of the strainer of the return following indicates there is insufficient oil for the
system.
oil filter element ⑦ by flushing can be avoided,
and it can be used after many times of cleaning.
The system works in this state, the back pres-
sure of the system is too high, and unsmooth oil
return will cause slow and powerless working.
To avoid this problem, the return oil filter ele-
ment shall be frequently cleaned or replaced.
② Magnet Safe oil level: above red line
Effect of magnet:
(1) Magnetize the oil tank:
(2) absorbing magnetizable solid particles in oil
together with the tank, which are mainly some
metal particles, such as the metal powder parti-
cles formed due to the abrasion between actuat-
ing mechanisms.
3-143
Working principle

&K

&K
0
'U3
7 'U 'U 'U 'U7 'U6 'U 'U

LG922E930E03134
Schematic diagram
(1) Suction element (4) Actuator (7) Oil return filter element
(2) Pump (5) Radiator (8) Oil tank
(3) Relief valve (6) Bypass valve (9) Air Filter
Ch2-Check valve
Ch1-Back pressure valve
3-144
T- Pilot return port, Dr1-Dr2-Dr3-Dr6-Dr7 main valve oil return, DrT - leakage oil return in travel motor
DrS - leakage oil return in swing motor, Drp - leakage oil return in pump
Oil suction process: oil passes through the oil suction filter element ① from the tank and flows into the
pump ② from the oil suction port IV of the tank ⑧ .
Oil return process: oil is transferred to the actuating mechanisms after being pressurized by the pump ② ,
then passes through the cooler ⑤ for cooling from the actuating mechanisms and flows to the oil port XI or
passes through the back pressure valve Ch1 and flows to oil port X, and returns to the tank ⑧ after being
filtered by the 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 X from the back pressure
valve Ch1, and returns to the tank ⑧ after being filtered by the oil filter return element ⑦ . Oil passing
across the back pressure valve indicates return oil pressure is too high, which is caused by too high liquid
resistance flowing across the radiator ⑤ .
3-145
June 10, 2015 3.3.3 Hydraulic working principle
3.3.3 Hydraulic working principle

3.3.3.1 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
LG922D03008
1. Oil tank
2. Suction hose
3. Suction pipe
4. Main pump
3-146
3.3.3 Hydraulic working principle June 10, 2015
Drain passage
8 9
9
7
6 7
6 5
4 2
5 4
LG922D03009
1. P1 hose assembly 4. Boom cylinder hose as 7. Travel motor hose as-rh

2. P2 hose assembly 5.Travel motor hose as-lh 8. Arm cylinder hose as
3. Main control valve 6. Bucket cylinder hose as 9. Swing motor hose as
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.
3-147
Return passage
6
1
LG922D03010
1. Return passage 1 3. Check valve 5. Check valve

2. Return passage 2 4. Oil cooler 6. Hydraulic oil tank
All the return oil of the actuators returns to the hydraulic tank through the return passage. As
shown in the above picture: a lot of oil return flow through the oil radiator (4) from No. 2 oil return
path, flow into one-way valve (3) from the radiator, flow into the hydraulic oil tank from No.1 return
oil loop.
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 (5) on the return passage
2 is opened, passage 2 helps to shunt and prevent the oil cooler from damage.
3-148
Leakage passage
LG922E930E03138
1. Travel motor-rh
2. Travel motor-lh
3. Center connector
3-149
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.
LG922D03011
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);
2. Leaked oil from the swing motor (2);
3. Leaked oil from the main pump (3).
3-150
3.3.3.2 Pilot circuit

LG922D03016
1. Pilot pump 4. Hand pilot valve-lh 7. Main control valve

2. Hydraulic oil tank 5. Hand pilot valve-rh
3. Pilot Valve Group 6. Foot 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 pres-
sure-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 leading oil from the pilot valve (3) flow into the hand pilot valve-lh (4), hand pilot valve-rh (5),
foot pilot valve (6). Control the valve rod of the main control valve (7) by operating the pilot valves
Hand pilot valve-lh (4) controls the machine arm and the revolving action. Hand pilot valve-rh (5) controls
the machine boom and the bucket action. Foot pilot valve (6) controls the travel action of the machine.
3-151
3.3.3.3 Negative flow control circuit tral)

(with the control spool in the neu- Negative flow control system (neutral)
4 5 6
9
3
10
12 11
LG922E930E03141
3-152
(1) Neutral passage (5) Orifice (9) Neutral passage

(2) Return passage (6) Relief valve (10) Hydraulic oil tank
(3) Negative flow control oil (7) Negative flow control oil (11) Right pump
(4) Relief valve (8) Return passage (12) Left pump
The negative flow control system is an energy
saving system. When the system does not work,
the pressure oil output from the left pump (12)
and the right pump (11) of the main pump pass
through the return passage (2) and (8) and
return to the hydraulic tank (10) through the ori-
fice (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 nega-
tive flow control port of the main pump respec-
tively 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.
3-153
3.3.3.4 Negative flow control circuit (with the control spool moving)
4 5 6
9
3
1 13
14
10
12 11
LG922E930E03142
3-154
Negative flow control system (operation) In case of any action, such as revolving, as
(1) Neutral passage shown in the figure above, the revolving spool
(2) Return passage (13) moves toward the left with the action of the
(3) Negative flow control oil pilot pressure, the right pump output pressure of
the main pump flows through the check valve
(4) Relief valve
(14), the right position of the revolving spool (13)
(5) Orifice
moves to the swing motor, the original neutral
(6) Relief valve
passage (9) is closed by the revolving spool, the
(7) Negative flow control oil
negative flow control line (7) is minimized, and
(8) Return passage the right pump swashplate swing angle of the
(9) Neutral passage main pump increases to supply oil to the swing
(10) Hydraulic oil tank motor; the left pump of the main pump keeps in
(11) Right pump the smallest swing angle with the action of the
(12) Left pump negative feedback control pressure (3).
(13) Swing valve core
(14) Check valve
3-155
3.3.3.5 Boom up circuit
Main pressure oil line

Main oil return line
Control pressure oil line
Control oil return line
3-156
The boom is lifted When the hand pilot valve (10) handle is rotated
(1) Boom cylinder backward, the pilot pressure reaches the port 4
(2) Boom cylinder big chamber oil pipe of the hand pilot valve (10) after passing through
(3) Arm cylinder small chamber oil pipe the pilot valve group (11) from the pilot pump
(15), and reaches the control ports of the boom
(4) Boom locking valve
spool 1 (7) and boom spool 2 (16) respectively
(5) Pressure oil passage
after passing through pilot line (6) and (9); at the
(6) Pilot control oil line
same time, the control oil in the right control
(7) Boom spool 1
chamber of the boom spool 1 (7) flows back to
(8) Check valve the tank (12) after passing through spool (7) oil
(9) Pilot control oil line pipe at the other end and the oil port 2 of the
(10) Pilot valve hand pilot valve (10); the boom spool 1 (7) and
(11) Solenoid valve the boom spool 2 (16) reverse to corresponding
(12) Pilot valve group positions with the action of the pilot control pres-
(13) Oil tank sure;
(14) Left pump The pressure oil output from the left pump (13)
(15) Right pump of main pump reaches the big chamber of boom
(16) Pilot pump cylinder (1) after passing through the check
valve, boom spool 1 (7) and pressure passage
(17) Boom spool 2
(5) boom locking valve (4); at the same time, the
(18) Check valve
pressure oil of the right pump (14) reaches the
big chamber of boom cylinder (1) after passing
through the boom spool 2 (16), the check valve
(17), boom spool 1(7); the oil in the boom cylin-
der (1) small chamber flows back to tank (12)
after passing through boom cylinder small
chamber oil piping (3) and boom spool 1(7),
thus, with the action of the pressure oil, the pis-
ton rod of the boom cylinder stretches out to lift
the boom.
3-157
3.3.3.6 Boom down circuit


3-158
The boom is lowered When the hand pilot valve (10) handle is rotated
(1) Boom cylinder forward, the pilot pressure reaches the port 2 of
(2) Boom cylinder big chamber oil pipe the right-hand pilot valve (10) after passing
(3) Arm cylinder small chamber oil pipe through the pilot valve group (11) from the pilot
pump (15), and reaches the control ports of the
(4) Boom locking valve
boom spool 1 (7) and boom locking valve (4)
respectively after passing through the pilot line
(9); at the same time, the control oil in the left
(7) Boom spool 1
control chamber of the boom spool 1 (7) flows
(8) Check valve back to the tank (12) after passing through the
(9) Pilot control oil line hand pilot valve (10) oil port 4, and the boom
(10) Pilot valve spool 1 (6) towards to right with the action of the
(11) Pilot valve group pilot control pressure;
(12) Oil tank The pressure oil in the left pump of the main
(13) Left pump pump (13) flows through the check valve (8), the
(14) Right pump boom spool 1 (7), and the small chamber oil
(15) Pilot pump pipe (3) of the boom cylinder to the small cham-
ber of the boom cylinder (1); the oil in the big
(16) Boom spool 2
chamber of the boom cylinder (1) flows through
(17) Check valve
the boom cylinder big chamber oil pipe line (2),
boom locking valve (4), and the part return tank
(12) of the boom spool 1 (7) to the small cham-
ber of the boom cylinder (1), and another part of
the hydraulic oil joints in the small chamber of
the boom cylinder (1) after passing the check
valve in the boom spool 1 (7). Thus, with the
action of the pressure oil, the boom cylinder
makes the piston rod withdraw, pull the boom
downward and realize the function of return oil
regeneration.
During the declining process, the boom spool 1
(7) has a certain amount of return oil, a certain
pressure still exists in the negative flow of the
left pump (13), which minimizes the discharge
capacity of the left pump (13), and then the
energy is saved.
3-159
3.3.3.7 Arm out circuit

Arm Out
Arm-out Circuit

LG922D03019
3-160
The arm stretches out When the left hand pilot valve handle is rotated
forward, the pilot pressure reaches the port 2 of
(1) Arm cylinder
the hand pilot valve (10) after passing through
(2) Arm cylinder big chamber oil pipe pilot valve group (11) and from the pilot valve
(15), and reaches the control ports of the arm
(3) Arm cylinder small chamber oil pipe
spool 1 (17) and the arm spool 2 (6) respectively
(4) Arm locking valve after passing through the switching valve (9) and
(5) Pressure oil passage pilot piping (8); at the same time, the control oil
in the control chamber-rh of the arm spool 1 (17)
(6) Arm spool 2
and arm spool 2 (6) flows back to the tank (12)
(7) Check valve after passing through the piping, switching valve
(8) Pilot control oil line (9), and the port 4 of the left hand pilot valve
(10); the arm spool 1 (17) and arm spool 2 (6)
(9) Switch valve (optional)
reverse to corresponding positions with the
(10) Hand pilot valve-lh action of the pilot control pressure;
(11) Pilot valve group The pressure oil output from the left pump (13)
of the main pump reaches the small chamber of
(12) Oil tank
the arm cylinder (1) after passing through the
(13) Left pump check valve (7), arm spool 2 (6), arm locking
(14) Right pump valve (4), and arm cylinder small chamber oil
pipe (3); at the same time, the pressure oil of the
(15) Pilot pump
right pump (14) reaches the arm spool 1 (17)
(16) Regeneration control valve and pressure passage (18) to joint after passing
through the check valve; the pressure oil of the
(17) Arm spool 1
arm spool 2 (6) reaches the small chamber of
(18) Pressure oil passage the arm spool (1) after passing through the arm
locking valve (4) and the arm cylinder small
chamber oil pipe (1); the oil in the arm cylinder
(1) big chamber flows back to the tank (12) after
passing through the arm cylinder big chamber
oil piping (2), arm spool 1 (17) and the arm spool
2 (6), thus, with the action of the pressure oil,
the piston rod of the arm cylinder withdraws to
make the arm stretch out.
3-161
3.3.3.8 Arm in circuit (regenerative)
Arm in (Light-load, Regenerative)

LG922D03020
Arm in (regenerative)
(1) Arm cylinder (7) Check valve (13) Left pump
(2) Arm cylinder big chamber oil (8) Pilot control oil line (14) Right pump
pipe
(9) Switch valve (optional) (15) Pilot pump
(3) Arm cylinder small chamber
(10) Hand pilot valve-lh (16) Regeneration control valve
oil pipe
(11) Pilot valve group (17) Arm spool 1
(4) Arm locking valve
(12) Oil tank (18) Pressure oil passage
(6) Arm spool 2

3-162
When the left hand pilot valve handle is rotated oil flows back to the tank after passing through
backward, the pilot pressure reaches the port 4 the regeneration control valve orifice, this circuit
of the hand pilot valve (10) after passing through can accelerate the moving speed, and the func-
the pilot valve group (11) from the pilot valve tion is called "regeneration". Thus, with the
(15), and reaches the control ports of the arm action of the pressure oil, the piston rod of the
spool 1 (17) and the arm spool 2 (5) and the arm cylinder stretches out to make the arm with-
control port of the arm locking valve (4) respec- draw.
tively after passing through the switching valve
(9) and pilot piping (8); at the same time, the
control oil in the arm spool 2 (6) and arm spool 1
(17) flows back to the tank (12) after passing
through the piping, switching valve (9), and the
port 2 of the left-hand pilot valve (10); the arm
spool 1 (17) and arm spool 2 (6) reverse to cor-
responding positions with the action of the pilot
control pressure; the pilot pressure oil opens the
reverse control valve of the arm locking valve (4)
at the same time to connect the control pressure
of the arm locking valve and that of the tank, and
unlock the arm small chamber return oil.
The pressure oil output from the left pump (13)
of the main pump reaches the big chamber of
pressure passage, check valve (7), arm spool 2
(6), and the arm cylinder big chamber oil pipe
(2); at the same time, the pressure oil of the right
pump (14) reaches the arm cylinder (1) big
chamber jointing the pressure oil of the arm
spool 2 (6) after passing through the arm spool 1
(17) and the arm cylinder big chamber oil pipe
(2); with the light load, the regeneration control
valve (16) 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 (17) after pass-
ing through the arm cylinder small chamber oil
piping (3) and the arm locking valve (4); a part of
oil reaches the big chamber of the arm cylinder
(1) after passing through the internal check
valve of the arm 1 (17) spool, another part of the
3-163
3.3.3.9 Arm in circuit (non-regenerative)
Arm in (Heavy-load, Non-regenerative)
DOUBLE SPEED
PLIOT UNLOCK BOOST

Control oil return line PLIOT VALVE GP
Arm in (non-regenerative)
(1) Arm cylinder (7) Check valve (13) Left pump

(2) Arm cylinder big chamber (8) Pilot control oil line (14) Right pump
oil pipe (9) Switch valve (optional) (15) Pilot pump
(3) Arm cylinder small cham- (10) Hand pilot valve-lh (16) Regeneration control
ber oil pipe (11) Pilot valve group valve
(4) Arm locking valve (12) Oil tank (17) Arm spool 1
(5) Pressure oil passage (18) Pressure oil passage
(6) Arm spool 2
3-164
With the heavy load, when the oil inlet pressure of the arm cylinder big chamber exceeds the set pressure
of the regeneration control valve (16) spring, the regeneration control valve (16) will reverse, at this
moment, the arm cylinder small chamber return oil can flow to the tank directly, and then the "regeneration"
function is unavailable.
When the left-hand pilot valve handle is rotated backward, the pilot pressure reaches the port 4 of the hand
pilot valve (10) after passing through the pilot valve group (11) from the pilot valve (15), and reaches the
control ports of the arm spool 1 (17) and the arm spool 2 (6) and the control port of the arm locking valve
(4) respectively after passing through the switching valve (9) and pilot piping (8); at the same time, the con-
trol oil in left control chamber of the arm spool 1 (17) and arm spool 2 (6) flows back to the tank (12) after
passing through the switching valve (9), and the port 2 of the left-hand pilot valve (10); the arm spool 1 (17)
and arm spool 2 (6) reverse to corresponding positions with the action of the pilot control pressure; the pilot
pressure oil opens the reverse control valve of the arm locking valve (4) at the same time to connect the
control pressure of the arm locking valve and that of the tank, and unlock the arm small chamber return oil;
The pressure oil output from the left pump of the main pump (13) reaches the big chamber of the arm cylin-
der (1) after passing through the check valve (7), arm spool 2 (6) and the arm cylinder big chamber oil pipe
(2); at the same time, the pressure oil of the right pump (14) reaches the big chamber of the arm cylinder
(1) jointing the pressure oil of the arm spool 2 (6) after passing through the arm spool 1 (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 the arm cylinder small chamber oil piping (3), arm locking valve (4) and the
arm spool 1 (17), thus, with the action of the pressure oil, the piston rod of the arm cylinder stretches out to
make the arm withdraw.
3-165
3.3.3.10 Bucket in circuit

Bucket in
(1) Bucket cylinder (7) Check valve (13) Left pump

(2) Bucket cylinder big cham- (8) Pilot control oil line (14) Right pump
ber oil pipe (9) Shuttle valve (15) Pilot pump
(3) Bucket cylinder small (10) Hand pilot valve-rh (16) Neutral passage
chamber oil pipe (11) Pilot valve group (17) Check valve
(4) Pilot control oil line (12) Oil tank (18) Shut-off valve
(6) Bucket valve core
3-166
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 (11) from the pilot pump
(15), 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
pump-rh (14); and the control oil in the right control chamber of the bucket spool (6) flows back to the tank
(12) after passing through the piping and the port 1 of right-hand pilot valve (10). With the action of the pilot
control pressure, the bucket spool (6) switches to the corresponding position;
The pressure oil of the left pump (13) 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 (14), together with the oil from the left pump (13), enters the
bucket spool (6) after passing through the neutral passage (16), check valve (17) and the pressure pas-
sage (5) to realize the jointing inside the valve.
3-167
3.3.3.11 Bucket out circuit

3-168
The bucket stretches out Operate the right-hand pilot valve (10) handle to
(1) Bucket cylinder make it rotate toward right, and the pilot pres-
(2) Bucket cylinder big chamber oil pipe sure reaches the port 3 of the hand pilot valve
(3) Bucket cylinder small chamber oil pipe (10) after passing through the pilot valve group
(11) from the pilot pump (15), and reaches the
control port of the bucket spool (4) after passing
through the pilot line (8); at the same time, the
(6) Bucket valve core
pressure oil output from the port 3 of the hand
(7) Check valve
pilot valve (10) makes the shut-off valve (18)
(8) Pilot control oil line switch to left after passing through the shuttle
(9) Shuttle valve valve (9) and the pilot control line (4) to shut off
(10) Hand pilot valve-rh the return oil of the right pump (14); and the con-
(11) Pilot valve group trol oil in the left control chamber of the bucket
(12) Oil tank spool (6) flows back to the tank (12) after pass-
(13) Left pump ing through the piping and the port 1 of hand
(14) Right pump pilot valve-rh (10). With the action of the pilot
control pressure, the bucket spool (6) switches
(15) Pilot pump
to the corresponding position;
(16) Neutral passage
The pressure oil of the left pump (13) reaches
(17) Check valve
the big chamber bucket cylinder (1) after pass-
(18) Shut-off valve
ing through the check valve (7), bucket spool (6)
and the bucket small chamber oil pipe (2); 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 (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 (14),
together with the oil from the left pump (13),
enters the bucket spool (6) after passing through
the neutral passage (16), check valve (17) and
the pressure passage (5) to realize the jointing
inside the valve.
3-169
3.3.3.12 Left swing circuit
6ZLQJ/
Left Swing

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LG922D03024
Left swing
(1) Hand pilot valve-lh (8) Pilot control pressure pip- (17) Swing valve core
(2) Switch valve ing (18) Swing motor A port piping
(3) Pilot control oil line (9) Negative flow feedback (19) Swing motor B port piping
(4) Pilot control oil line pressure piping (20) Swing motor & reduction
(5) Motor unlock control line (10) Oil tank gear
(6) Throttle port (11) Left pump (21) Motor unlock piping
(7) Pilot valve group (12) Right pump (22) Time delay valve
(13) Pilot pump (23) Motor unlock control line
(14) Return oil check valve (24) Neutral passage
(15) Swing motor oil supple- (25) Shut-off valve
ment piping
(16) Swing logic valve
3-170
When the left hand pilot valve (1) handle is of the main pump flows back to the tank after
rotated to left, the pilot pressure reaches the passing through the neutral passage (24) and
port 1 of the hand pilot valve after passing the shut-off valve (25); the front feedback pres-
through the pilot valve group (7) from the pilot sure at the throttle port acts on the variable
pump (13), and reaches the control port of the mechanism of the left pump (11) through the
swing spool (17) after passing through the pilot negative flow feedback pressure piping (9),
line (4); at the same time, the control oil in the which minimizes the discharge capacity of the
right control chamber of the swing spool (17) left pump (11).
flows back to the tank (10) after passing through
the piping (3) and the oil port 3 of the left-hand
pilot valve (0). With the action of the pilot control
pressure, the swing spool (17) switches to the
corresponding position; at this moment, the pilot
pressure oil generates the pressure after pass-
ing through the piping (8), throttle valve (6) and
the swing spool (17) stops after reversing; the
control pressure provided by the pilot valve
group (7) reaches the time delay valve (22)
unlocked by the swing motor after passing
through the pilot control pressure piping (8),
throttle port (6) and the motor unlock control pip-
ing (5) and (23), and pushes the reverse valve of
the time delay valve to reverse; the control pres-
sure oil output from the pilot valve group (7)
enters the locking cylinder of the motor after
passing through the motor unlock piping (21) to
realize the unlocking;
The pressure oil of the pump-rh (12) reaches the
swing motor and & reduction gear (20) after
passing through the swing logic valve (16),
swing spool (17), and the swing motor B port
piping (19); the oil of the swing motor & reduc-
tion gear (20) A port flows back to the tank after
passing through the swing motor A port piping
(18) and the swing spool (17), thus, with the
action of the pressure oil, the swing motor &
reduction gear drive the platform to rotate
toward the left.
3-171
3.3.3.13 Swing priority circuit

3-172
Arm in (regenerative) The main function of the priority valve (15) is to

(1) Arm cylinder distribute the pressure oil output to the swing
(2) Arm spool 2 spool (14) and the arm spool 1 (17) by the right
(3) Swing pilot control oil passage pump (12). As shown in the circuit diagram, the
throttle passage is at the right position.
(4) Swing shuttle valve pilot control oil passage
When the left handle of the hand pilot valve (8)
(5) Arm pilot control oil passage
is operated at about 45° toward rear right, the
(6) Shuttle valve
pilot pressure reaches the port 3 and port 4 of
(7) Switch valve (optional)
the left hand pilot valve from the pilot pump (13)
(8) Pilot valve
after passing through the pilot valve group (9),
(9) Pilot valve group and reaches the swing spool (15) and the corre-
(10) Oil tank sponding control ports of the arm spool 1 (17)
(11) Left pump and the arm spool 2 (2) after passing through
(12) Right pump the switching valve (7) and the pilot piping (3)
(13) Pilot pump and (5) respectively. At this moment, the control
(14) Swing valve core oil of the swing pilot control oil passage (3)
(15) Swing priority valve reaches the pilot control port PSP of the swing
priority valve (15) after passing through the shut-
(16) Swing motor & reduction gear
tle valve (6), which makes the valve move to the
(17) Arm spool 1
right throttle position.
of the main pump reaches the big chamber of
arm spool 2 (2).
One part of the right pump's (13) pressure oil
flow into the swing motor (17) through the rotary
valve core (15). The other part flow into the arm
tank through the right restricted passages of
rotary priority valve (16) and arm spool1(18). At
the same time, one part of the right pump's (13)
pressure oil flow into the swing motor (16)
through the rotary valve core (14). The other
part flow into the arm tank (1) large chamber
through the right restricted passages of rotary
priority valve (15) and arm spool 1(17). The
rotary priority valve (15) restrict the rate of flow
in arm spool 1(17) to make sure the priority of
the arm.
3-173
3.3.3.14 Right swing circuit

Right swing
(1) Hand pilot valve-lh (9) Negative flow feedback (17) Swing valve core
(2) Switch valve (optional) pressure piping (18) Swing motor B port piping
(3) Pilot control oil line (10) Oil tank (19) Swing motor A port piping
(4) Pilot control oil line (11) Left pump (20) Swing motor & reduction
(5) Motor unlock control line (12) Right pump gear
(6) Throttle port (13) Pilot pump (21) Motor unlock piping
(7) Pilot valve group (14) Return oil check valve (22) Time delay valve
(8) Pilot control pressure pip- (15) Swing motor oil supple- (23) Motor unlock control line
ing ment piping (24) Neutral passage
(16) Swing logic valve (25) Shut-off valve
3-174
When the left hand pilot valve (1) handle is rotated to left, the pilot pressure reaches the port 1 of the hand
pilot valve after passing through the pilot valve group (7) from the pilot pump (13), and reaches the control
port of the swing spool (17) after passing through the pilot line (3); at the same time, the control oil in the
right control chamber of the swing spool (17) flows back to the tank (10) after passing through the piping (8)
and the oil port 1 of the hand pilot valve-lh (13). With the action of the pilot control pressure, the swing
spool (17) switches to the corresponding position; at this moment, the pilot pressure oil generates the pres-
sure after passing through the piping (8), throttle valve (6) and the swing spool (17) stops after reversing;
the control pressure provided by the pilot valve group (7) reaches the time delay valve (22) unlocked by the
swing motor after passing through the pilot control pressure piping (8), throttle port (6) and the motor
unlock control piping (5) and (23), and pushes the reverse valve of the time delay valve to reverse; the con-
trol pressure oil output from the pilot valve group (7) enters the locking cylinder of the motor after passing
through the motor unlock piping (21) to realize the unlocking;
The pressure oil of the pump-rh (12) reaches the swing motor and & reduction gear (20) after passing
through the swing logic valve (16), swing spool (17), and the swing motor A port piping (19); the oil of the
swing motor & reduction gear (20) B port flows back to the tank after passing through the swing motor B
port piping (18) and the swing spool (17), thus, with the action of the pressure oil, the swing motor & reduc-
tion gear drive the platform to rotate toward the right.
The pressure oil output from the left pump (11) of the main pump flows back to the tank after passing
through the neutral passage (24) and the shut-off valve (25); the front feedback pressure at the throttle port
acts on the variable mechanism of the left pump (11) through the negative flow feedback pressure piping
(9), which minimizes the discharge capacity of the left pump (11).
3-175
3.3.3.15 Travel forward (fast)

LG922D03027
Travel forward (fast)

(1) Left travel motor & reduction (10) Motor B port passage (21) Check valve
gear (11) Pilot control oil line (22) Transmission reversing valve
(2) Right travel motor & reduction (12) Pilot control oil line (23) Control passage
gear (13) Foot pilot valve (24) Variable cylinder
(3) Motor brake (14) Travel fast and slow gear (25) Motor brake
(4) Unlock pressure oil passage control line (26) Control passage
(5) Motor A port oil passage (15) Travel motor B port piping-rh (27) Check valve
(6) Balanced valve (16) Travel motor A port piping-rh (28) Transmission reversing valve
(7) Travel motor A port piping-lh (17) Motor A port oil passage (29) Variable cylinder
(8) Travel motor B port piping-lh (18) Control passage (30) Center Swivel Joint
(9) Control passage (19) Balanced valve (31) Pilot control oil line
(20) Return passage (32) Pilot control oil line
3-176
(35) Travel valve core (left) (41) Pilot pump (45) Pilot valve group
(36) Pressure oil passage (42) Left pump (46) Travel valve core (right)
(38) Pilot return lines (43) Right pump (47) Control passage
(40) Hydraulic oil tank (44) Pressure switch
When the travel fast-slow gear control switch is in the "Rabbit" state and the foot pilot valve (13) is operated
toward forward, the pilot pressure reaches the port 1 and port 3 of the foot pilot valve (13) after passing
through the pilot valve group (45) from the pilot pump (41), and reaches the control ports of the left travel
spool (35) and the right travel spool (46) after passing through the pilot lines (31) and (11) respectively; at
the same time, the control oil in the left control chamber of the left travel spool (35) and the right travel
spool (46) flows back to tank (40) after passing through the piping (32) and (12), oil port 2 and 4 of the foot
pilot valve (13) and the pilot return line (38); with the action of the respective pilot control pressure, the left
travel spool (35) and the right travel spool (46) reverse to corresponding position respectively, at this
moment, the travel fast-slow gear control switch is in the "Rabbit" state of the fast gear; the pilot control
pressure reaches the transmission reverse valve (28) and (22) of the left travel motor and the reduction
gear (1) as well as the right travel motor and reduction gear (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), transmission reverse valve (22) and control passage (23), 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;
The pressure oil output from the left pump (42) of the main pump reaches the port A of the left travel motor
& reduction gear (1) after passing through the pressure passage (36), left travel spool (35), center swivel
joint (30) and the port B piping (8) of left travel motor; the pressure oil enters the motor by passing through
the motor port B passage (10); at the same time, the pressure oil pushes the balanced valve (6) to reverse
by passing through the control passage (9), and the pressure oil enters the motor brake (3) to unlock after
passing through the balanced valve (6) and the control passage (4); the return oil of the motor connects
with the hydraulic oil tank (40) after passing through the return passage (5) and balanced valve (6) to port
A , and then passing through the port A piping (7) of left travel motor, the center swivel joint (30) and the left
travel spool (35); at the same time, the pressure oil of the right pump (43) reaches the port A of the right
travel motor & reduction gear (2) after passing through the check valve (45), right travel spool (46), center
swivel joint (30) and the port B piping (16) of right travel motor; the pressure enters the motor by passing
through the motor port A passage (17); at the same time, the pressure oil pushes the balanced valve (19)
to reverse by passing through the control passage (18), and the pressure oil enters the motor brake (25) to
unlock after passing through the balanced valve (19) and the control passage (26); the return oil of the
motor reaches the port B of the balanced valve (19) after passing through the return passage (20) and the
3-177
balanced valve (19), and then connects with the hydraulic oil tank (40) after passing through the port B pip-
ing (15) of right travel motor, center swivel joint (30) and the right travel spool (46); thus, with the action of
the pressure oil, the left and right motors and the reduction gear drive the machine to move backward
slowly.
As the reversing of the right travel spool (46), the return passage outputting the control pressure from the
pilot valve group (45) port B is stopped and the pressure is produced, this pressure acts on the pressure
switch (44) after passing through the control passage (47) and (48), and then the pressure switch (44)
transmits the electrical signal to realize the function of travel warning.
3-178
3.3.3.16 Backward travel (low

speed)

3-179
Backward travel (low speed) (38) Pilot return lines

(1) Left travel motor & reduction gear (39) Four-step solenoid valve group
(2) Right travel motor & reduction gear (40) Hydraulic oil tank
(3) Motor brake (41) Pilot pump
(4) Unlock pressure oil passage (42) Left pump
(5) Motor A port oil passage (43) Right pump
(6) Balanced valve (44) Pressure switch
(7) Travel motor A port piping-lh (45) Pilot valve group
(8) Travel motor B port piping-lh (46) Travel valve core (right)
(9) Control passage (47) Control passage
(10) Motor B port passage (48) Control passage
(11) Pilot control oil line When the travel fast-slow gear control switch is
(12) Pilot control oil line in the slow gear - “Tortoise” state and the foot
(13) Foot pilot valve pilot valve (13) is operated toward backward, the
(14) Travel fast and slow gear control line pilot pressure reaches the port 2 and port 4 of
the foot pilot valve (13) after passing through the
(15) Travel motor B port piping-rh
pilot valve group (45) from the pilot pump (41),
(16) Travel motor A port piping-rh
and reaches the control ports of the left travel
(17) Motor A port oil passage
spool (35) and the left travel spool (46) after
(18) Control passage
passing through the pilot lines (32) and (12)
(19) Balanced valve respectively; at the same time, the control oil in
(20) Return passage the left control chamber of the left travel spool
(21) Check valve (35) and the right travel spool (46) flows back to
(22) Transmission reversing valve tank (40) after passing through the piping (31)
(23) Control passage and (11), oil port 1 and 3 of the foot pilot valve
(24) Variable cylinder (13) and the pilot return line (38); with the action
(25) Motor brake of the respective pilot control pressure, the left
travel spool (35) and the right travel spool (46)
(26) Control passage
reverse to corresponding position respectively,
(27) Check valve
and at this moment, the travel fast-slow gear
(28) Transmission reversing valve
control switch is in the “Tortoise” state of the
(29) Variable cylinder
slow gear, as shown in the figure); the control
(30) Center Swivel Joint pressure (14) is back to the tank after passing
(31) Pilot control oil line through the pilot valve group (45); the transmis-
(32) Pilot control oil line sion reverse valve (28) and (22) reset with the
(35) Travel valve core (left) action of the spring, and the control pressure in
(36) Pressure oil passage the variable cylinder (29) and (24) of the left and
(37) Solenoid valve right travel motor connect with the drainage port
3-180
and are back to the tank after passing through valve (19) after passing through the return pas-
the transmission reverse valve (28) and (22) sage (17) and the balanced valve (19), and then
respectively, thus, with the action of the spring connects with the hydraulic oil tank (40) after
force, the variable cylinders of the left and right passing through the travel motor A port piping-rh
motors make the motor in the position with the (16), center swivel joint (30) and the travel
maximum discharge capacity, namely, the "slow spool-rh (46); thus, with the action of the pres-
gear" state; sure oil, the left and right motors and the reduc-
The pressure oil output from the left pump (42) tion gear drive the machine to move backward
of the main pump reaches the port A of the left slowly.
travel motor & reduction gear (1) after passing As the reversing of the right travel spool (46),
through the pressure passage (36), travel spool- the return passage outputting the control pres-
lh (35), center swivel joint (30) and the Port A sure from the pilot valve group (45) port B is
piping (7) of left travel motor; the pressure oil stopped and the pressure is produced, this pres-
enters the motor by passing through the motor A sure acts on the pressure switch (44) after pass-
port passage (5); at the same time, the pressure ing through the control passage (47) and (48),
oil pushes the balanced valve (6) to reverse by and then the pressure switch (44) transmits the
passing through the control passage (9), and the electrical signal to realize the function of travel
pressure oil enters the motor brake (3) to unlock warning.
after passing through the balanced valve (6) and
the control passage (4); the return oil of the
motor connects with the hydraulic oil tank (40)
after passing through the return passage (10)
and balanced valve (6) to the B port, and then
passing through the travel motor B port piping-lh
(8), the center swivel joint (30) and the travel
spool-lh (35); at the same time, the pressure oil
of the right pump (43) reaches the B port of the
travel motor-rh & reduction gear (2) after pass-
ing through the check valve (45), travel spool-rh
(46), center swivel joint (30) and the travel motor
B port piping-rh (15); the pressure enters the
motor by passing through the motor B port pas-
sage (20); at the same time, the pressure oil
pushes the balanced valve (19) to reverse by
passing through the control passage (18), and
the pressure oil enters the motor brake (25) to
unlock after passing through the balanced valve
(19) and the control passage (26); the return oil
of the motor reaches the A port of the balanced
3-181
3.3.3.17 Circuit for bilateral travel and boom up
Linear traveling (Traveling

forward + Boom up)
LG922D03029
3-182
Straight travel Under normal travel state (namely without other

(1) Left travel motor & reduction gear actions), the left pump (17) supplies oil to the left
(2) Foot pilot valve travel spool (6) and the right pump (18) supplies
(3) Hand pilot valve-rh the oil to the right travel spool (20). With the both
sides traveling, when any actions of the swing or
(5) Boom spool 1
working device are operated synchronously, the
(6) Travel valve core (left)
control pressure (11) of the straight travel valve
(9) is produced because of the stopping function
of the spool reversing of the travel spool and the
(9) Straight travel valve boom or the work implement, which pushes the
(10) Orifice straight travel valve (9) to reverse, at this
(11) Pilot control oil line moment, the output oils of the left and right
(12) Pilot control oil line pumps are distributed again by passing through
(13) Orifice the straight travel valve (9); the pressure oil out-
(14) Pilot control oil line put from the right pump (18) is supplied to the
(15) Pilot control oil line left and right travel valve, and the pressure oil
output from the left pump (17) is supplied to the
(16) Pilot valve group
work implement preferentially, then, the redun-
(17) Left pump
dant oil is supplied to travel, thus, it is equal to
(18) Right pump
that the left and right travel is supplied by one oil
(19) Pilot pump
source, which keeps them traveling straightly.
(20) Travel valve core (right)
(21) Right travel motor & reduction gear
3-183
CLG920D/922D 3.4 Work implement
June 10, 2015 3.4.1 Sizes of components
3.4 Work implement

3.4.1 Sizes of components
C
G
F
H
Q
A
LG922E930E03156
3-184
3.4 Work implement CLG920D/922D
3.4.1 Sizes of components June 10, 2015
Unit: mm
Cou
nter
No. Item Judgment standards
mea
sure
Tolerance Permissibl
Clearance between Standard Standard
e
mounting pin and size Shaft Hole clearance
1 clearance
bushing of swing
-0.036 +0.210
platform and boom 90 0.122~0.281 0.122~1.0
-0.071 +0.086
Clearance between
mounting pin and -0.036 +0.210
2 90 0.122~0.281 0.122~1.0
bushing of boom and -0.071 +0.086
arm
Clearance between
mounting pin and 0 +0.165
3 80 0.092~0.239 0.092~1.0 Repl
bushing of arm and -0.074 +0.092 ace
bucket
ment
Clearance between
mounting pin and -0.03 +0.158
4 70 0.101~0.218 0.101~1.0
bushing of arm and -0.06 +0.071
lever
Clearance between
-0.03 +0.158
5 mounting pin and 70 0.101~0.218 0.101~1.0
-0.06 +0.071
bushing of link and lever
Clearance between
mounting pin and 0 +0.165
6 80 0.092~0.239 0.092~1.0
bushing of link and -0.074 +0.092
bucket
3-185
June 10, 2015 3.4.1 Sizes of components
A G
B H
C N
1
4
D E Q
F K
6
2
LG922E930E03157
3-186
3.4.2 Arm part June 10, 2015
3.4.2 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
3-187
June 10, 2015 3.4.2 Arm part
Unit: mm
CLG920D/922D
No. Position for Tolerance
Standard size
measurement Shaft Hole
-0.03 +0.074
1 — φ100
-0.06 0
+1.5
Arm side 114
0
2
0
Cylinder side 112
-0.5
-0.036 +0.294
3 — φ90
-0.071 +0.24
+0.5
Boom side 346
0
4
0
Arm side 344
-0.5
5 — 260.9 ±0.5
6 — 440 ±0.5
7 — 812.8 ±1
8 — 2910 ±4
9 — ±1
10 — 450 ±1
11 — 603 ±0.5
12 — 580 ±0.5
13 — 475 ±0.5
14 — 1450 —
0 +0.196
15 — φ80
-0.074 +0.150
0
Link itself 305
-0.5
16
0
Press fitting of bushing 337
-0.7
0 +0.196
17 — φ80
-0.074 +0.150
0
Arm itself 305
-0.5
18
0
Press fitting of bushing 336
-0.7
Min. 1593 ±4
19
Max. 2651 ±4
3-188
3.4.3 Bucket part June 10, 2015
3.4.3 Bucket part
3
5
A
A
9 4
B
8 B 6
A-A
13
12 10
17
16
18
15
14
20
B-B
13
12 10
18
17
14
15
16
20
LG922E930E03159
3-189
June 10, 2015 3.4.3 Bucket part
Unit: mm
CLG92D/922D
No. Position for
Standard size Tolerance
measurement
1 — 475 ±0.5
2 — 1450 —
3 — 256 —
4 — 102.4 —
5 — 131.4 —
6 — 100.2 —
7 — R110 —
8 — R95 —
9 — R1200 —
10 — 337
11 — 68 —
12 — 93 —
13 — 480 —
+0.174
14 — φ80
+0.1
15 — 85 —
16 — 140 —
17 — 160 —
18 — φ21 —
3-190
3.5 A/C system CLG920D/922D
3.5.1 Layout of A/C pipeline June 10, 2015
3.5 A/C system

3.5.1 Layout of A/C pipeline
4
5
3
2
6
C B A 7
LG922E930E03160
1. Air conditioner air duct 6. Air conditioning condenser

2. Evaporator as (HVAC) 7. Refrigerant pipeline
3. Thermal return pipeline A: Fresh air intake
4. Thermal inlet pipeline B: Internal circulation air
5. A/C compressor C: Cold and hot air
3-191
CLG920D/922D 3.6 Electrical system
June 10, 2015 3.6.1 Engine control
3.6 Electrical system

3.6.1 Engine control
Engine
Control signal
Sensor signal
Frequent
Power supply signal power supply
of start motor signal of start
motor
ECM control starting signal
Starting signal of
main controller
Engine controller
Control signal
of pilot lever Starter relay
(Sensor signal)
Power supply
CAN bus (Speed control signal
signal and other
signals)
Power-on signal
of electric lock
Main controller
Electric lock start signal
Throttle control signal
Engine oil level signal
Battery relay
Battery
3-192
3.6 Electrical system CLG920D/922D
3.6.1 Engine control June 10, 2015
1) Start the engine 2) Engine speed control

When the electric lock is turned to the "Start" Each gear of the accelerator knob corresponds
position, the electric lock starting signal is to an engine speed, and the engine controller
detected by the main controller, and then the controls the oil injection quantity according to
main controller sends main controller control the speed control signal sent by the main con-
starting signal to transmit the power supply sig- troller, so as to control the engine speed.
nal to the power end of the start motor, then the 3) Stop the engine
engine is started. When the electric lock is turned to the "OFF"
(Note: The starting signal of the starter relay is position, the engine stops.
controlled by the ECM, and the starter relay is
driven jointly by the main controller control start-
ing 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.)
At the same time, the main controller detects the
accelerator knob signal, and sets the corre-
sponding 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.
3-193
June 10, 2015 3.6.2 Display system
3.6.2 Display system (3) Instrument appearance and display

The display instrument is mainly composed of
(1) Display model
alarm indicator, LCD display and the operating
buttons.
Part No. Name Model
WDJLGCOLORDI
35B0206 Indicator
SP-63
(2) Technical parameters
Rated voltage DC24V

Continuous work DC18-32V
voltage
Working temperature -25°C~ ＋ 65°C
Storage temperature -30°C~ ＋ 80°C
Atmospheric pressure 86~106KPa
Relative humidity (30~90)％RH
Impact strength 10g at 0.03~0.08 Hz

(1) Alarm indicator part
Vibration intensity 5g at 10~1000Hz
(2) LCD screen part
Protection grade IP65 (3) Operating buttons part
Mechanical life 100 thousand times

3-194
3.6.2 Display system June 10, 2015
3-1 Warning indicator part 3-3 Operating buttons part

Three alarm indicators for standby
Icon Name Function
3-2 LCD display part When the alarm buzzer rings,
Mute
press this switch, and then
button
the buzzer may stop resound
Menu Select to enter the main

buttons menu interface
Return Return the PREVIOUS

buttons interface
Confirm
Enter the selection/set item
buttons
Select the TOP item (Select

UP
the below item after the upper
buttons
item)
Right
Select the RIGHT item
button
(1) Water temperature/oil level pointer
Select the NEXT item (select
(2) Hourmeter/power display area Down
the upper item after the below
button
(3)Working state indicator area item)
(4)Time/information tip message
Left
Select the left item
button
3-195
(4) Instrument interface 4-2 Main Interface

4-1 Start-up interface
4-1-1 Initialization interface with normal
operation
Turn on the switch, energize the keys, the LCD
display shows the initialize interface Show the
main interface 5 s later
(1) Fuel level gauge

(2) Engine coolant temperature gauge
(3) Service hour meter
(4) System working voltage
4-1-2 The initialize interface of certain time (5) Working position of engine
after the GPS device is bound. (6) Overload
Turn on the switch, energize the keys, the LCD (7) Traveling high and low speed
display shows the specific initialize interface (8) Transient power boosting
Show the main interface 10 seconds later The (8) Idling speed indicator
picture shows after choosing "WITH GPS" and (10) Hoisting assembly
receiving the controlling information of LCD. (11) Time/ alarm message hint
(Appendix I)
1. Fuel level gauge: red zone for the lower level
while the green zone for the normal level
2. Engine cooling water temperature gauge: red
zone for the high temperature while green zone
for the normal temperature;
3. Service hour meter: calculate the working time
of the machine. The flashing icon of the hourme-
ter means calculating is on
4. System working voltage: 18V~32V
5. Engine working gears: gear range is 1~10
3-196
6. Overload mode: cancel the function, the icon (5) Instrument menu
can not display; the icon is flashing with alarm. Select the menu button, enter the main menu
7. The traveling high and low speed: the rabbit interface (system settings, usage informa-
means FAST-speed, the tortoise means LOW - tion, maintenance information, system
speed state), by selecting the UP, DOWN, LEFT,
8. The instantaneous power: cancel the instanta- and RIGHT buttons. Press the confirm but-
neous power function, the icon can not display. ton to get into the next menu or content
9. Idling speed indicator: cancel the idling speed,
the icon can not display
10. Hoisting assembly: cancel the function, the icon
will disappear;
11. Time/ alarm message hint: this area display the
current time in normal working state. This area
displays the alarm reminder with the alarm infor-
mation and other information. This area displays
the information circularly with a lot of information
 Note: three levels alarm function of the

instrument The first level alarm reminds the
operator of checking the machine; the sec-
ond level alarm reminds the operator of
changing the working style or maintaining
the machine; the third level alarm shows
the immediate repair of the machine. (See
Annex II)
3-197
(6) System settings 6-1-1 Time setting

Include the common setting, parameter set- Select the time setting after the common set-
ting, factory setting, instrument setting The ting, press the confirm button and enter. Set
common setting is for the excavators users. the right time by the four direction buttons;
The parameter setting and the factory setting save the setting by the confirm button and
are factory debugging for the excavators. exit.
The instrument setting is factory debugging
for the instrument manufacturer. (See Annex
VII)
6-1 General settings

Select the general setting menu, press the
confirm button to see the followed interface
Includes the time setting; the language set-
tings ; the display settings; stage timekeep-
ing; cooling liquid, rated speed.
3-198
6-1-2 Language setting 6-1-3 Display setting;

Select the language setting in the general set- Select the display setting after the general set-
ting, press the confirm button and enter. Select ting, press the confirm button and enter Adjust
the language by the up and down button, pre- brightness by the left and right button, save the
serve the setting by the confirm button and exit. setting by the confirm button and exit.
Chinese, English and Russian for option.
Default is Chinese.
3-199
6-1-4 Stage timekeeping

Select "stage timekeeping" after the common
setting; enter the password input interface; enter
the phase timing after the password has been
entered, or return the TOP menus
Select "start stage timekeeping" or "cancel
stage timekeeping" after entering the submenus
of stage timekeeping, press the confirm button.
Stage timekeeping start from zero, hided work-
ing hours in the main interface, it shown as
"XXXXX.X" It stands for the total time of working
hours during stage timekeeping. Press the UP
and DOWN button to switch the working hours
to stage timekeeping in the main interface.
Select the "cancel stage timekeeping"; press the
confirm button and stop the stage timekeeping.
3-200
6-1-5 Coolant 6-1-6 Revolution calibration

Select the display setting after the general set- Use the function to debug new machine or to
ting, press the confirm button and enter View the demarcate the rated speed again Select "revolu-
coolant temperature, but cannot set. Default is tion calibration"; press the confirm button to
40 °C. enter the password interface after starting the
engine. Return the TOP menus with the wrong
password. If the password is correct, the monitor
send the request of remote monitor to controller,
and show "Password is correct, please wait"
3-201
The monitor shows "Please start the engine to

demarcate the revolution calibration" after
receiving the reply. At this time, pressing any
key will not exit the screen and enter the next
screen, until the controller receives the data with
the start mark or process of the revolution cali-
bration.
The controller will continuously send data (pro-

cess of revolution calibration) to the display. At
this time, you cannot exit the picture by pressing
any button.
The remote monitor shows "please check

the controller line" if the monitor doesn't
receive the reply in 10 s or receive the wrong
The remote monitor shows "please turn off the
reply; and returns to the previous screen.
electric lock and start the engine again" after
receiving the data of ending the process of revo-
lution calibration.
3-202
The remote monitor shows "please shut down,

adjust the accelerator's flexible shaft, re-cali-
brate the revolution" after receiving the unsuc-
cessful data in 10 minutes.
 Note: the above two interfaces means the

ending of the revolution calibration; all but-
tons are invalid at this time; wait to restart
the engine.
6-2 Parameter setting
Select the parameter setting menu in system
settings, press the confirm button and as shown
below interface. The parameter settings include
GPS system setting; working hours settings;
telecommunication testing.
3-203
6-2-1 GPS system setting Select "remove the heartbeat query", " start
Select the GPS system setting in the parameter the heartbeat query" & " remove the lock of
setting; enter the dynamic password input inter- the complete vehicle" after entering the GPS
face; enter GPS system setting after the pass- system setting with the right password.
word has been entered, otherwise return the Default option is "remove the heartbeat
TOP menu. See the dynamic password man- query"
agement instructions to get the dynamic pass-
word
Show "succeed in setting the parameter", other-

wise"fail in setting the parameter"
3-204
6-2-2 Working hours setting Set the correct time by the four direction's but-
Select the working hours setting after the tons after entering the working hours setting with
parameter setting; enter the dynamic password right password; store the data by the confirm
input interface; enter the control parameter set- button and quit.
ting after the password has been entered, other-
wise return the TOP menu. See the dynamic
password management instructions to get the
dynamic password
3-205
6-2-3 Telecommunication testing

Select the telecommunication testing after the
parameter setting and enter by pressing the
confirm button. Show "telecommunication is
abnormal" ; or "telecommunication is normal"
Enter the submenus of factory settings with the

password has been entered. The factory set-
tings include "control parameter setting",
"mode", "product S/N" and "parameter setting".
6-3 Factory settings

Select the factory settings after the system set-
ting; enter the dynamic password input inter-
face; enter the control parameter setting after
the password has been entered, otherwise
return the TOP menus with password error. See
the dynamic password management instructions
to get the dynamic password.
3-206
6-3-1 Control parameter settings 6-3-2 Model

Select the control parameter setting after the Select "Model" after the factory settings and
factory settings and enter by pressing the con- enter by pressing the confirm button. Set Model
firm button. Set the heartbeat query. Include by the four direction's buttons; press the confirm
"remove the heartbeat query" and" start the button and quit.
heartbeat query" Default is "remove the heart-
beat query".
3-207
6-3-3 S/N of production 6-3-4 Parameter settings

Select "S/N of production" after the factory set- Select "Parameter setting" after the factory set-
tings and enter by pressing the confirm button. tings and enter by pressing the confirm button.
Set the S/N of production by the four direction The parameter setting include "fault record
buttons; press the confirm button and quit. reseting", " working hours setting", "flywheel
gear setting" and "instruments type setting".
3-208
6-3-4-1 Fault record reset 6-3-4-2 Working hours setting

Select "the fault record reseting" after the Select "working hours setting" after the parame-
parameter setting and enter by pressing the ter setting and enter by pressing the confirm but-
confirm button Reset the fault record Select ton. Reset the working hours Enter "working
"Yes"or "NO" Default is "NO". hours setting" without the dynamic password
Default working hour is “10000.0H”.
3-209
6-3-4-3 Flywheel gears setting 6-3-4-4 Instruments type setting

Select "flywheel gears setting" after the parame- Select "instruments type setting" in the parame-
ter setting and enter by pressing the confirm but- ter settings, and enter by pressing the confirm
ton Set the flywheel gears by the four direction's button Switch three different types in the pro-
buttons; press the confirm button and quit. cess of debugging new machine or collocating
Default is 127. different types of excavators; default to type 2.
The differences among the three types are the
displayed contents of system status. (See the
Annex III)
6-4 Instrument settings

Users can't enter the function of setting instru-
ments for the display manufacturers
3-210
(7) Information for use 7-1 Fault record

Select "use information" in the main menu, Select different fault record by the UP and
and press the confirm button and enter. DOWN button; press the confirm button to see
the details of the fault record.
3-211
7-2 Machine information 7-3 Instrument information

The machine information includes the model, The instruments information includes the instru-
the product S/N, the hardware version of con- ments model, the hardware version, the soft-
troller, the software version of controller, the ware version and the instruments production S/
controller S/N and the controller ID. Reserve the N.
controller S/N and the controller ID, but show
the rest four of the machine information.
3-212
(8) System state

Select "system state" in the main menu,
press the confirm button and enter to see the
present system state, check current system
state in this interface. Different types of
instrument displays its correspondent sys-
tem status (see Annex III).
(9) Information of maintenance
Select "the information of maintenance" in
the main menu, press the confirm button and
enter the submenus of maintenance Every
submenus means different content of regu-
lar maintenance ; press the confirm button to
see the details (See Appendix IV)
3-213
Appendix I: GPS alarm hint
Display the
GPS Display the LCD
initialization
functi Code Description alarm of Alarm level
interface of
on instrument
instrument
Mortgage prompts 1 Dear customer,

(It will be displayed at each please pay this
01 time of power-on when 24 payment in time for
hours after receiving the the last five days of
data) the repayment
Mortgage prompts 2 Dear customer, your

(It will be displayed at each machine has been
02
time of power-on after limited. Please pay
receiving the data) this payment in time
Mortgage prompts 3 Dear customer, your

Mortg
(It will be displayed at each machine has been out
age 03
time of power-on after of service. Please pay
prom
receiving the data) this payment in time
pts
Mortgage prompts 4 Dear customer, we
(It will be displayed at the have received the
04 next time of power-on, and payment and the
meanwhile, clear out all machine will be back
saved data) to normal.
Mortgage prompts 5 Dear customer, we

(It will be displayed at the have received the
05 next time of power-on, and payment. Appreciate
meanwhile, clear out all your trust and support
saved data) for CLG
Telecommunication fault GPS

The third
0xBB (The instrument records the telecommunicatio
level alarm
Fault alarm) n fault
prom
pts Antenna fault
The third
0xCD (The instrument records the GPS antenna fails
level alarm
alarm)
Grade I vehicle locking The machine has

The third
0x06 (The instrument doesn’t been limited to
level alarm
Locki record the alarm) use
ng
hint Grade II vehicle locking
The machine is The third
0x07 (The instrument doesn’t
forbidden to use level alarm
record the alarm)
3-214
Appendix II: three levels alarm message
The first level alarm Alarm amount for Level II The third level alarm
The hydraulic oil temperature

System voltage is too low System voltage is too high
is too high
Cooling water temperature is

The fuel level is too low Oil pressure too low
too high
GPS telecommunication
Please maintain the machine
fault
Admission pressure of engine GPS antenna fails
The water level is too low
Appendix III: differences among the three instrument types
Menu Version I Version II Version III
Engine oil pressure Engine oil pressure Engine oil pressure Engine oil pressure
Whether increase
Whether increase the power Whether increase the Coolant
the power instantly
instantly or not power instantly or not Temperature
or not
Hydraulic oil Hydraulic oil Hydraulic oil

Hydraulic oil temperature
temperature temperature temperature
System voltage System voltage System voltage System voltage
Admission pressure of Admission pressure

Admission pressure of engine Engine speed
engine of engine
The working gears of The working gears of The working gears of

Working position of engine
the machine the machine the machine
Fuel level Fuel level Fuel level Fuel level
The walking gear The walking gear The walking gear The walking gear
Pressure on left
Main pump pressure None None
pump
Pressure on right
Right main pump pressure None None
pump
Pilot pressure None Pilot pressure None

3-215
Pump regulating Pump regulating

Pump current None
current current
Engine speed None Engine speed Engine speed
 Note: default of ex-factory is version II.

3-216
Appendix IV: Regular maintenance checklist

1. Check the instrument.
2. Check engine oil level for lubrication.
8 hours 3. Check coolant level.
maintenance 4. Check the hydraulic oil level
5. Drain the water and dirt from the oil tank.
6. Check the leakage of A/C refrigerant.
1. Lubricate the boom hydraulic cylinder bottom pin.
2. Lubricate the shear leg hydraulic cylinder bottom pin.
50 hours
3. Lubricate the connecting pin of the bucket and the linkage.
maintenance
4. Check and adjust the droop of track.
5. Clean the filter parts of the air filter.
1. Lubricate the connecting pin of the boom and arm.
2. Lubricate the piston rod pin and the bottom pin of the arm hydraulic
cylinder.
100 hours 3. Lubricate the hydraulic cylinder bottom pin of the bucket.
maintenance 4. Lubricate the piston rod pin of the boom hydraulic cylinder and the
bottom pin of the arm hydraulic cylinder.
5. Check and adjust the tension of fan belt.
6. Check and adjust the tension of compressor belt.
Information 1. Check the gear oil level of swing reduction gear.
for
maintenance 2. Check the gear oil level of travel reduction gear.
3. Check the tightening torque of bolt and nut.
250 hours
4. Replace the engine oil.
maintenance
5. Replace the lubricants filter.
6. Replace the fuel coarse filter.
7. Clean the outer of A/C condenser
1. Lubricate slewing bearing
2. Lubricate the inner swing gears.
500 hours 3. Check the fuel filter.
maintenance 4. Replace the outer and inner filtering elements of air filter.
5. Clean the outer of radiator set.
6. Replace the return filter of hydraulic oil tank.
1. Clean the filter of fuel feed pump.
1000 hours
2. Replace the swing reduction gear oil.
maintenance
3. Replace the pilot oil filter.
1500 hours 1. Replace hydraulic oil.
maintenance 2. Clean the fuel suction filter.
2000 hours 1. Change coolant and clean the inner of radiator.
maintenance 2. Change the gear oil of travel reduction gear.
3-217
Appendix V: Dimensional Figure of the Display
Be firstly used for Belong to

State-operated Yongqing
Oscilloscope Plant
Drawing mark Weight () Proportion
Total 1 page Page 1
LG922D03030
3-218
Appendix VI: Port Diagram of the Dislay
Direction K
Be inserted with the

display diagonally
Terminal No. Wire No. Terminal No. Wire No.
F2
179mm×249mm
Direction A Direction K
None None Green purple
CAN GND signal Gray white

CAN Signal Red and green
CAN Signal Yellow and blue
Power cable (-) Black

Drawn by Power cable (+) Red white
Function illustration Wire No. Wire color

Checked by
Be firstly used for Subject to
Old traced drawing No. State-operated Yongqing

Mark Place Modification No. Signature Date LiuGong excavator
Oscilloscope Plant
Designed by
WDJLGCOLOFDISP-40
Traced drawing No. Checked by
Examined by Drawing mark Weight () Proportion Display wiring diagram V10

Countersigned by
Signature Date
Standardized by
Approved by Page 1 of 1
LG922D03031
3-219
Appendix VII: the process of setting system
Time setting Time setting: year /month/day/hour/ minute
Chinese
Language
English
setting
Russian
Gene
ral Display setting Adjusting brightness
Setti
ngs Stage Enter the password: the Start the time keeping
timekeeping default password is 30000000 Cancel the time keeping
Coolant Coolant temperature
Revolution Enter the password: the

Password is correct, please wait
calibration default password is 30000000
Remove the
heartbeat query
Submit the validate code, get
GPS system the password, and input the Start the
setting password heartbeat query
Para Remove the lock of the complete machine

mete
r Working Submit the validate code, Working hours Working hours Succeed in
setti hours setting get the password, and input setting setting ****** setting
ng the password parameter
Telecommunicati
Telecommunic Telecommunication is in test, on is abnormal
ation testing please wait! Telecommunicati
on is normal
3-220
Remove the heartbeat query

Control parameter setting
Start the heartbeat query
Model number Model setting
S/N of production S/N setting of production
Submit the Reset the fault No

Fact validate code, record Yes
ory get the
setti password, and
Working hours
ngs input the Working hours setting
setting
password
Parameter setting Flywheel gears Flywheel gears setting: the fault is
setting 127
Version 1
Instruments type
Version 2
setting
Version 3
3-221
June 10, 2015 3.6.3 Electrical control system
3.6.3 Electrical control system

3-222
3.6.3 Electrical control system June 10, 2015
3.6.3.1 Automatic idling function
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 handle or pedal, either or the joystick 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)
Engine speed will decrease to the idling speed (about 1000 RPM) in case of no hydraulic request
signal is received within 3 seconds.
2) 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 accelera-
tor knob indicates.
 Note: Hydraulic request signals include the handle pilot pressure switch signal and the pedals pilot
pressure switch signal.
3-223
June 10, 2015 3.6.3 Electrical control system
3.6.3.2 Transient power boosting function
Indicator
(Automatic power boosting Command)

CAN Bus
Signal of transient power

Control signal for solenoid
boosting button
valve of instantaneous power
Main controller
Instantaneous boost
solenoid valve
pedal pilot pressure
pressure signal
pressure signal
Switching signal of
P1 pump-lh
P2 pump-lh
Function:
At normal operation, Increase the excavator digging force in certain time
Operator press the button of "Increase the excavator digging force instantly" by manual operation; keep
increasing the force for 8 seconds, then reset automatically.
3-224
3.6.3 Electrical control system June 10, 2015
3.6.3.3 Travel speed control function
Indicator
(Travel variable
speed command)
CAN Bus
Switching signal of
pedal pilot pressure
P1 pump-lh pressure signal
Main controller
P2 pump-lh pressure signal
Travel shift solenoid control

signal
Travel shift solenoid
Function:
The traveling speed include LOW-gear and FAST-gear; switch by the speed controlling button
4-1
CLG920D/922D
June 10, 2015
4 Parameters
4.1 Basic parameters ........................................................................................... 4-3

Major technical parameters ................................................................................ 4-3
Dimension drawing ............................................................................................ 4-3
Complete vehicle parameters ............................................................................. 4-4
Components’ parameters ................................................................................... 4-5
Scope of work ..................................................................................................... 4-8
4.2 Performance parameters of diesel engine ............................................. 4-10
4.3 Performance parameters of complete machine ................................... 4-11
4-2
CLG920D/922D
June 10, 2015
4-3
CLG920D/922D 4.1 Basic parameters
June 10, 2015 Major technical parameters
4.1 Basic 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 imple-
ments such as backacting shovel, crowd shovel, hydraulic breaker, plum claw, etc.
• Altitude: ≤ 3048m
• Ambient temperature: -32 °C ~ 40 °C
Fording depth: no matter what kind of position the machine is in, the fording depth is not allowed to
exceed the center of the carrier roller.
Major technical parameters

All rated operational 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 condi-
tions (for example, working on soft or uneven ground or slopes), then operator shall consider these condi-
tions.
Dimension drawing
J
I E
H
C
G A
F B
LG922E930E04001
4-4
4.1 Basic parameters CLG920D/922D
Complete vehicle parameters June 10, 2015
Complete vehicle parameters
Item Unit
Engine model Cummins QSB7
Operating weight kg 22000
Standard bucket capacity m3 1
Running speed (high/low) km/h 0~5.0, 0~2.8
Swing speed r/min 10.5
Gradeability 35° (70%)
Pressure to the ground
kPa 45.6
(track width is 600mm)
J: Overall length mm 9690
Overall width (track width is
mm 2990
600mm)
Overall height mm 3050
D: Height of cab roof mm 3050
E: Total width of the upper
mm 2700
platform
*H: Counterweight ground
mm 1070
clearance
*C: Minimum ground
mm 440
clearance
I: Tail end length of the
mm 2855
upper platform
End rotating radius mm 2860
G: Frame axle base mm 3650
F: Frame length mm 4456
A: Frame track distance mm 2390
B: Frame width (track width
mm 2990
is 600mm)
Note: The sizes with * exclude track height

4-5
June 10, 2015 Components’ parameters
Components’ parameters
Components Item Unit

Model Cummins QSB7
Turbo charged and air to air intercooling/
Type
high pressure
Stage II of European and American off-
Emission
highway vehicle
Cooling method Water cooling
Ignition order 1-5-3-6-2-4
Cylinder bore X stroke mm 107X124
Cylinder displacement L 6.7
Compression ratio 17.2:1
Engine Rated power 120kW//2100r/min
Net power 117kW
Maximum torque (1500 r/min) N.m 658
Engine oil level L 24
Net weight of diesel engine kg 490
Maximum no-load speed r/min 1850
Minimum no-load speed r/min 1000
Rated fuel consumption rate g/kW.h 225
Starter motor 24V-7.5kW
Alternator 24V-70A(Bosch)
4-6
Components’ parameters June 10, 2015
Main pump Double axial variable plunger pump

Max. flow of system L/min 2X210
Main relief
Setting pressure 31.8
valve
When
instantaneously MPa 33.3
supercharging
Big chamber/
Setting small chamber of MPa 37.2
pressure of boom
outlet
safety Big chamber/
valve small chamber of MPa 37.2
arm
Big chamber/
small chamber of MPa 37.2
bucket
Hydraulic Relief valve setting pressure of
MPa 25.5
system swing motor
Safety valve setting pressure of
MPa 31.8
travel motor
Pilot pump Gear pump
Pilot circuit MPa 3.9
Quantity - bore ×
Boom rod diameter × mm 2-φ120×φ85×1187
cylinder stroke
Buffer When stretching out
Quantity - bore ×
Arm rod diameter × mm 1-φ135×φ95×1450
cylinder stroke
Buffer When stretching out and retracting
Quantity - bore ×
Bucket rod diameter × mm 1-φ120×φ85×1058
cylinder stroke
Buffer When stretching out
Work Boom (standard configuration) mm 5680
implement Arm (standard configuration) mm 2910
Track shoe width mm 600
Track as Bar 2
Number of track shoe (each
49
bar)
Travel device Track tension device Piece 2
Sprocket Piece 2
Idler as Piece 2
Track roller 8 at each side
Carrier roller 2 at each side
4-7
June 10, 2015 Components’ parameters
Electrical System voltage V 24

system Battery 2×12V
Refrigerating capacity W 5000
Cooling air output m3/h 550
Heating capacity W 5800
Heating air output m3/h 400
Voltage V.DC 24
A/C System Total power consumption W ≤ 310
Compressor’s shaft power kW 3.02
Refrigerant R134a
Refrigerant filling quantity g 950±50
Compressor 10S15C (Denso compressor)
Refrigeration oil ND-OIL8 (Denso special compressor oil)
4-8
Scope of work June 10, 2015
Scope of work
10
5
A
4
B
2
E
3
D
C
7
10 9 8 7 6 5 4 3 2 1 0 metre
G
H
4-9
June 10, 2015 Scope of work
Item Unit CLG922D

Arm length mm 2910
Boom length mm 5680
*A: Maximum digging height mm 9540
*B: Maximum unloading height mm 6770
*C: Maximum digging depth mm 6615
*E: Maximum vertical digging depth mm 5655
H: Maximum digging radius mm 9850
G: Maximum ground digging radius mm 9705
*D: Maximum digging depth (2.5m
mm 6410
horizontal plane)
F: Minimum swing radius mm 3510
Maximum digging force of bucket (ISO) kN 159
Maximum digging force of arm (ISO) kN 103
Note: The sizes with * exclude track height

4-10
4.2 Performance parameters of diesel engine CLG920D/922D
4.2 Performance parameters of diesel engine
Name Parameters
Engine model QSB7
Turbo charged and air to air intercooling/high pressure
Mode
common rail/direct injection/water-cooling
Number of cylinder 6
Cylinder diameter x stroke 107mm×124mm
Displacement 6.7L
Compression ratio 17.2:1
Ignition order 1-5-3-6-2-4
Rated power 120kW/2100RPM
Maximum power 125kW/1950RPM
Maximum torque 658N.m/1300RPM
Engine oil level 23L
Engine oil Low idle Minimum 69kPa
pressure Rated speed Minimum 207kPa
Fan 6-Φ700
Starter motor 24V-7.5kW
Air intake heater 24V-112A
Alternator 24V-70A
Intake valve 0.25 mm(limit value: 0.17 to 0.33 mm)
Valve clearance
Exhaust valve 0.51 mm(limit value: 0.43 to 0.59mm)
Opening
79°C-83°C
temperature
Thermostat
Full open
95°C
temperature
4-11
CLG920D/922D 4.3 Performance parameters of complete machine
4.3 Performance parameters of complete machine

Performance
Item Unit
temperature
Minimum speed (idling) 800±50
Engine speed (A/C OFF) r/min
Maximum speed (idling) 2050±50
Rabbit position/forward 14.95±1.5
Rabbit position/backward 14.95±1.5
Running speed Sec/20m
Tortoise position/forward 23.91±2.5
Tortoise position/backward 23.91±2.5
Tortoise position/
32±2.5
forward
Tortoise position/
32±2.5
backward
Left track
Rabbit position/
19.6±1.5
forward
Rabbit position/
19.6±1.5
backward
Track travel speed Sec/3rev
Tortoise position/
32±2.5
forward
Tortoise position/
32±2.5
backward
Right track
Rabbit position/
19.6±1.5
forward
Rabbit position/
19.6±1.5
backward
Tortoise position ≤ 150
Travel deflection test mm/20m
Rabbit position ≤ 200
Swing speed Sec/3rev 16.18±1.5
Swing function drifting mm/180° ≤ 1300
Swing bearing clearance (horizontal direction) mm ≤ 55
Boom cylinder stretches out 2.98±0.5
Hydraulic oil cylinder Boom cylinder retracts /
action time (with the air Extension of arm cylinder 2.65±0.5
conditioner closed and sec
the engine at the Arm cylinder retracts 2.25±0.5
maximum speed) Bucket cylinder stretches out 3.36±0.5
Bucket cylinder retracts 1.96±0.5
Retraction of boom cylinder (mm) ≤ 10
Stretch of arm cylinder (mm) ≤ 10
Cylinder settlement mm/10min
Retraction of arm cylinder (mm) ≤ 30
Retraction of bucket cylinder (mm) ≤ 30
4-12
4.3 Performance parameters of complete machine CLG920D/922D
Boom control lever 10±3

Arm control lever 10±3
Bucket control lever 10±3
Control force of control
Swing control lever N 10±3
lever
Travel control lever 17±5
Travel control pedal (forward) 60±10
Travel control pedal (backward) 70±10
Boom control lever 88±10
Arm control lever 87±10
Control lever stroke Bucket control lever mm 90±10
Swing control lever 91±10
Travel control lever 146±10
Lift and swing the Time of swinging
boom at the same sec 3.67±0.1
90°
time. When the
Check of boom lifting and upper mechanism
swing action swings 90°, release Height of bucket
the control lever to mm 7400±200
tooth
stop these two kinds
of actions
Adjustment of pilot Engine: high idle speed MPa 3.9~4.1
pressure Engine: low idle speed MPa 3.5~4.1
The boom is lifted MPa 3.9~4.1
The boom is lowered MPa 3.9~4.1
The arm retracts MPa 3.9~4.1
The arm stretches out MPa 3.9~4.1
Secondary pilot pressure Left swing MPa 3.9~4.1
(Handle full stroke) Right swing MPa 3.9~4.1
The bucket retracts MPa 3.9~4.1
The bucket stretches out MPa 3.9~4.1
Forward MPa 3.9~4.1
Backward MPa 3.9~4.1
Pressure of main relief valve MPa 33.3~34.3
Left swing MPa 25.5±1
Main circuit pressure
Right swing MPa 25.5±1
Drive (travel hold pressure) MPa 31.8±1
The boom is lifted MPa 37±0.5
The boom is lowered MPa 37±0.5
Pressure testing of oil The arm retracts MPa 37±0.5
port relief valve The arm stretches out MPa 37±0.5
Rolling in of bucket (large cavity) MPa 37±0.5
Stretch in of bucket (small cavity) MPa 37±0.5
Main pump flow L/min 210×2 (2 pumps)
4-13
CLG920D/922D 4.3 Performance parameters of complete machine
Swing motor oil unloading

Oil drainage pressure MPa ≤ 0.2
(oil drainage)
Travel motor oil unloading
Oil drainage pressure MPa ≤ 0.2
(oil drainage)
4-14
4.3 Performance parameters of complete machine CLG920D/922D
5-1
CLG920D/922D
June 10, 2015
5 Testing and Adjusting
5.1 Performance test of complete machine ..................................................... 5-3

5.1.1 Diesel engine speed................................................................................... 5-6
5.1.2 Travel speed (idling speed) ........................................................................ 5-6
5.1.3 Running speed (actual speed) ................................................................... 5-8
5.1.4 Travel deflection ......................................................................................... 5-9
5.1.5 Swing parking brake angle ....................................................................... 5-10
5.1.6 Swing speed............................................................................................. 5-12
5.1.7 Swing bearing clearance .......................................................................... 5-13
5.1.8 Action time of cylinder .............................................................................. 5-16
5.1.9 Cylinder settlement................................................................................... 5-19
5.1.10 Operating force of control lever .............................................................. 5-20
5.1.11 Control lever stroke ................................................................................ 5-20
5.1.12 Boom lifting and swing action................................................................. 5-21
5.1.13 Pilot pressure ......................................................................................... 5-22
5.1.14 Secondary pilot pressure........................................................................ 5-23
5.1.15 Output pressure of solenoid proportional valve...................................... 5-24
5.1.16 Setting pressure for main relief valve ..................................................... 5-26
5.2 Other tests ...................................................................................................... 5-34
5.2.1 Adjustment of valve clearance ................................................................. 5-34
5.2.2 Measurement of blow-by of crankcase..................................................... 5-42
5.2.3 Measurement of engine oil pressure ........................................................ 5-49
5.2.4 Measurement and adjustment of track tension ........................................ 5-52
5.2.5 Inspection and adjustment of minus feedback pressure N1..................... 5-54
5.2.6 Inspection and adjustment of minus feedback pressure N2..................... 5-55
5.2.7 Release of remaining pressure in hydraulic oil lines ................................ 5-56
5.2.8 Exhaust of various devices....................................................................... 5-58
5.2.9 Inspection of diode ................................................................................... 5-61
5.2.10 Adjustment of compressor belt tensioner ............................................... 5-62
5.2.11 Performance test of travel motors and reduction gears ......................... 5-63
5-2
CLG920D/922D
June 10, 2015
5-3
CLG920D/922D 5.1 Performance test of complete machine
June 10, 2015
5.1 Performance test of complete machine

The standard values of the tested data involved in the Chapter are as follows:
Table 1 Standard value list of diesel engine speed
Model CLG922D & 920D (TIER II/RB valve - Guangkang)

Gear
Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Gear 6 Gear 7 Gear 8 Gear 9
10
No-load
800±10 1000±5 1300±5 1400±5 1540±5 1600±5 1700±5 1900±5 2050±5
speed (r/ 1250±50
0 0 0 0 0 0 0 0 0
min)
Maximum
working
535±10 560±10 600±10 610±10 620±10
current
(mA)
Minimum
working ≤100 290±5 320±5 370±5 400±5
380±10 400±10 420±10 420±10 420±10
current
(mA)
Idling
current 360±10 380±10 400±10 400±10 400±10
(mA)
Table 2: Standard value of complete machine performance parameter
Diesel
Model CLG922D engine TIER 2- Cummins QSB7
configuration
NO. Item Unit Standard value
Left/right Forward sec/3rev 31.9±2.5
Tortoise travel
position mechani Backward sec/3rev 31.9±2.5
Travel speed sm
1
(Idling speed) Left/right Forward sec/3rev 19.6±1.5
Rabbit travel
position mechani Backward sec/3rev 19.6±1.5
sm
5-4
5.1 Performance test of complete machine CLG920D/922D
June 10, 2015
Forward sec/20m 23.91±2.5

Tortoise position
Backward sec/20m 23.91±2.5
Running speed Forward sec/20m 14.95±1.5
2 (Actual measurement Rabbit position
speed) Backward sec/20m 14.95±1.5
Maximum running speed km/h 4.9
Minimum running speed km/h 2.9
Forward mm/20m ≤150
Tortoise position
Backward mm/20m ≤150
3 Travel deflection
Forward mm/20m ≤200
Rabbit position
Backward mm/20m ≤200
Swing parking brake Clockwise ° ≤130
4
angle Counterclockwise ° ≤130
Swing speed r/min 11.5
Swing 5 circles Clockwise sec 16.2±1.5
5 Swing speed
Countercloc
Swing 5 circles sec 16.2±1.5
kwise
Swing bearing Vertical direction mm ≤0.65
6
clearance Horizontal direction mm ≤55
Extension sec 3.36±0.5
Bucket cylinder
Retraction sec 1.96±0.5
7 Action time of cylinder Arm cylinder
Retraction sec 2.25±0.5
Boom cylinder
Retraction sec ---
Retraction of boom cylinder mm/10min ≤30
Extension of arm cylinder mm/10min ≤30
8 Cylinder settlement
Retraction of arm cylinder mm/10min ≤40
Retraction of bucket cylinder mm/10min ≤40
5-5
June 10, 2015
Boom control lever N 10±3

Arm control lever N 10±3
Bucket control lever N 10±3
Operating force for
9 Swing control lever N 10±3
control lever
Travel control lever N 17±5
Travel control pedal Forward N 60±10
Travel control pedal Backward N 70±10
Boom control lever mm 88±10
Arm control lever mm 87±10
10 Control lever stroke Bucket control lever mm 90±10
Swing control lever mm 91±10
Travel control lever mm 146±10
Lift and swing Time of
sec 3.67±0.5
the boom at the swinging 90°
same time.
When the upper
Boom lifting and mechanism
11
swing actions swings 90°, Height of
release the mm 7400±200
bucket tooth
control lever to
stop these two
kinds of actions
When diesel Max. MPa 4.1
engine is at rated
speed Min. MPa 3.9
12 Pilot pressure
When diesel Max. MPa 4.1
engine is at
idling speed Min. MPa 3.5
Secondary pilot Max. MPa 4.1

13
pressure Min. MPa 3.9
Output pressure of Max. MPa 3.9
14 solenoid
proportional valve Min. MPa 0
Setting pressure of Max. MPa 35.3

15
main relief valve Min. MPa 34.3
Caution: First test whether diesel engine speed reaches technical specification before all other tests. If the
diesel engine speed is not adjusted correctly, the data of all other performances are not reliable.
5-6
5.1.1 Diesel engine speed June 10, 2015
5.1.1 Diesel engine speed 5.1.2 Travel speed (idling

A. Tools and testing instrument speed)
1. Reflective sheeting
A. Tools and testing instrument
2. Tachometer
1. Stopwatch.
B. Preparations
2. Tool used for marking staring point.
Turn off the air conditioner and the automatic
3. Test is performed by two persons.
idling, and turn the gear to the position to be
B. Machine state and parking site
tested with no load.
1. Solid and flat parking site.
C. Test method
2. Maintain hydraulic oil temperature between
1. Open the diesel engine hood.
45°C and 55°C.
2. Stick the reflective sheeting on the output end
3. Set the engine in the maximum speed (with
of the diesel engine crankshaft or the fan shaft,
the air conditioning turned off).
but it is required to multiply by the speed ratio of
the fan and the diesel engine at this moment. 4. The working current of the pump is within the
normal range.
3. By illuminating the place pasting with reflec-
tive sheeting with tachometer, diesel engine 5. The complete machine works in the normal
speed can be obtained from the instrument. mode.
4. Repeat to measurement three times and cal- 6. The working pressure and the pilot pressure
culate average value. of the pump are within the normal range.
C. Travel speed test
1. Park the machine at a solid and flat site.
2. Maintain the hydraulic oil temperature
45°C~55°C.
3. Operate the right swing until the upper mech-
anism 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 1.
5-7
June 10, 2015 5.1.2 Travel speed (idling speed)
13. Repeat the step 4 to 11, and measure the

travel speed of the left track in same way.
14. Refer to attached table 1 for test table.
Figure 1
5. Lower the boom until the right track is raised
for about 100 ~ 200 mm from the ground to keep
the track away from the ground during operation
as shown in Figure 1. Mark on the appropriate
position of the track.
6. Set accelerator linkage or knob to maximum
positions of engine speed.
7. Turn the travel speed selector switch to "1"
position (tortoise position).
8. Push the right travel control lever to the front
end, and then measure and record the time for
the right track swinging 3 circles.
9. Repeat the Step 7 to 8 to measure three
times. Calculate average value of measured
data for three times.
10. Measure the data of the right track "1" posi-
tion (tortoise position) backwards using the
same method.
position (rabbit position), repeat the Step 8 to
10, and compare the average value of mea-
sured data with the standard values in the Table
below.
12. Lift the boom till the bottom of the bucket off
the ground 300 mm. Operate the left swing and
turn the upper mechanism by 180°.
5-8
5.1.3 Running speed (actual speed) June 10, 2015
5.1.3 Running speed (actual with 30m on the ground, and then draw another
line at the position about 10m away from the
speed) starting point and make it parallel with the
A. Tools and Figure 8 Testing Instruments machine. As shown in Figure 3.
1. Stopwatch.
2. Tape (50m).
3. Test is performed by two persons.
45°C and 55°C.
Point starting to time At the end point
4. The working current of the pump is within the
normal range.
5. The complete machine works in the normal Figure 3
mode. 5. Set accelerator linkage or knob to maximum
6. The working pressure and the pilot pressure positions of engine speed.
of the pump are within the normal range. 6. Turn the travel speed selector switch to "1"
C. Travel speed test position (tortoise position).
1. Park the machine in a solid and flat site (the 7. Driving into the test road, the front 10m of
flat site for straight travel about 30m). which is for acceleration, at the steady speed.
Starts timekeeping when the front end of the
track enters the timing line and stop it when the
45°C~55°C.
front end of the track reaches the finishing line.
3. Operate the work implement and make it at
Record the time for the machine running through
the transport status, as shown in Figure 2.
the test road. As shown in Figure 3.
8. Repeat step 7 to measure three times, and
calculate average value of measured data for
three times.
9. Rotate the upper mechanism by 180°, and
measure the data of the right track "1" position
backwards (tortoise position) using the same
method.
position (rabbit position) and repeat steps 6~9.
Figure 2
11. Refer to attached table 1 for test table.
4. Starting the front end of the track, draw a line
5-9
June 10, 2015 5.1.4 Travel deflection
5.1.4 Travel deflection 4. Starting the front end of the track, draw a line
with 25m on the ground and make it parallel with
A. Tools and testing instrument the machine. Draw a line at each position about
1. Tape (30m). 5m and 15m away from the front end of excava-
2. Tool used for marking the location of the tor track and at the finishing point respectively.
machine. 5. Set accelerator linkage or knob to maximum
B. Machine state and parking site positions of engine speed.
1. Solid and flat parking site. 7. Turn the travel speed selector switch to "1"
2. Maintain hydraulic oil temperature between position (tortoise position).
45°C and 55°C. 7. Push the left and right travel control lever to
3. Set the engine in the maximum speed (with the front end at the same time. When the exca-
the air conditioning turned off). vator reaches the position about 5m away from
4. The working current of the pump is within the the starting point, mark A (stand for the relative
normal range. location of the track on the ground) at the posi-
5. The complete machine works in the normal tion. Similarly, mark B when the excavator
mode. reaches the position about 15m away from the
6. The working pressure and the pilot pressure starting point and Mark C when the excavator
of the pump are within the normal range. reaches the finishing point. As the figure:
7. The maximum wind speed shall be no more

than 6m/s during the test.
C. Travel deflection test
45°C~55°C.
3. All work implements, such as boom, arm and
bucket cylinder, extend, as shown in Figure 4.
Figure 5
8. Measure the perpendicular distance (e) of
point "B" to straight line AC.
times. Calculate average value of measured
data for three times.
position (rabbit position), repeat steps 7~9 and
Figure 4 measure the travel deflection value at "2" posi-
5-10
5.1.5 Swing parking brake angle June 10, 2015
tion (rabbit position). 5.1.5 Swing parking brake angle

11. Rotate the lower mechanism by 180°, repeat
the Step 3 ~10, and measure the travel deflec-  Danger: Please confirm that testing site
tion values when the excavator reverses and allows 360° swing of the machine!
compare them with the standard values in the Please confirm that there are no other
Table below. personnel or facilities within 3m scope
12. Refer to attached table 2 for travel deflection of swing area!
test table. A. Tools and testing instrument
1. Tool used for marking staring point.
2. Tape.
3. Plumb bob.
4. Measurement is performed by three persons.
45°C and 55°C.
normal range.
5. The complete machine works in the normal
mode (and the idling state).
6. The working pressure and the pilot pressure
of the pump are within the normal range.
C. Swing parking brake angle test
1. Park the machine in a solid and flat site, as
shown in Figure 7.
3. Extend the arm completely (retract cylinder),
as shown in Figure 6.
5-11
June 10, 2015 5.1.5 Swing parking brake angle
7. After operation is allowed by whistling, oper-

ate 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 Figure 8.
Figure 6
Figure 8
8. Measure the distance of AB with the tape (chord
length swing angle corresponds to), as shown in
Figure 8.
9. Repeat steps 6 and 7 to measure three times,
and calculate average value.
LG922D03033
10. Measure the distance of AB during
Figure 7 anticlockwise swing with the same method.
4. Retract the bucket completely (extend cylin- 11. Refer to attached table 3 for swing parking brake
der), as shown in Figure 6. angle test table.
5. Adjust boom height till bucket tooth is 1.5m
from the ground, as shown in 6.
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 track front end, and get
the distance L1 of swing bearing center to track
front end, as shown in the figure.
 Warning: please honk the horn before

swing action!
5-12
5.1.6 Swing speed June 10, 2015
5.1.6 Swing speed

 Danger: 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!
1. Stopwatch.
2. Tool used for marking staring point. Figure 9
3. Two test personnel who are familiar with

4. Retract the bucket completely (extend cylin-
operating the excavator.
der), as shown in Figure 9.
5. Adjust the height to make the bottom of the
bucket at the height of boom hydraulic cylinder
2. Maintain hydraulic oil temperature between articulated axle, as shown in Figure 9.
45°C and 55°C.
 Warning: please honk the horn before
swing action!
normal range.
6. After operation is allowed by whistling, oper-
ate swing right pilot valve to maximum stroke,
mode.
swing clockwise with fastest speed, start time-
keeping from third circle, record the time for
three circles in total, and then stop swing.
C. Swing speed test
1. Park the machine at a solid and flat site. times. Calculate average value of the measured
2. Set accelerator linkage or knob to maximum clockwise swinging time for three times.
positions of engine speed. 8. Measure the time of anticlockwise swinging 3
3. Extend the arm completely (retract cylinder), circles with the same method.
as shown in Figure 9. 9. Refer to attached table 4 for swing speed test
table.
5-13
June 10, 2015 5.1.7 Swing bearing clearance
5.1.7 Swing bearing clearance C. Measurement of swing bearing clearance

(vertical direction)
Swing bearing clearance (vertical direction)
2. As shown in Figure 10, install magnet base on
1. Dial indicator. swing bearing support, and the probe of dial
2. Dial gage bracket (can be rotated freely). indicator contacts with mounting bolt of swing
3. Tape. bearing outer ring.
4. Measurement is performed by two persons.
In front of machine
45°C and 55°C.
normal range. Magnet base
Dial
mode. indicator
LG922E930E05014
of the pump are within the normal range. Figure 10
3. Operate the arm to retract or stretch out to
 Caution: Pay close attention to the make the included angle between it and boom is
machine when reading the dial indica- about 90°, as shown in Figure 11.
tor! During maintenance and test, the 4. Operate the bucket to retract or stretch out to
qualified protective suit, safety shoes make bucket bottom parallel with the ground.
and helmet must be worn. Make sure 5. Lower the boom to make bucket bottom con-
that there are no barriers within the tact with the ground. Continue to lower the
maximum swing radius. boom, and jack machine front end to 450mm of
5-14
5.1.7 Swing bearing clearance June 10, 2015
the track from the ground, as shown in Figure11. 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 12.
8. Release the bucket completely, and lift or lower
boom to make the distance between bucket tooth
and ground is 450mm, as shown in Figure 12.
90o
450mm
LG922E930E05015
Figure 11 450mm
LG922E930E05016
Figure 12
9. Record readings of dial indicator.
10. Repeat the Step 3 to 9 to measure 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 clearance
of swing bearing of other side.
12. Refer to attached Table 5 for swing bearing
clearance (vertical direction)
5-15
June 10, 2015 5.1.7 Swing bearing clearance
Swing bearing clearance (horizontal

direction)
 Caution: Pay close attention to the
machine during swing! During mainte-
nance and test, the qualified protective
suit, safety shoes and helmet must be
worn. Make sure that there are no barri-
10mm
ers within the maximum swing radius.

1. 30cm steel rule.
2. Triangle base. LG922E930E05017
Figure 13
4. Lift and lower the boom until the distance from
45°C and 55°C.
the bucket tooth to the ground is 10mm, as
shown in Figure 13.
normal range.
5. Mark in the middle part of the bucket.
6. As shown in Figure 14, mark on the ground in
mode.
accordance with the mark in the middle part of
the bucket.
6. Engine flameout.
C. Measurement of swing bearing clearance
(horizontal direction)
2. Extend the bucket completely (retract cylin-
LG922E930E05018
Figure 14
7. Push the bucket to the left until the bucket
cannot move with hands (one person), measure
and record the deviation distance from the mark
5-16
5.1.8 Action time of cylinder June 10, 2015
in the middle part of the bucket to the mark on 5.1.8 Action time of cylinder
the ground, as shown in Figure 14.
8. Push the bucket to the right until the bucket  Caution: Be sure to move the machine
cannot move with hands (one person), measure (standard configuration) out of the route
and record the deviation distance from the mark of other machines before testing so that
in the middle part of the bucket to the mark on there are no obstacles within maximum
the ground, as shown in Figure 14. swing radius. Other personnels can not
9. Repeat the Step 7 to 8 to measure three approach the machine when starting the
times. Calculate average value of measured machine for adjustment or test.
data for three times respectively.
 Caution: only time to buffer stroke start-
10. Rotate the upper mechanism by 180°, and
ing point needed to be measured when
repeat the step 2-9 to measure the deviation
measuring the action time of cylinder.
value of the other side.
11. Refer to attached table 6 for swing bearing
clearance (horizontal direction) test table. 1. Stopwatch.
2. Two test personnel who are familiar with
operating the excavator. (One for operating the
excavator and the other for timekeeping &
record)

45°C~55°C (subject to the temperature on the
display, similarly hereinafter).
normal range.
mode.
C. Measurement of the boom cylinder action

time
5-17
June 10, 2015 5.1.8 Action time of cylinder
positions of engine speed. D. Measurement of the arm cylinder action

3. The height of bucket tooth is in accordance time
with that of the front pin of the arm, as shown in
 Warning: This test method is for stan-
Figure 15.
dard-configuration excavator. If the
machine equipment is available for
optional configuration, check and con-
firm whether there is interference
between the front attachments and the
cab!

Figure 15
3. Lift the boom cylinder to certain height, as
4. The arm cylinder retracts completely, as
shown in Figure 16.
shown in Figure 15.
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 personnel starts time-
keeping when finding the boom action and
records the time from action to boom cylinder
reaching buffer stroke starting point.
7. Operate pilot valve which controls the boom LG922EIII05011
lowering to the maximum stroke and lower the Figure 16

boom at the fastest speed. The personnel starts The bucket cylinder must be retracted to make
timekeeping when finding the boom action and sure the bucket can't bump
records the time from action to bucket touching
against the ground, see Figure16
the ground.
5. Extend the arm completely (retract the cylin-
der).
times. Respectively calculate average values of
6. Operate arm pilot valve to the maximum
the boom lifting & lowering time for three times.
stroke and retract the arm at the fastest speed
9. Refer to attached table 7 for boom cylinder
(stretch out the cylinder). The personnel starts
action time test table.
timekeeping when finding the arm action and
records the time from action to arm cylinder
reaching buffer stroke starting point.
7. Operate arm pilot valve to the maximum
5-18
5.1.8 Action time of cylinder June 10, 2015
stroke and release the arm at the fastest speed 7. Operate bucket pilot valve to the maximum
(the cylinder retracts). The personnel starts stroke and release the bucket at the fastest
timekeeping when finding the arm action and speed (the cylinder retracts). The personnel
records the time from action to arm cylinder starts timekeeping when finding the bucket
reaching buffer stroke starting point. action and records the time from action to
8. Repeat the Step 6 to 7 to measure three bucket cylinder reaching buffer stroke starting
times. Calculate the average values of time for point (if any).
arm retracting and stretching out for three times 8. Operate bucket pilot valve to the maximum
respectively and compare them with the stan- stroke and retract the bucket at the fastest
dard values in the Table below. speed (extend the cylinder). The personnel
9. Refer to attached table 7 for arm cylinder starts timekeeping when finding the bucket
action time test table. action and records the time from action to
bucket cylinder reaching buffer stroke starting
E. Measurement of the bucket cylinder point (if any).
action time 9. Repeat the Step 7 to 8 to measure three
1. Park the machine at a solid and flat site. times. Calculate the average values of time for
2. Set accelerator linkage or knob to maximum bucket stretching out and retracting for three
positions of engine speed. times respectively and compare them with the
standard values in the Table below.
3. Lift the boom to highest position.
10. Refer to attached table 7 for bucket cylinder
4. Adjust the arm to make the angle between the
action time test table.
arm and its cylinder about 90 °, as shown in
Figure 17.  Caution: be careful for climbing opera-
tion.
Figure 17
5. Lower the boom till the height of the front pin
of arm in accordance with that of rear pin of the
boom, as shown in Figure 17.
6. Retract the bucket completely (extend cylin-
5-19
June 10, 2015 5.1.9 Cylinder settlement
5.1.9 Cylinder settlement 3. Retract the bucket completely (stretch out cyl-
inder), as shown in Figure 18.
4. Adjust boom height till bucket tooth is 1.5m
1. 30cm steel rule. from the ground, as shown in Figure 18.
2. Stopwatch. 5. Shut down the engine, keep 10 minutes, and
3. Tape used for marking staring point. measure and record moving distances of boom,
4. 3m tape. arm, and bucket cylinder piston and settlement
5. Plumb bob. distance of tooth.
6. Two test personnel who are familiar with 6. Repeat the Step 4 to 5 to measure three
operating the excavator. times. Respectively calculate average values of
B. Machine state and parking site the moving distances of boom, arm, and bucket
1. Solid and flat parking site. cylinder piston and settlement distance of tooth
for three times.
45°C and 55°C. 7. Bucket cylinder and arm cylinder is extended
completely, and the boom is lowered to certain
height to make articulated joint between link and
normal range.
bucket cylinder is 250~300mm from the ground,
mode.
6. Engine flameout.
C. Measurement of cylinder settlement
1. Park the machine in a solid and flat site and
maintain the hydraulic oil temperature between
45°C and 55°C.
Figure 19
8. Shut down the engine, keep 10 minutes, and
measure and record moving distance of arm cyl-
inder piston.
9. Repeat step 8 to measure three times. Calcu-
late the average value of moving distances of
arm cylinder piston rod.
10. Refer to attached table 8 for cylinder settle-
ment test table.
Figure 18
5-20
5.1.10 Operating force of control lever June 10, 2015
5.1.10 Operating force of con- 5.1.11 Control lever stroke

trol lever A. Tools and testing instrument
Steel ruler
Spring balance: range 200N
1. Solid and flat parking site
2. Shut down the diesel engine.
C. Measure of control lever stroke
2. Shutdown the engine
1. Measure control lever stroke from neutral
position to ending point respectively at the tops
of boom, arm, bucket, swing and travel control
levers.
2. Repeat to measurement three times and cal-
culate average value.
3. Record measurement value.
LG922E930E05026
Figure 20
C. Measure of control lever operating force
1. Make spring balance hook on control lever as
shown in Figure 20 and operate the following
functions: boom lifting and lowering, arm retract-
ing and stretching out, bucket retracting and
stretching out, left and right swing and travel
2. Measure the maximum operating force when
each actuating mechanism is in maximum
stroke.
3. Record measurement data.
5-21
June 10, 2015 5.1.12 Boom lifting and swing action
5.1.12 Boom lifting and swing

action
1. Stopwatch
2. Tape
positions of engine speed. Lift the boom cylinder
and make sure that the cylinder runs smoothly
without collision. LG922E930E05028
3. Extend all the arms, retract all the buckets,

Figure 22
and lower the buckets to the ground, and the
3. When upper mechanism swings by 90°,
buckets shall be at idle. As shown in Figure 21.
release control lever to stop these two kinds of
actions, as shown in Figure 23. Measure the
50±5°.
time of swinging by 90° and the height of bucket
tooth (H).
LG922E930E05027
Figure 21
LG922E930E05029
C. Check of boom lifting and swing action
Figure 23
positions of engine speed. Turn the air condi-
tioner and automatic idling off.
2. Conduct full-stroke operation while lifting
boom and conducting swing. As shown in Figure
22.
5-22
5.1.13 Pilot pressure June 10, 2015
5.1.13 Pilot pressure

Caution: If the pressure display can be set on
cab display screen of your machine, you can use
the information on display screen to conduct the
Press the exhau
following tests. If your machine does not support the valve stem
function, the following operation steps will guide you

to install pressure gauge.
Pressure gauge, range 0~10MPa;
50±5°. Figure 25
2) Connect the pressure gauge at position (1)
C. Measurement of pilot pressure of Figure 26.
1. Install pressure gauge. Specific operations
are as follows
1) Release the residual pressure in oil tank.
Shut down the diesel engine, and unscrew
the dust cover on the breather valve as shown
in Figure 24, and then press the exhaust
1
valve stem on the breather valve, as shown in
Figure 25.
LG922D03034
Dust co
Figure 26
3) Start the diesel engine, and confirm there is
no obvious oil leakage at the connection posi-
tion of pressure gauge.
Figure 24 3. Operate control lever, and record pressure
value.
5-23
June 10, 2015 5.1.14 Secondary pilot pressure
5.1.14 Secondary pilot pressure

cab display screen of your machine, you can
use the information on display screen to conduct
the following tests. If your machine does not Press the exhaust
valve stem
support the function, the following operation

steps will guide you to install pressure gauge.
1. Pressure meter, range: 0 - 10 MPa;
2. Tee (Material No.: 32c0411)

Figure 28
1. Solid and flat parking site 2) Connect the pressure gauge. Connect the tee
2. Maintain hydraulic oil temperature between (Material No.: 32c0411) and pressure gauge in
50±5°. the pilot lines. Start the diesel engine, and con-
firm there is no obvious oil leakage at the con-
C. Measurement of secondary pilot pressure nection position of pressure gauge.
1. Install pressure gauge. Specific operations Figure 34 – Installation of pressure gauge
are as follows
Release the residual pressure in oil tank. Shut
down the diesel engine, and unscrew the dust
cover on the breather valve as shown in Figure
26, and then press the exhaust valve stem on
the breather valve, as shown in Figure 27.
1
Dust cover
LG922D03035
Figure 29
4. Full-stroke operation of corresponding control
Figure 27
lever and measurement of pilot pressure, includ-
5-24
5.1.15 Output pressure of solenoid proportional valve June 10, 2015
ing: 5.1.15 Output pressure of sole-

(a) Boom lifting and lowering
(b) Arm retraction and stretching
noid proportional valve
(c) Bucket retraction and stretching Caution: If the pressure display can be set on
(d) Left and right swing cab display screen of your machine, you can
(e) Forward and backward travel use the information on display screen to conduct
5. Operate control lever and record measure- the following tests. If your machine does not
ment value. support the function, the following operation
culate average value. A. Tools and testing instrument
1. Transition joint (Material No.: 00a0969)
2. O-ring (Material No.: 12b0428)
3. Pressure gauger, with range of 0 - 10 MPa
50±5°.
C. Measurement of output pressure of sole-

noid proportional valve
1. Install pressure gauge. Specific operations
are as follows
Shut down the diesel engine, and unscrew
the dust cover on the breather valve as shown
in Figure 30, and then press the exhaust
valve stem on the breather valve, as shown in
Figure 31.
5-25
June 10, 2015 5.1.15 Output pressure of solenoid proportional valve
Dust co
LG922D03036
Figure 30
Figure 32
Press the exhau

4. Full-stroke operation of corresponding control
valve stem
lever and measurement of the pressure of the
solenoid proportional valve, including:
(a) Boom lifting and lowering
(b) Arm retraction and stretching
(c) Bucket retraction and stretching
(d) Left and right swing
(e) Forward and backward travel
Figure 31 5. Repeat to measurement three times and cal-

Remove the plug from the main pump, refer to
Figure 32 for the position. Connect the O-ring
(Material No.: 12b0428) and transition joint
(Material No.: 00a0969), and then connect the
pressure gauge.
3) Start the diesel engine, and confirm there is
no obvious oil leakage at the connection posi-
tion of pressure gauge.
5-26
5.1.16 Setting pressure for main relief valve June 10, 2015
5.1.16 Setting pressure for main

relief valve
cab display screen of your machine, you can
use the information on display screen to conduct Dust cover
the following tests. If your machine does not
support the function, the following operation
1. Tee (Material No.: 32c0529)
2. O-ring (12b0428)
3. Transition joint (00a1964) Figure 33
4. Pressure gauge, with range of 0 - 10 MPa
1. Solid and flat parking site;
50±5°. Press the exhaust
valve stem
C. Measurement of setting pressure for main

relief valve
Shut down the diesel engine, and unscrew the
dust cover on the breather valve as shown in
Figure 33, and then press the exhaust valve
stem on the breather valve, as shown in Figure Figure 34
34.
5-27
June 10, 2015 5.1.16 Setting pressure for main relief valve
2. Connect the pressure gauge (take the left pump as an example):

1) Unscrew the plug (1) shown in the Figure;
2) Install the O-ring (2);
3) Install the transition joint (3);
4) Install the tee (4);
5) Connect the sensor of electrical system into port A of tee;
6) Connect the tie-in into port B of tee.
7) Start the diesel engine, and confirm there is no obvious oil leakage at the connection position of pres-
sure gauge.
The method for connecting right pump with the pressure gauge is the same as that of left pump.
Pressure test port

of right pump
Pressure test
port of left pump
Figure 35
1- Plug on the pump (originally equipped on the pump)
2- O-Ring
3- Transition joint
4- Tee
5-28
Figure 36
3. Set accelerator linkage or knob to maximum positions of engine speed. Turn the air conditioner and
automatic idling off.
4. Slowly operate control levers of bucket, arm, 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.
7. Press the transient boost switch, operate the bucket, arm and boom control lever slowly within 8s to the
maximum stroke to make the hydraulic system overflow, and then measure and record the pressure value.
5-29
Attached Table 1
Travel speed (idling speed/actual speed)
Unit: s
Model of complete machine: Testing date:
Number of complete machine: Testing site:
Testing personnel:
1st gear position 2nd gear position 2nd gear position

Model 1st gear position forward
backward forward backward
The first The first The first The first
time time time time
The The The The
second Average second Average second Average second Average
time value time value time value time value
The third The third The third The third
time time time time
Attached table 2
Travel deflection value table
Unit: m

Testing personnel:
1st gear position 2nd gear position 2nd gear position

Model 1st gear position forward
backward forward backward
The first The first The first The first
time time time time
The The The The
Average Average Average Average
second second second second
value value value value
time time time time
The third The third The third The third
time time time time
5-30
Attached table 3
Swing parking brake angle table
Unit: m

Testing personnel:
Model Clockwise Counterclockwise

The first time The first time
The second time Average value The second time Average value
The third time The third time
Attached table 4
Swing speed table
Unit: s

Testing personnel:
Model Clockwise Counterclockwise

The first time The first time
The second time Average value The second time Average value
The third time The third time
5-31
Attached table 5
Swing bearing (vertical direction) clearance table
Unit: mm

Testing personnel:
Model Swing bearing clearance (vertical direction)

The first time
The second time Average value
The third time
Attached table 6
Swing bearing (horizontal direction) clearance table
Unit: mm

Testing personnel:
Model Swing bearing clearance (horizontal direction)

The first time
The second time Average value
The third time
5-32
Attached table 7
Test of the excavator work implement action time

Testing personnel:
Standard
value of
Item Working condition for measurement Unit Test time
the new
machine
 Engine runs at full speed The first time
 The complete machine works The second Avera
in the normal mode Liftin
S time ge
g
 Hydraulic oil temperature is The third value
within the normal working time
Boo
range The first time
m
 Working current and working
The second Avera
pressure of the pump are Low
S time ge
within the normal range ering
 Refer to Figure 15 for The third value
measuring posture time
 The complete machine works Retr The second Avera
in the normal mode actio S time ge
Spee
 Hydraulic oil temperature is n The third value
d of
work
Arm range The first time
impl
eme  Working current and working
Exte The second Avera
nt pressure of the pump are
nsio S time ge
within the normal range
 Refer to Figure 16 for n The third value
 The complete machine works Exca The second Avera
in the normal mode vatio S time ge
 Hydraulic oil temperature is n The third value
Buck
range The first time
et
 Working current and working
Unlo The second Avera
pressure of the pump are
adin S time ge
within the normal range
 Refer to Figure 17 for g The third value
5-33
Attached table 8
Cylinder settlement table
Unit: mm
Testing personnel:
Boom cylinder Arm cylinder Arm cylinder Bucket cylinder Bucket tooth
Model
(Retraction) (Extension) (Retraction) (Retraction) (Settlement)
The first The first The first The first The first
time Aver time time Aver time Aver time Ave
The second age The second Averag The second age The second age The second rage
time valu time e value time valu time valu time valu
The third e The third The third e The third e The third e
time time time time time
5-34
5.2 Other tests CLG920D/922D
5.2.1 Adjustment of valve clearance June 10, 2015
5.2 Other tests

5.2.1 Adjustment of valve clear-
ance
Preparation steps
Explosive gas may leak from the battery. To
avoid personal injury, the diesel compartment
must be with good ventilation before the mainte-
nance of the battery. To avoid generating the
electric arc, the wire of the battery negative pole
(-) must be removed first and connected last. LG922E930E05037
1. Disconnect the battery.
 If the inlet joint is removed, regardless of

the time of removing, seal the pipe hole
with an adhesive tape to avoid the falling of
the fragments into the intake pipe.
LG922E930E05036
2. Remove the inlet joint if necessary.

Remove the 4 mounting screws, the inlet joint
and the gasket.
LG922E930E05038
Remove the air intake heater component and
the gasket.
 Various inlet joints are equipped for the die-

sel engine, and the two shown in the right
figure are the common ones.
5-35
CLG920D/922D 5.2 Other tests
June 10, 2015 5.2.1 Adjustment of valve clearance
3. Remove the crankcase respirator from the

valve chamber cover.
 It may be possible to approach the crank-

case respirator/rocker arm chamber cover
unless the diesel engine cover is removed.
4. Disconnect the crankcase respirator pipe
from the crankcase respirator as.
5. Disconnect the crankcase respirator oil return
pipe from the crankcase respirator as.
LG922E930E05040
8. Remove the rocker arm chamber cover and

the valve chamber cover gasket.

When the compressed air is used, the proper
goggle and the protective mask shall be worn.
The flying fragments and the dirt may cause per-
sonal injury.
LG922E930E05039
Before removing any components, clean the
surrounding of the mounting fasteners and the
6. Remove the mounting screws. connector to remove the loose fragments.
7. Vertically pull the respirator assembly upward
to remove the respirator from the rocker arm
chamber cover.
LG922E930E05041
 For the diesel engine whose rocker arm

5-36
chamber cover gasket is installed in the The flying fragments and the dirt may cause per-
groove of the bucket lever chamber cover sonal injury.
bottom, do not remove the bucket chamber
cover gasket. This can be used continu- 
ously. The gasket must be replaced once it When cleaning the rocker arm chamber cover, if
is removed from the rocker arm chamber the bucket lever gasket is still installed on the
cover. base of the rocker arm chamber cover, do not
soak the bucket lever chamber in the solvent.
9. Remove the mounting bolts and the vibration
Do not soak the gasket in the solvent too much.
insulator from the bucket lever chamber cover.
This can be used continuously. The gasket must
10. Remove the rocker arm chamber cover.
be replaced once it is removed from the rocker
arm chamber cover.
Clean the rocker arm chamber cover with the
solvent. Dry the bucket lever chamber cover
with the compressed air.
LG922E930E05042
11. Clean it and check whether it can be used

continuously.

When the solvent, acid or alkalic material is LG922E930E05043
used for cleaning, please follow the advice of

the manufacturer. Wear the goggle and the pro-  When the gasket is installed in the valve
tective suit to avoid personal injury.
chamber cover, check the gasket. The gas-
 ket must be replaced once it is removed
from the rocker arm chamber cover.
Some solvent is flammable and toxic. Please
read the instructions provided by the manufac- Check the silicone clad layer for flaw.
turer prior to use. Replace the gasket if any damage is found.
 If the gasket is removed from the rocker arm

chamber cover groove, replace the gasket with
When the compressed air is used, the proper
a new one.
goggle and the protective mask shall be worn.
5-37
Adjustment
 The temperature of the diesel engine cool-

ant must be less than 60°C.
1. Rotate the crankshaft until the cylinder 1 is in
the TDC.
LG922E930E05044
Check the rubber vibration insulator for flaw.

Replace it if any flaw or break is found.
LG922E930E05046
The TDC can be confirmed by the following

methods:
Align to the shock absorber/crankshaft speed
indicating ring, so as to make the TDC pointer
point to the 12 o'clock position. If the two rocker
arms of cylinder 1 are loose, go to the following
steps. If the two bucket levers of cylinder 1 are
not loose, rotate the crankshaft by 360°.
LG922E930E05045
LG922E930E05047
5-38
2. When the diesel engine is in this position, you

can conduct the following check of the rocker
arm clearance:
(E = Exhaust, I = Intake)
1I-1E-2I-3E-4I-5E
LG922E930E05049
 When the feeler gage slides between the

jumper plate and the rocker arm bearing
support, if a certain resistance can be “felt”,
the clearance is correct.
LG922E930E07147 3. Insert the feeler gage between the jumper
Limiting value of the clearance check: plate and the rocker arm bearing support to
Minimum: 0.17mm measure the clearance. If the clearance mea-
Maximum: 0.33mm surement value is beyond the technical specifi-
cation, loosen the locknut, and adjust the
Exhaust
clearance to the nominal technical specification.
Minimum: 0.43mm
Technical specification of valve clearance:
Maximum: 0.59mm
Intake: 0.25mm
 Generally, checking the setting value of the Exhaust: 0.51mm
overhead mechanism is a part of the fault
diagnosis procedure. As long as the clear- 4. Tighten the locknut and conduct the measure-
ance measurement value is within the ment.
range above, it is not necessary to reset
Torque value: 24N.m
the value during the check.
5-39
Last procedures

Explosive gas may leak from the battery. To
avoid personal injury, the diesel compartment
must be with good ventilation before the mainte-
nance of the battery. To avoid generating the
electric arc, the wire of the battery negative pole
(-) must be removed first and connected last.
1. Install the rocker arm chamber cover gasket
and the cover.
LG922E930E05050
 If the gasket has been removed from the
5. Rotate the crankshaft by 360°. rocker arm chamber cover, the gasket
installed must be a new one.
6. Measure the following rocker arm clearance
according to the same procedures and the tech- If the bucket lever gasket is replaced, the instal-
nical specifications above: lation procedure below must be followed when
(E = Exhaust, I = Intake). press-in mating gasket is installed.
2E, 3I, 4E, 5I, 6I and 6E. • Press the gasket pressed by module into
the corners of the rocker arm chamber
If the clearance does not meet the technical
cover;
specification, reset it.
• Press the rest of the gasket into the rocker
arm chamber cover.
LG922E930E05051
LG922E930E05052
2. Install the rocker arm chamber cover on the

mounting screw.
5-40
3. Install the vibration insulator and the mounting 9. Install the crankcase respirator pipe to the
nut. crankcase respirator as.
4. Tighten the mounting nut. 10. Install the crankcase respirator oil return
Torque value: 24N.m pipe to the crankcase respirator as.
 The diesel engine cover that has been

removed before installation may be used.
LG922E930E05042
5. Install the crankcase respirator. LG922E930E05054
6. Install the respirator and the mounting screw 11. Install the inlet joint (if it has been removed).
in the rocker arm chamber cover. 12. Clean it and check whether it can be used
7. Lubricate the O-ring and the rocker arm continuously.
chamber cover with oil. Clean the sealing surface of the air intake heater
core.
8. Tighten the screw. Clean the sealing surface of the inlet cover.
Clean the sealing surface of the inlet joint.
Torque value: 10N.m
 Sealing material and any other materials
are forbidden to enter the air inlet.

LG922E930E05053
5-41
15. If equipped, install the single black (ground)

heater lead wire.

16. Connect the battery.
17. Run the diesel engine and check for leak-
age.
LG922E930E05055
 If the adhesive tape is found on the intake

manifold, remove it.
13. Install the new gasket and the inlet joint on
the air start auxiliary device - heater.
14. Install and tighten the 4 mounting screws.
Torque value: 24N.m

LG922E930E05037
5-42
5.2.2 Measurement of blow-by of crankcase June 10, 2015
5.2.2 Measurement of blow-by

of crankcase
Overview
 The actual diesel engine configurations are Crankcase
ventilating
device hose
not showed in some figures in this step.
However, the steps are same.
To
If crankcase pressure and/or blow-by volume is pressure
gauge
too much, it indicates that fault occurs in the die-
sel engine or its related components, and con-
sequently burning gas or air leaks into the
crankcase. The result is that the generated pres-
sure exceeds normal crankcase pressure, and
therefore the blow-by level is increased.
How to measure the crankcase pressure/blow-
by and how to determine the fault components
are described in this step.
The general purpose of blow-by measurement

lies in:
1. Check the diesel engine running-in upon
reloading;
2. For the open crankcase breather system,
LG922E930E05057
conduct troubleshooting when excess engine oil
overflows from the crankcase breather pipes It is worth noticing that the two terms about
(generally also known as oil carry-out). “blow-by” and “carry-out (engine oil overflows
from the breather pipe)” are usually equivalent.
3. Conduct troubleshooting for probable diesel
engine internal damages, such as worn piston The engine oil quantity will directly affect the
rings, oil seals or tubes of valve rods, turbo- measurement results of blow-by if excess
chargers, air compressors, etc. engine oil overflows from the breather pipes
when measuring blow-by.
These steps provide the general guideline
about measurement of gas blow-by related The blow-by measurement results shall also be
to above condition. affected by the engine oil collected on the
metering holes of blow-by measurement and
maintenance tools. This reduces the sizes of
metering holes, and therefore, the measurement
results always exceed the actual blow-by mea-
surement values.
5-43
June 10, 2015 5.2.2 Measurement of blow-by of crankcase
If so, the following measures shall be taken: that the internal faults of the diesel engine cause
1. Find different measuring positions on the die- excess blow-by. These steps include:
sel engine to measure the crankcase pressure 1) Confirm the maintenance regulations for
(engine oil filler, engine oil filler cover, drainage crankcase.
position of unused 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 com- 3) Get an engine oil sample and check whether
pletely. there are pollutions.
3.Confirm whether there are some factors mak-
ing the breather be full with engine oil, for exam- Measurement tools
ple:
The tools used for measuring blow-by are gen-
4. Engine oil level is incorrect;
erally similar in the structure. The sizes of
5. Vehicle operation (excessive incline, exces-
metering holes are their main distinctions. Differ-
sive all-round rotation of the diesel engine);
ent sizes of metering holes are designed for
6. The diesel engine internal components make accurately measuring blow-by, which can also
engine oil deviate to the breather cavity (piston meet the needs for various diesel engine config-
cooling nozzle, attachment drain pipe of engine urations and rated power. Because the diesel
oil, etc.); engine blow-by depends on the volume of inlet
7. Confirm whether there is another breather air.
option for the diesel engine being repaired. For example:
Other steps can be adopted to verify the doubt If the measurement of blow-by is conducted on
that the internal faults of the diesel engine cause two diesel engines with same configurations and
excess blow-by. sizes, but with different horsepowers and rated
Blow-by measurement shall be considered only speeds, the measured maximum blow-by values
when the running-in of diesel engine after re- will be different.
installation is confirmed or other symptoms Part number of blow-by tool: 3822566
appear. Emerging symptoms include:
Size of metering hole: 7.67mm
1) Excess engine oil carry-out (the engine oil is
Pictures of blow-by tools:
carried-out from the crankcase breather pipes)
2) Excess crankcase pressure (for the diesel
engine equipped with crankcase pressure sen-
sor)
3) Low power
4) Engine oil consumption
5) Exhaust smoking
It is not necessary to measure the blow-by if
there are no other symptoms.
Other steps can be adopted to verify the doubt
5-44
Crankcase
ventilating
device hose
To
pressure
gauge
LG922E930E05058
The relationship between measured pressure

Connect the hydraulic gauge (the part number is value of orifice with 7.67-mm diameters and flow
ST1111-3), pressure gauge or sensor on the velocity is shown in the table below.
blow-by measurement and maintenance tools
when measuring the crankcase/blow-by pres- The blow-by conversion table for the orifice with
7.67mm diameters and blow-by
sure.
mmH2O[inH2O] Liter/min [cfm]
 It is supposed to measure the water column 25.4[1] 50[1.766]
for 944mm at most by using the hydraulic 50.8[2] 84[2.966]
gauge (the part number is ST1111-3). 76.2[3] 103[3.637]
101.6[4] 119[4.202]
127[5] 133[4.697]
152.4[6] 145[5.121]
177.8[7] 155[5.474]
203.2[8] 164[5.792]
228.6[9] 172[6.074]
254[10] 180[6.357]
279.4[11] 187[6.604]
304.8[12] 193[6.816]
330.2[13] 200[7.063]
LG922E930E05059
355.6[14] 206[7.275]
381[15] 211[7.451]
406.4[16] 217[7.663]
431.8[17] 222[7.840]
457.2[18] 226[7.981]
5-45
482.6[19] 229[8.087]
508[20] 235[8.299]
533.4[21] 239[8.440]
558.8[22] 242[8.546]
584.2[23] 246[8.687]
609.6[24] 248[8.758]
LG922E930E05061
 Check the engine oil level in the diesel

engine. If the oil level is too high, the blow-
by pressure will exceed normal level and/or
excess engine oil will be carried out.
LG922E930E05060
Initial inspection
 The locations and types of crankcase
breathers will change along with the differ-
ences of diesel engine configurations (front
gear power train or rear gear power train)
and/or diesel engine applications.
 Check whether the crankcase breather LG922E930E05062
pipes are sealed 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 removed prior
to blow-by measurement in order to clean and
clear all collected engine oil away.
5-46
Measurement mometers for the diesel engine running-in.
1. Connect the hydraulic gauge (the part number 2) Use chassis dynamometers or diesel dyna-
is ST1111-3), pressure gauge or sensor on the mometers for the diesel engine test.
blow-by measurement and maintenance tools 3) Stall test (for the diesel engine only equipped
when measuring the crankcase/blow-by pres- with an automatic transmission).
sure.
 The locations of crankcase breather pipes

may change along with the diesel engine
configurations and/or its specific applica- 500
C
0
2500
tions. 500
0
0
2. Installation of applicable blow-by mainte- RPM
nance tools:
30 40 50
For the open crankcase breather/ventilating sys- 20 60
70
tem, connect applicable blow-by maintenance 10
0
tools at the end of crankcase breather respirator MPH
pipes. Connect a hydraulic gauge, pressure

LG922E930E05064
gauge or sensor on the blow-by maintenance
tools.  Excess engine oil overflows from the
breather pipes during the blow-by mea-
surement. So the engine oil volume also
directly affect the blow-by measurement
results.
3.2 Operate the diesel engine with rated speed
and full load until stable values are obtained.
 During the blow-by measurement, a “peak”

shall appear initially in numerical values
when the diesel engine achieves peak
power and rated speed. Starting reading
after the blow-by measured value is stable.
LG922E930E05063
 For the diesel engine running-in, if blow-by
3. Check the effects of crankcase blow-by on is increased suddenly or it exceeds the

the following conditions. maximum limit value in any running-in
steps, it is supposed to go back to the pre-
3.1 The following methods for operating the die-
vious step to continue the running-in. If the
sel engine with rated speed and load are
blow-by does not reach acceptable level,
optional:
interrupt the running-in and confirm the
1) Use chassis dynamometers or diesel dyna-
5-47
causes.
3.3 Record the blow-by measured values in
steady state.
Remove the diesel engine blow-by maintenance
tools and hydraulic gauges or pressure gauges
if blow-by is within the technical specifications.
0 0
RPM RPM
LG922E930E05066
 Do not operate the diesel engine more than

1 minute. Supervise the engine oil quantity
in the vessel. Otherwise, the diesel engine
oil will be used up, consequently causing
severe damage to diesel engine.
LG922E930E05065
The methods about turbocharger isolation are
4. Check the effects of turbocharger blow-by on described in these steps.
the following conditions.
4.3 Place the turbocharger oil tube into a big
If the diesel engine blow-by maintenance tools vessel when the turbocharger oil drain tube and
and hydraulic gauges or pressure gauges are the diesel cylinder body are disconnected.
still installed on the turbocharger:
4.4 Seal the ports of turbocharger engine oil
4.1 Isolate a turbocharger (if equipped), and drain tubes on the cylinder body.
confirm whether the high blow-by pressure is
4.5 The following methods for operating the die-
caused by the leakage of turbocharger seals.
sel engine with rated speed and load are
4.2 Disconnect turbocharger engine oil tubes optional:
when measuring the blow-by generated by the
• Use chassis dynamometers or diesel dyna-
turbocharger.
mometers for the diesel engine test.
4.6 Record the measured peak value of blow-by
pressure.
5-48
LG922E930E05067
LG922E930E05068
5. Determine the distributions of turbocharger
6. Install the turbocharger oil tubes.
blow-by pressures by confirming the blow-by
7. Check the diesel engine oil level, fill engine oil
pressure measurement difference values
when necessary.
between them under the disconnected condition
with isolation and the connected condition with-
out isolation between turbocharger oil tubes and
turbocharger engine oil tubes.
Blow-by pressure difference

Blow-by generated by a
Maximum: 30%
turbocharger
Check whether there are engine oil leakage in

the compressors of turbochargers and turbine
areas if the blow-by generated by turbochargers
does not conform to the technical specifications. LG922E930E05066
Change the turbocharger if necessary.

5-49
June 10, 2015 5.2.3 Measurement of engine oil pressure
5.2.3 Measurement of engine oil along the main engine oil passage.
2. Remove plugs.
pressure Note: It is preferred to check the engine oil pres-
Measurement tools: Compuchek™ connectors sure in the main passage s if applicable.
Material No.: 3824842 3. Install the Compuchek™ connectors.
Figure:
LG922E930E05070
LG922E930E05069
 If there is no engine oil pressure generated
in diesel engine within 15 seconds
 upon starting, close the diesel engine to avoid
Some states and federal agencies in America internal damage.
have firmly believed that the used engine oil Connect the pressure gauge. Start the diesel
has carcinogenic effect and can cause repro- engine.
duction disease. It is supposed to avoid
inhalation of engine oil steam, swallowing by
mistake and contacting the used engine oil
for long time. If not used again, such coolant
and oil should be treated according to the
local environmental protection regulations.

Skin shall be protected from hot engine oil in
order to reduce the possibilities of personnel
injury.
1. Find proper ports in order to measure the
LG922E930E05071
engine oil pressure. For most diesel engines,
the ports can be on the locations near ECM
5-50
5.2.3 Measurement of engine oil pressure June 10, 2015
5. Operate the diesel engine until it reaches the

operating temperature. Check whether there is
leakage.
6. Record the diesel engine oil pressure values
in idle running.
The minimum engine oil pressure at idling is 69
KPa.
RPM
LG922E930E05073
8. Remove the engine oil pressure gauge /Com-

puchek™ connectors, and then install the plugs
removed previously.
RPM
9. Apply a layer of plug sealed glue on (the part
number is 3375066) on the thread.
LG922E930E05072
10. Install and tighten the plugs by referring to
the torque table below.
7. Increase the diesel engine speed to rated
value and keep it running continuously for 30
seconds.
Record the diesel engine oil pressure values
under rated speed.
The minimum engine oil pressure at rated diesel
engine speed is 207 KPa
LG922E930E05074
5-51
June 10, 2015 5.2.3 Measurement of engine oil pressure
Plug torque value
Dimension Torque Torque

Install it into aluminum Install it into the cast iron or
Thread Actual thread external diameters
components. steel components.
in. mm (in) N·m (ft-lbs) N·m (ft-lbs)
1/16 8.1 (0.32) 5 (45 in-lb) 15 (10)
1/8 10.4 (0.41) 15 (10) 20 (15)
1/4 13.7 (0.54) 20 (15) 25 (20)
3/8 17.3 (0.68) 25 (20) 35 (25)
1/2 21.6 (0.85) 35 (25) 55 (40)
3/4 26.7 (1.05) 45 (35) 75 (55)
1 33.5 (1.32) 60 (45) 95 (70)
1¼ 42.2 (1.66) 75 (55) 115 (85)
1½ 48.3 (1.90) 85 (65) 135 (100)

5-52
5.2.4 Measurement and adjustment of track tension June 10, 2015
5.2.4 Measurement and adjust- Measurement of the track tension

ment of track tension 2. Maintain the hydraulic oil temperature
Measurement of the track tension 45°C~55°C.
Tools and testing instrument 3. Operate the right swing until the upper mech-
anism is vertical to the lower one.
1. Steel rulers.
4. Operate the boom, arm and bucket until the
bucket bottom is on the ground as shown in the
Figure 6.
150mm
LG922E930E05075
Figure 6
Machine state and parking site
LG922E930E05076
Figure 7
5. Lower the boom until the right track is raised
45°C and 55°C.
for about 100 ~ 200 mm from the ground to keep
3. Set the diesel engine in the maximum speed
the track away from the ground during operation
(with the air conditioning turned off).
6. Operate the track at this side to rotate back-
normal range.
ward and forward 2 circles each. Taking the
5. The complete machine works in the normal middle part of the track as the inspection point,
mode. measure the distance A between the bottom of
6. The working pressure and the pilot pressure the track beam and the backside of the lower
of the pump are within the normal range. track plate as shown in Figure 7.
Standard value of the track tension
Track type Standard value
Metal track 350~380mm

5-53
June 10, 2015 5.2.4 Measurement and adjustment of track tension
1 2
LG922E930E05077 LG922E930E05078
Figure 8 Figure 9
Adjustment of track tension 1) Loosen the filling valve 2, discharge the
grease and then tighten it.
If the track tension is abnormal, adjust it accord-
ing to the following procedures.  Caution: the valve may fly off as a result of
1. Increase the tension the internal high-pressure grease, so do
1) Fill the grease from the grease fitting 1 using not loosen the filling valve 2 more than two
grease gun. circles.
2) To determine that the tension of the track 2) To determine that the tension of the track
shoe is normal, operate the diesel engine in low shoe is normal, operate the diesel engine in low
idle speed and drive the machine forward for a idle speed and drive the machine forward for a
distance which equals to the length of the track distance which equals to the length of the track
shoe on the ground and then stop the machine shoe on the ground and then stop the machine
slowly. slowly.
3) After adjustment, measure the tension again 3) After adjustment, measure the tension again
according to the procedures above to guarantee according to the procedures above to guarantee
that the tension is normal. that the tension is normal.
2. Reduce the tension
5-54
5.2.5 Inspection and adjustment of minus feedback pressure N1 June 10, 2015
5.2.5 Inspection and adjust-

ment of minus feedback pres- 1
sure N1 2
Check
3
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.
LG922E930E05080
Feedback
pressure N1
Pressure test tee and

pressure test notch
Measurement steps:
1. Remove the connector assembly (1) from the
main pump;
2. Connect it with the main pump feedback pres- 4
sure port N1 after installing the O-ring (3) into 2
the pressure tee (2).
3. Install the tie-in (4) into the pressure port of
the pressure tee (2).
4. Insert the pressure gauge (6 MPa measuring
range) with pressure hoses into the tie-in (4) and
measure the pressure on the main pump feed-
back pressure port N1.
LG922E930E05082
5-55
June 10, 2015 5.2.6 Inspection and adjustment of minus feedback pressure N2
Checklist: 5.2.6 Inspection and adjust-

S/N Material number Name
ment of minus feedback pres-
1
32C0529 Tee sure N2
12C2000 Edge valve
1. Directly read the minus feedback pressure N2
2 32C0617 Pressure tee on the display. Contact Liugong service provider
3 12B0428 O-ring if it needs to read pressure.
Pressure 2. Measure the minus feedback pressure F2 on
4 12C1140 measurement
joint its port shown in the figure below.
Adjustment
Change the minus feedback pressure values by Feedback
changing the current values of octa-electromag- pressure N2
net A6. The corresponding curve of current with

output feedback pressure N1 is shown in the fig-
ure below.
4
6(&21'$5<35(6685(
The measurement steps are same with that of

⅗ু࣑δ03Dε
3
2.8
N1
2
3. Change the minus feedback pressure values
by changing the current values of octa-electro-
1
magnet A5. The corresponding curve of current
0 with output feedback pressure F2 is shown in
0 400 700
Ӱ࣑⭫⍷δᰬ䰪ᒩൽεδP$ε the figure below.
,1387&855(17 $9(5$%( LG922E930E05083
5-56
5.2.7 Release of remaining pressure in hydraulic oil lines June 10, 2015
5.2.7 Release of remaining

5
pressure in hydraulic oil lines
4

6(&21'$5<35(6685(
⅗ু࣑δ03Dε
3
2.8 The high pressure liquid medium in the hydraulic
2 system and hot hydraulic medium upon opera-
tion may cause personnel injury.
1 There is still high pressure in the hydraulic sys-
tem after the diesel engine is stopped. If the
0
0 400 700 pressure is not released before maintaining any
Ӱ࣑⭫⍷δᰬ䰪ᒩൽεδP$ε
,1387&855(17 $9(5$%( LG922E930E05085 hydraulic system, serious personal injury may
be caused. Be sure that all the accessories have
been put on the ground, and the hydraulic oil
has been cooled before removing any compo-
nents or lines. The oil filler cap can be removed
only when the diesel engine has been stopped,
and the oil filler cap has been cooled enough to
be touched by hands.
Release the pressure of the hydraulic system

according to the following procedures:
1. Park the excavator on the flat ground.
2. Completely place the work implement on the
flat ground. Make the bucket in complete contact
with the ground, as shown in the figure below:
LG922E930E05086
5-57
June 10, 2015 5.2.7 Release of remaining pressure in hydraulic oil lines
personnel injury.
3. Stop the diesel engine.
4. Turn the diesel engine starting switch to “ON”
position, but do not start the diesel engine.
5. Turn the pilot shutoff lever to "ON" position.
6. Repeatedly turn the pilot lever or foot pilot
valve to the maximum angle, release high pres-
sure oil in corresponding lines, and meanwhile,
release pressure in corresponding pilot lines.
7. Turn the pilot shutoff lever to "OFF" position.
8. After releasing the pressure in lines, turn the
pilot shutoff lever to "OFF" position.
9. Turn the diesel engine starting switch to
"OFF" position.
10. Turn the diesel engine starting switch to
"ON" position, start the diesel engine, operate it
at low idling about 10 seconds for storage of the
pressure in the accumulator, and then stop the
diesel engine.
11. Repeat the steps from the 3rd to the 10th
above for several times.
12. Screw out the exhaust valve protective caps
of an air filter above the hydraulic oil tank, press
the exhaust valve and release air pressure in
the hydraulic oil tank until the gas with pressure
is released fully.
13. Tighten the exhaust valve protective caps on
the air filter.
14. When the pressure in the hydraulic system
pipeline has been released, the corresponding
lines or components can be removed.

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
5-58
5.2.8 Exhaust of various devices June 10, 2015
5.2.8 Exhaust of various devices

Exhaust shall be carried out upon the following repair:
Exhaust project
Steps 1 2 3 4 5 6
Work content Hydrau- Start the Oil Swing Travel Start
lic pump diesel cylinder motor motor work
exhaust engine exhaust exhaust exhaust
. Replace the hydraulic oil ż ż ż ż ż ż

. Cleaning of filter element
Replacement of backflow filter
. element ż ż
Repair or replacement of
. hydraulic pump ż
Replacement
ż ż ż
. Remove the suction tube
Repair or replacement of Replacement
. control valve ż ż ż
. Replacement of oil cylinder ż ż ż
. Remove the cylinder line
. Replacement of swing motor ż ż ż
. Remove the swing motor line
. Replacement of travel motor ż ż ż
. Remove the travel motor line
5-59
June 10, 2015 5.2.8 Exhaust of various devices
Exhaust the air in the pump 3. Loosen the exhaustion plug and check for
overflowed oil.
When maintaining the main pump or replacing
the hydraulic oil lines, exhaust the air according 4. If not, fill the hydraulic oil to the pump housing
to the methods below: body.
5. Make the diesel run at idle. If there is no bub-
 ble any more, tighten the exhaustion plug and
The hydraulic oil pressure and the hot oil may the exhaust is over.
cause personal injury.
 If the pump runs without full oil in the pump
When the diesel engine is stopped, the hydraulic
body, the abnormal heat may be produced
oil can still be in the hydraulic system. If the
resulting in the early damage for the pump.
pressure is not released before maintaining any
hydraulic system, serious personal injury may
be caused. Exhaust the air in the cylinder
Be sure that all the accessories have been put 1. Start the diesel engine and operate it for 5min
on the ground, and the oil has been cooled with low idling.
before removing any components or lines. 2. Operate the diesel engine in low speed and
The oil filler cap can be removed only when the telescope the cylinder to the position about 100
diesel engine has been stopped, and the oil filler mm away from the stroke end for 4-5 times.
cap has been cooled enough to be touched by  Do not telescope the cylinder to the stroke
hands.
end, or. The piston seal will be damaged by
the air in the cylinder.
3. Operate the cylinders to the stroke end for 3-4
times
1
4. Operate the cylinders to the stroke end for 4-5
times to exhaust the air completely.
LG922E930E05088
(1) Exhaustion plug

1. Park the machine on the flat ground, lower the
bucket to the ground and pull the pilot control
level to the locked position.
2. Shut down the diesel engine and take the key
out.
5-60
5.2.8 Exhaust of various devices June 10, 2015
Exhaust the air in the travel motor (1) Oil drain hose
2. Operate the diesel engine in low idle speed,
 The air can be exhausted only after the
unscrew the nuts of oil drain hose connector on
hydraulic oil in the travel motor housing the motor housing, and tighten the nuts when
was discharged. the hydraulic oil overflows.
1. Before starting the diesel engine, remove the 3. Operate the diesel engine in low speed and
oil drain hose on the travel motor housing, fill the swing the work implement by 90° to make it
hydraulic oil to the motor housing until the level locate in the side of the track.
reaches the discharge port, and then connect
the oil drain hose.
LG922E930E05090
LG922E930E05089
4. Jack up the machine with the work implement
to make the track off the ground a little, and
operate the track in no-load condition for 2 min.
5. Repeat the operation above in the left and
right side. And rotate the track forward and
backward evenly.
5-61
June 10, 2015 5.2.9 Inspection of diode
Exhaust the air in the accessories (if 5.2.9 Inspection of diode

any) The diode, which is also called crystal diode, is
1. If the knapper or other accessories are electronic device capable of unidirectional con-
equipped, make the diesel engine run in low duction current. There is one PN joint and two
speed, and repeatedly operate the auxiliary lead terminals in the semiconductor diode.
pedal (1) for about 10 times until the air is According to the direction of the applied voltage,
exhausted from the oil line of the accessories. the electronic device, which is popular, has the
transduction performance of the unidirectional
current.
LG922E930E05091
1. Auxiliary pedal
 Conduct the exhaust according to the

LG922E930E05092
Figure a
method specified by the manufacturer.
2. After exhausting the air, shut down the diesel
and leave the machine alone for 5 min to elimi-
nate the bubble in the hydraulic cylinder.
After exhausting the air, check the oil level. If
it is low, fill the oil.
LG922E930E05093
Figure b
5-62
5.2.10 Adjustment of compressor belt tensioner June 10, 2015
1. Use the diode grade of the digital multimeter 5.2.10 Adjustment of compres-
to measure the diode:
a) Connect the red probe (+) to the positive pole
sor belt tensioner
(P) of the diode, and the black probe (-) to the Caution: Before checking, move the machine to
negative pole (N) of the diode, then the diode is the level ground, lower the work implement to
in positive biased. If the diode is normal, the the ground and shutdown the diesel engine.
multimeter will display a certain value.
Inspection
b) Connect the red probe (+) to the negative
1. Open the engine hood, remove the left and
pole (N) of the diode, and the black probe (-) to
right fan shields above the compressor.
the positive pole (P) of the diode, then the diode
2. Press the middle parts of the belt between the
is in reverse biased. If the diode is normal, the
diesel engine pulley and compressor pulley to
multimeter will display 0L or a very large value.
measure the flexibility (f) of the belt. When the
c) During the measurement, if the values mea-
pressure is Wd = 58.5N (about 6 kg), the pro-
sured in two times are very little, there is a short
duced flexibility of the belt shall be f = 5~8 mm.
circuit in the diode; if the values are very large or
0L, there is an open circuit in the diode.
2. Use the Ohm grade of the digital multimeter to
measure the diode:
a) Connect the red probe(+) to the diodes anode Wd f
(P)
Connect the black probe (-) to the diodes nega-
tive (N), if diodes is positively biased, read the
testing resistant 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 the measured resis- LG922E930E05094
tance value.
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.
5-63
June 10, 2015 5.2.11 Performance test of travel motors and reduction gears
Adjustment 5.2.11 Performance test of

If the belt flexibility is abnormal, adjust it accord-
travel motors and reduction
ing to the following procedures.
1. Unscrew the tension pulley locknut (1); gears
2. Clockwise screw the bolt (2) to adjust the A/c Carry out the following performance tests upon
belt tension. disassembly and maintenance of travel motors
3. Screw the tension pulley locknut (1) after and reduction gears.
adjusting the tension pulley (3) to the proper Test method
location. Test the pressure of the following points: left
motor is for a1, a2 and T1; right motor is for a1,
a2 and T1.
Pressure
measurement side
3 Left side
1
2 Right
side
LG922E930E05095
Caution:

(1) If the belt cannot be tensed because of

excessive stretch, or there are scratches and
cracks on the belt, replace a new belt timely.
T1
(2) If the belt is replaced, adjust the tension
e a2
of the belt again after the machine works for
1 hour. a1
(3) After tightening the bolt, check the ten-
D D
sion of the belt according to the methods
above.
4. Reinstall the removed components upon
LG922E930E05097
completion of belt flexibility measurement.
Test conditions:
1. Air is not allowed in the lines.
2. Hydraulic oil temperature is approx 50±5°C.
5-64
5.2.11 Performance test of travel motors and reduction gears June 10, 2015
Test items and standard values:

Operation status
Horizont Vertical Test
S/N Contents Operation Gears Criteria
al directio ground
direction n
Left and right pumping
pressure difference < 3
Low MPa, without dragging
Travel and Oil drainage <0.2MPa,
stop on Max<0.69MPa
1 flat ground
Flat Left and right pumping
ground pressure difference < 3
High MPa, without dragging
Oil drainage <0.2MPa,
Max<0.69MPa
Slow
Low Curve is flat, without
operation
dragging
2 Forward
Oil drainage <0.2MPa,
→Backwa High Max<0.69MPa
rd
Normal pressure <
34.3 MPa, Max < 34.3
Unilateral
3 High MPa
drive
Oil drainage
Max<0.69MPa
Normal pressure <
Concret 34.3 MPa, Max < 34.3
Unmovabl e MPa
4 High
e rotation
Oil drainage
Max<0.69MPa
Differential pressure of
left and right pump: <
Rapid 3MPa; pressure of left
5 alternate High and right pump: max. <
(forward) 34.3 MPa
Oil drainage
Max<0.69MPa
Go
forward by Synchronous
switching switching, without
Low
6 between dragging
High
high and Oil drainage <0.2MPa,
low Max<0.69MPa
velocity
Go
forward
7 and Low
backward
slope
6-1
CLG920D/922D
June 10, 2015
6 Fault Diagnosis
6.1 Precautions for fault diagnosis ..................................................................... 6-3

6.2 Basic fault detection before maintenance ................................................. 6-4
6.3 Classification of faults .................................................................................. 6-6
6.4 Fault diagnosis of electrical system ............................................................ 6-8
6.4.1 E1 Troubleshooting solution for battery power loss .................................. 6-8
6.4.2 E2 Troubleshooting solution for abnormal battery ................................... 6-10
6.4.3 E3 Automatic idle speed is abnormal ....................................................... 6-13
6.4.4 E4 Engine cannot be started .................................................................... 6-17
6.4.5 E5 Engine flame-out during operation...................................................... 6-25
6.4.6 E6 Engine cannot be shutdown................................................................ 6-30
6.4.7 E7 Preheater does not work..................................................................... 6-34
6.4.8 E8 All the work implements, swing mechanism and travel system
cannot move........................................................................................... 6-39
6.4.9 E9 Display panel showing nothing ........................................................... 6-44
6.4.10 E10 Incorrectly displayed hydraulic oil temperature............................... 6-48
6.4.11 E11 Fuel gauge unable to display correct value .................................... 6-52
6.4.12 E12 Wiper does not work ....................................................................... 6-57
6.4.13 E17 Travel alarm unable to sound ......................................................... 6-62
6.5.14 E14 A/C panel unable to display. ........................................................... 6-66
6.5.15 E15 A/C no wind or abnormal air volume............................................... 6-71
6.5.16 E16 Poor A/C refrigeration ..................................................................... 6-74
6.5.17 E17 Abnormal alarm of the A/C E11 - Inner air sensor line broken ....... 6-77
6.5.18 E18 Abnormal alarm of the A/C E12 - Inner sensor short-circuited ....... 6-79
6.5.19 E19 Abnormal alarm of the A/C E15 - Water temperature sensor
line broken.............................................................................................. 6-81
6.5.20 E20 Abnormal alarm of the A/C E16 - Water temperature sensor
short-circuited......................................................................................... 6-83
6.5.21 E21 Abnormal alarm of the A/C E18 - Insolation sensor short-circuited 6-85
6.5.22 E22 Abnormal alarm of A/C E43 - abnormal air outlet ........................... 6-87
6-2
CLG920D/922D
June 10, 2015
6.5.23 E23 Abnormal alarm of the A/C E44 – Abnormal blend air door ............ 6-89
6.5 Fault diagnosis of hydraulic system and mechanical system ............. 6-91
6.5.1 System table of hydraulic system and mechanical system....................... 6-91
6.5.2 H1 Excessive braking angle for swing stop .............................................. 6-91
6.5.3 H2 Abnormal noise from pump mounting position.................................... 6-92
6.5.4 H3 No response after engine start............................................................ 6-93
6.5.5 H4 Hydraulic oil emulsification.................................................................. 6-94
6.5.6 H5 Abnormal hydraulic oil temperature rise.............................................. 6-95
6.5.7 H6 Swing abnormally to left and right directions....................................... 6-96
6.5.8 H7 No response for single-direction swing ............................................... 6-97
6.5.9 H8 Rotation unable to stop ....................................................................... 6-98
6.5.10 H9 Failure to actuate unilateral travel mechanism.................................. 6-99
6.5.11 H10 Travel deflection............................................................................ 6-100
6.5.12 H11 Slow speed of the boom, arm or bucket........................................ 6-101
6.5.13 H12 Weak actions of the boom, arm or bucket..................................... 6-102
6.5.14 H13 Significantly reduced engine speed or engine stalling .................. 6-103
6-3
CLG920D/922D 6.1 Precautions for fault diagnosis
June 10, 2015
6.1 Precautions for fault diagnosis

• Park the machine on the flat ground, check whether the locking pin and cushion block are
fixed firmly.
• When two or more workers are operating, follow the agreed signal strictly, and any unautho-
rized 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 any jammed rotating components.
• When disconnecting wire, firstly disconnect the battery negative (-) terminal wire; and connect
the battery negative (-) terminal wire before recovering.
• 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.
6-4
6.2 Basic fault detection before maintenance CLG920D/922D
June 10, 2015
6.2 Basic fault detection before maintenance

Do the following tests before having your authorized LiuGong dealer repair your excavator or when your
excavator is not functioning properly. Doing these tests can help the maintenance personnel to repair your
excavator as soon as possible.

Do the following tests when the engine is running and shuts down, respectively.
If the excavator operates in a closed space, be sure to discharge the exhaust gases before starting
the engine to maintain the excavator.
No irrelevant personnel is allowed to be close to the excavator working and detection area.
Some tests may be required to be done when the excavator is traveling. Therefore, before starting
any test, make sure the driver has been trained specially and has been qualified.
 Notice: 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.
S/N Test items Test requirements
Rotate the engine starting switch to "ON" position but do not start the
1
engine.
Shut down the engine, park

the machine on a firm and
Hydraulic oil state
horizontal ground, and make
the machine in the hydraulic 1. Check whether the oil level is within the normal range.
2 oil testing state (all the arms Notice: Check before the engine is started.
are stretched out, the bucket 2. Check whether the oil level is between the MIN and MAX marks at
is withdrawn, and the work the end of the dipstick.
attachment is lowered to the
ground). 3. Check whether the cold hydraulic oil level is between the maximum
scale and the minimum scale of the dipstick.
4. Check the hydraulic oil lines or the connectors for damage or
leakage.
6-5
CLG920D/922D 6.2 Basic fault detection before maintenance
June 10, 2015
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.
3 Horn Check the horn for ring. (Yes or No)
Wiper Check whether the front wiper works normally. (Yes or No)
Fan Check whether the inner circulation fan works? (Yes or No)
Lighting equipment
(work light, revolving signal
Check whether the outdoor light and dome light works normally.
light, brake light, dome light,
etc.)
Instrument, meter and Check whether all the indicators come on.
indicator If not, do not start the engine.
Operate all the switches and controls to check whether they can work
Switches and controls normally.
If not, do not start the engine.
4 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.
Check whether the cab windows and doors can be opened smoothly.
Gate lock and engine hood Whether the gate lock can be locked.
lock Check whether the engine hood can be closed. Whether the engine
hood can be locked?
5 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?
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?
6 Check whether the engine working temperature is within the normal
Engine operates in idle range.
speed After the engine operates in idle speed for several minutes, check
whether the A/C refrigerates.
7 Start the engine and check the system voltage. The voltage after
Charging of battery starting should be more than that before starting (battery voltage),
normally, greater than 26V.
6-6
6.3 Classification of faults CLG920D/922D
June 10, 2015
6.3 Classification of faults

The default is divided into two types by the system
(1) 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 as follows
Fault S/N Fault phenomenon Consequence
E1 The battery is undercharged The battery is damaged.
E2 The battery is abnormal The battery is damaged.
E3 Automatic idle speed is abnormal Increased fuel consumption and noise
Engine cannot be started (the engine
E4 Failed to work.
does not rotate)
E5 Engine shuts down during operation. System fault
E6 The engine can not shut down System fault
E7 Preheater fails to work The machine is difficult to start or won’t start.
All the work implements, revolving
E8 No motion, failed to work.
and travel cannot move
E9 Display panel shows nothing It can not display the machine information.
Reducing the pump current and engine
Incorrectly displayed hydraulic oil speed can affect the overall performance, or
E10
temperature cause damage to the engine and hydraulic
components.
Fuel amount cannot be displayed The fuel level display is inaccurate, and it
E11
correctly brings trouble to the work.
Foreign matters on glass cannot be
E12 Wipers are out of 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 displays nothing A/C system cannot work
A/C blows no air or air volume is
E15 The service effect of A/C is poor
abnormal
E16 Poor A/C refrigeration The refrigeration effect of A/C system is poor
Abnormal A/C alarm E11 -- Inner
sensor line broken
sensor short-circuited
Abnormal A/C alarm E15 -- Water
temperature sensor line broken
6-7
CLG920D/922D 6.3 Classification of faults
June 10, 2015
Abnormal A/C alarm E16 - Water

temperature sensor short-circuited
Abnormal A/C alarm E18 - Insolation
Abnormal A/C alarm E43 - Abnormal
air outlets
Abnormal A/C alarm E44 -- Abnormal
blend air doors
(2) Hydraulic & mechanical system faults

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". Replace the parts by the maintenance princi-
ples mentioned in the chapter of hydraulic components
The faults introduced in this chapter are shown as follows
S/N Fault phenomenon

H1 Excessive braking angle for swing 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
Normal swing cannot be achieved either in the left direction or
H6
in the right direction.
H7 Unidirectional swing operation is unresponsive.
H8 Rotation cannot be stopped.
H9 Unilateral running gear 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
6-8
6.4 Fault diagnosis of electrical system CLG920D/922D
6.4.1 E1 Troubleshooting solution for battery power loss June 10, 2015
6.4 Fault diagnosis of electrical system

6.4.1 E1 Troubleshooting solution for battery power loss
Fault SN Faults Consequence
E1 The battery is undercharged The battery is damaged.
System description
The battery functions: Store the electric energy; when the engine starts and powers the motor to 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.
LG922E930E06103
LG922E930E06104
6-9
CLG920D/922D 6.4 Fault diagnosis of electrical system
June 10, 2015 6.4.1 E1 Troubleshooting solution for battery power loss
Fault diagnosis and elimination procedures

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 of multimeter,
connect the red probe to the positive terminal and the black probe to the negative terminal. Under the normal
condition, the voltage is 24V. If the voltage is too low, the battery needs to be charged.
Whether the battery needs to be charged or not?
Yes No
Charge the battery

Go to Step 3 Go to Step 2
Step 2 The battery is aging and lack of power.
 When replacing the components, please be sure to use LiuGong parts.
Inspection method
The machine does not work for a long time and the battery has not been charged so it is lack of power
seriously. Check it by referring to E2.
Is the battery lack of power because of aging?
Yes No
Replace it with a new one.

Step 3 Check whether this fault is eliminated

Inspection method
After replacing a new battery, connect the battery firmly.
Has this fault been eliminated?
Yes No
Troubleshoot the faults according to the steps again or

contact the local LiuGong dealers and authorized
Maintenance is over
service centers.
Back
6-10
6.4.2 E2 Troubleshooting solution for abnormal battery June 10, 2015
6.4.2 E2 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 to 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.
Daily maintenance: The electric quantity of the battery can be learned by the change of the hydrometer
color. Green means good, black means requiring to be charged, and white means the battery needed to be
replaced.
+\GURPHWHU
Electric eye
Component position
LG922E930E06104
6-11
June 10, 2015 6.4.2 E2 Troubleshooting solution for abnormal battery

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 scrap.

Inspection method
Is the color of battery hydrometer white?
Yes No
Repair or replace battery

6-12
6.4.2 E2 Troubleshooting solution for abnormal battery June 10, 2015
Inspection method
Yes No

Maintenance is over
service centers.
Back
6-13
June 10, 2015 6.4.3 E3 Automatic idle speed is abnormal
6.4.3 E3 Automatic idle speed is abnormal

Can’t switch to the idle speed Increased fuel consumption and
E3
automatically 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 handle
or pedal, either or the joystick of attachment is operated, the engine speed will restore to the corresponding
speed of the current accelerator knob.
Ground
Signal ground
Oil temperature
position 1
Oil temperature
position 2
Oil temperature
position 3
Oil temperature
position 4
Hand pilot
pressure switch
Foot pilot
pressure switch
No automatic No automatic idling

idling
Manual idling Manual idling
6-14
6.4.3 E3 Automatic idle speed is abnormal June 10, 2015
Component position
Handle pressure switch
Pedal pressure switch
Pressure switch of
attachments
LG922E930E06106
Indicator Throttle knob
LG922E930E06107
ECU controller
LG922E930E06108
6-15
June 10, 2015 6.4.3 E3 Automatic idle speed is abnormal

Step1 Line fault of switch box
Turn the ignition switch to "OFF" position.
Inspection method
Check the lines of the following switches signal with multimeter. In general, the resistance of every line should
be lower than 10 Ω; the insulation resistance should be higher than100kΩ
1. Switch case X5 (5) - X26 (9) - main controller JP201 (G1)
2. Switch case X5 (6) - X26 (10) - main controller JP201 (G2)
Any fault in the switch box?
Yes No
Check the wire harness, insert the connector, and

repair the fault Go to Step 2
Go to Step 4
Step 2 Pilot pressure switch fault
 Disconnect the connector between the hand pilot pressure switch and the foot pilot pressure switch
 When replacing the pilot pressure switch, please make sure to use LiuGong parts.
Inspection method
Check the hand pilot pressure switch and the foot pilot pressure switch with multimeter. The switch is on, the
resistance should be lower than 10Ω; the switch is off, the resistance should be higher than 100kΩ
Check whether the pilot pressure switch has fault?
Yes No
Replace the pilot pressure switch

6-16
6.4.3 E3 Automatic idle speed is abnormal June 10, 2015
Step 3 CAN bus abortion
 Disconnect the connector among the engine controller, the main controller and the display.
Inspection method
1. Inspect the cable resistance and the terminal resistance of CAN with multimeter. X8 (A) and (B), X64 (A)
and (B), the normal measured resistance is 120Ω.
2. Measure the resistance of J22 (62) and (84), X7 (3) and (4), JP200 (L3) and (M3) with multimeter. In
general, the resistance should be 60 Ω; and the insulation resistance should be 100kΩ.
Check whether the CAN cable has fault?
Yes No
Check the harness, find the fault of CAN cable and

repair it.

Inspection method
Operate the machine, and check whether each action is normal.
Yes No

Maintenance is over
service centers.
Back
6-17
June 10, 2015 6.4.4 E4 Engine cannot be started
6.4.4 E4 Engine cannot be started
Fault S/N Faults Consequence

Engine cannot be started (the
E4 Failed to work.
engine does not rotate)
System description
Make sure no fault and correct steps to start the excavator; turn the lock to "start" and the starting relay
droved by the starting signal controlled by the ECM and the signal controlled by the pilot handlebar; send
the power signal to the starting terminal to start the engine
 "The schematic diagram of electrical start" as follows; see some details to the LG922D06049-sub-
graph
Start protection
Earthing cable
Ignition switch ON
Power -
Power -
Power -
Power +
Power +
Power +
To pilot cut-off solenoid
Control unit
Switch 3
Switch 2
X63 (grey)
Power supply control 7.5A
Engine controller 30A
Fuse 50A
Fuse 150A
Fuse 50A×2
LG922D06049
6-18
6.4.4 E4 Engine cannot be started June 10, 2015
Component position
Ignition switch IPC Controller
Fuse box
Pilot cut-off valve switch
LG922E930E06112
Start motor
LG922E930E06113
ECU controller
LG922E930E06108
6-19

Step 1 Fuel level is too low.
Inspection method
Check the fuel level.
Whether the fuel level is low or not?
Yes No
Refuel.
Step 2 Battery voltage is too low.
Inspection method
1.Turn the switch to "ON" and start the engine to confirm if there is a low voltage alarm of the battery.
2. Measure the battery voltage with the multimeter. Turn the multimeter to its DC voltage function, 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
Voltage value is 24V in the normal condition.
Whether the battery voltage is too low or not?
Yes No
Check the battery by E1 and E2 method, or charge up

the battery, or replace the battery
6-20
Step 3 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 fuse of power supply and the engine controller to see whether the fuse is
blown or to make sure whether the both ends of the fuse are connected with a multimeter's diode.
Note: There may be ground fault, so please refer to step 10.
Is fuse blown?
Yes No
Replace the fuse

Step 4 Ignition 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 ignition switch?
Yes No
Replace the start switch

6-21
Step 5 Pilot solenoid cut-off switch fault

Inspection method
Measure the resistance between the pilot solenoid cut-off switch X2(1) and X2(3) with a multimeter
1. When the switch of pilot solenoid valve is turned to Locked state, the resistance between X2(1) and X2(3) is
less than 10Ω.
2. When the switch of pilot solenoid valve is turned to Unlocked state, the resistance between X2(1) and X2(3)
is infinite.
Whether the disconnecting switch of pilot solenoid valve fails or not?
Yes No
Repair or replace the pilot solenoid cut-off switch

Step 6 ECM controller start relay fault
Inspection method
Measure the starter relay controlled by the ECM with a multimeter
Unplug the starter relay controlled by the ECM; Measure the following resistances.
The resistance between 85 and 86 (coil resistance) normally is about 320-360Ω.
The normal resistance is higher than 100kΩ between 30 and 87.
The resistance between 30 and 87a normally is less than 10Ω.
Plug the 24V power between 85 and 86 end; Measure the following resistance
The resistance between 30 and 87 normally is less than 10Ω.
The normal resistance is higher than 100kΩ between 30 and 87a
Whether ECM controller start relay fault?
Yes No
Replace the ECM controller start relay.

6-22
Step 7 Start relay K1 fault
Inspection method
Measure the starting relay K1 with a multimeter.
1.Remove the starter relay k1; Measure the resistance:
The normal resistance of the coil is 80Ω.
The normal resistance of the main contact is higher than100kΩ.
2. Supply 24V power to both ends of the coil and measure the resistance between two main
contacts.
The resistance between two main contacts normally is less than 10Ω.
Whether start relay K1 fails or not?
Yes No
Replace the starter relay.

Step 8 Fault of starter motor.
 Remove the wiring on the end 50 and end 30 on the start 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 between starting motor 30 and the
ground wire for 24V.
2. Turn the start switch to START position, and then measure the voltage between wire 183 of starting motor
end 50 and the ground wire for 24V.
If the input signals are normal, but the starter motor does not rotate, it can be judged that there is a fault in the
starter motor.
Whether the start motor has fault or not?
Yes No
Replace the start motor.

6-23
Step 9 Open circuit or poor contact of lead in harness or connector.
 Correctly tie up harness and wire.
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.
Try to keep far way from oil and water.
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. No. 101 wire of the switch - No. 125 wire on the main contract of the starter relay K1
2. Wire 183 on the main contact of start relay K1 - end 50 of starter motor.
3. Wire No. 100 - X60 (1) on the main power switch - power control fuse - X62 (1) - End B2, X87 (5) of
ignition switch.
4. End S, X87(4) of ignition switch - control unit X74(8)
5. End 30 of the starting relay K8 controlled by ECM - X63(3) - control unit X74(9)
6. No. 310 wire of the starting relay K1 - pilot cut-off valve switch X2(1)
7. Pilot cut-out valve switch X2(3) - frame grounding
8. End 86 of starting relay K8 controlled by the ECM - X63(15) - ECM controller J22(9)
10. End 87A of the starter relay K8 controlled by the ECM - X63 (1) - No. 316 wire of the starter relay K1
11. End M, X87(2) of ignition switch - control unit X74(5) - ECM controller J22(15)
12. End P of alternator - X67(1) - control unit X74(4)
13. Engine controller fuse - X61(2) - ECM controller J22(1,3,5)
Is the harness open-circuit?
Yes No
Connect the harness again and wrap the harness

6-24
Step 10 Wire harness grounded short circuit
 Shutdown operation is needed
Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, check whether the following circuit
forms a short circuit with the ground, and normally the resistance between any check point and the ground
shall be greater than 100kΩ.
1. No. 101 wire of the switch - No. 125 wire on the main contract of the starter relay K1
2. Wire No. 100 - X60 (1) on the main power switch - power control fuse - X62 (1) - End B2, X87 (5) of ignition
switch.
3. End M, X87(2) of ignition switch - control unit X74(5) - ECM controller J22(15)
4. End S, X87(4) of ignition switch - control unit X74(8)
5. End 30 of the starting relay K8 controlled by ECM - X63(3) - control unit X74(9)
8. End 87A of the starter relay K8 controlled by the ECM - X63 (1) - No. 316 wire of the starter relay K1
9. Engine controller fuse - X61(2) - ECM controller J22(1,3,5)
10. End P of alternator - X67(1) - control unit X74(4)
Whether the harness is shorted to ground or not?
Yes No
Troubleshoot the faults according to the steps again

or contact the local LiuGong dealers and authorized
Go to Step 11
service centers.
Inspection method
Yes No

Maintenance is over
service centers.
Back
6-25
June 10, 2015 6.4.5 E5 Engine flame-out during operation
6.4.5 E5 Engine flame-out during operation

Engine shuts down during
E5 System fault
operation.
System description
During the operation, the engine may be choked because of overload, or because of open circuit in the
power circuit of the engine controller. The supply circuit of engine controller is shown in the following figure.
Power -
Power -
Power -
Power +
Power +
Power +
Fuse 50A×2
Preheat relay 5A
6-26
6.4.5 E5 Engine flame-out during operation June 10, 2015
Component position
Ignition switch
Fuse box
LG922E930E06115
Alternator
LG922E930E06008
6-27


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 B2 is less than 10Ω.
Is the start switch damaged?
Yes No

Step 2 Fuse at the switch is blown

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 fuse of power control and engine controller with safety clip to see whether
the fuse is blown or to make sure whether the both ends of the fuse are connected with a multimeter's diode
file
Note: There may be ground fault, so please refer to step 4
Is fuse blown?
Yes No
Replace the fuse

6-28
6.4.5 E5 Engine flame-out during operation June 10, 2015

Inspection method
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of ignition 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

Step 4 Conductor in harness shorted to the ground wire
Inspection method
shall be greater than 1MΩ.
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of ignition switch.
2. X2 (Male 8) - X1 (2) - J5 (1, 25, 26, 27, 28)
3. End B2 of start switch - X1(28) - X2(1) - J5 (5)
Is the harness short-circuit?
Yes No

6-29
Inspection method
Yes No
Find out the engine system fault or contact the local

Maintenance is over LiuGong dealers or authorized service centers.
Back
6-30
6.4.6 E6 Engine cannot be shutdown June 10, 2015
6.4.6 E6 Engine cannot be shutdown

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 supply circuit of engine controller is shown in the following
figure.
ECM Controller
Earthing cable
Air intake
preheating (+)
Fuse 150A
Fuse 50A×2
Preheat relay 5A
6-31
June 10, 2015 6.4.6 E6 Engine cannot be shutdown
Component position
Ignition switch
Fuse box
LG922E930E06115
Handle pressure switch
Pedal pressure switch
Pressure switch of
attachments
LG922E930E06106
6-32
6.4.6 E6 Engine cannot be shutdown June 10, 2015


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

Step 2 Lead in harness is short circuit
 Correctly tie up harness and wire:

Inspection method
forms a short circuit with the battery (+), and normally the resistance between any check point and the battery
(+) shall be greater than 100kΩ.
1. End B2 of ignition switch - X87 (5) - X62 (1) - power control fuse
2. End M of ignition switch - X87(2) - engine controller J22(15)
Yes No

6-33
June 10, 2015 6.4.6 E6 Engine cannot be shutdown

Inspection method
Yes No

Back
6-34
6.4.7 E7 Preheater does not work June 10, 2015
6.4.7 E7 Preheater does not work

The machine is difficult to start or
E7 Preheater does not work
won’t start.
System description
The preheat function is divided into manual preheat and automatic preheat. Manual preheat means to turn
the start switch from OFF position to HEAT position, preheat relay K3 is close, and the battery supplies
power to the preheater (assist to the starting preheater) of the engine. Automatic preheat means that the
engine controller can make judgment based on the external environment to determine whether it requires
preheat or not. When preheat is required in accordance with the judgment, the output of J22-31 on engine
controller is 24V, the driving automatic preheat relay K6 is close to make preheat relay K3 powered, so that
the preheat relay K3 is close and the battery supplies power to the engine. The figure below is the electrical
circuit diagram of engine preheater.
ECM Controller
Earthing cable
Air intake
preheating (+)
Fuse 150A
Fuse 50A×2
Preheat relay 5A
6-35
June 10, 2015 6.4.7 E7 Preheater does not work
Component position
Ignition switch
Fuse box
LG922E930E06115
Pre-heater
Pre-heater
Engine
Engine controller
controller
LG922E930E06117
6-36


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 preheat relay K3 with a multimeter;
1. Remove the preheating relay K3; Measure the coil and main contacts resistance
The resistance of coil is about 61-63Ω.
The normal resistance of the main contact is higher than100kΩ.
2. Supply 24V power to both ends of the coil and measure the resistance between the two main contacts.
The resistance between two main contacts normally is less than 10Ω.
Is there a fault in the preheating relay?
Yes No
Replace the preheating relay.

6-37
June 10, 2015 6.4.7 E7 Preheater does not work
Step 3: Power control fuse is blown

Inspection method
1. Open the electrical control unit, remove the power control fuse, visibly check whether the fuse blows or
check whether both ends of the fuse are connected by the multimeter at the position of 200Ω.
2. Open the fuse box, unplug the fuse of auto preheating relay with a safety clip, and observe by visual
inspection whether the fuse is blown or measure by the 200Ω position of multimeter whether both ends of fuse
are connected.
Note: There may be ground fault, so please refer to step 5
Is fuse blown?
Yes No
Replace the fuse


Inspection method
1. No. 101 wire of the switch - NO. 102 wire on the main contracts of the preheating relay K3
2. Wire 188 on the main contact of preheat relay K3 - terminal of the preheater (starting heater).
3. Wire 223 on the preheat relay K3 - frame ground (GND).
4. End 87 of preheating relay K6 - X62(14)- G1 of ignition switch - No. 190 wire of the preheating relay K3
5. No.100 wire of the main power switch - X60(1) - 30 of the preheating relay K6
6. End 86 of the preheating relay K6 - X62(13) - engine controller J22(31)
Yes No
Connect the harness again and wrap the

harness
6-38
Step 5 Lead inside the harness is short circuited to ground.
Inspection method
shall be no less than 10kΩ.
1. NO.101 wire of the main power switch - 150A fuse - main contacts of the preheating relay K3
2. No.100 wire of the master power switch - X60(1) - the preheating relay fuse 150A fuse - terminal 30 of the
preheating relay K6
3. End 87 of the preheating relay K6 - X62(14) - G1 of ignition switch - No. 190 wire of the preheating relay K3
Yes No

Step 6 Preheater 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 preheater and the
ground is 24V, if the preheater still does not work, it can be determined as the assist starting heater fault.
Is there a fault in the preheater?
Yes No
Replace the preheater.

Inspection method
Yes No

Back
6-39
June 10, 2015 6.4.8 E8 All the work implements, swing mechanism and travel system cannot move
6.4.8 E8 All the work implements, swing mechanism and travel

system cannot move

All the work implements,
E8 swing mechanism and travel No motion, failed to work.
system cannot move
System description
Power on, pull up the disconnection switch of pilot solenoid valve to connect wire 313 and 218, at this time,
the electrical circuit of pilot of pilot shutoff solenoid valve is established, and the oil path of the pilot shutoff
solenoid is open, so the hydraulic system starts running. The following is the electrical circuit diagram cut
by the pilot.
Solenoid valve 10A
Fuse 50AX2
6-40
6.4.8 E8 All the work implements, swing mechanism and travel system cannot move June 10, 2015
Component position
Ignition switch
Fuse box
Pilot cut-off valve
switch
LG922E930E06119
$
$
$
$
$
$
$
$
LG922E930E06120
6-41

Step 1 Ceck if the solenoid valve fuse is blown
Inspection method
Unplug the solenoid valve fuse by a fuse clip, observe by visual inspection whether fuse is blown or measure
by the 200 ohm position of multimeter whether both ends of fuse are connected.
Is the solenoid valve fuse blown?
Yes No
Replace the fuse

Step 2 Pilot solenoid cut-off switch fault
Inspection method
1. turn off the pilot magnetic valve switch; check whether pin 2 and pin 3 are connected normally with a
multimeter's diode position.
Is there fault on the switch?
Yes No
Repair or replace the shutoff switch of the pilot

solenoid valve.
6-42
6.4.8 E8 All the work implements, swing mechanism and travel system cannot move June 10, 2015
Step 3 check if there is any fault of power relay
Inspection method
Measure the power relay K5 with a multimeter:
1. Unplug power relay K5; Measure the following resistance
The resistance between 85 and 86 (coil resistance) normally is 320-360Ω.
The normal resistance is higher than 100kΩ between 30 and 87.
The resistance between 30 and 87a normally is less than 10Ω.
2. Connect the End 85 and End 86 to the 24V power, and measure the following resistances.
The resistance between 30 and 87 normally is less than 10Ω.
The normal resistance is higher than 100kΩ between 30 and 87a
Check whether power relay has fault?
Yes No
Replace the power relay


Inspection method
1. No.100 wire of the main power switch - X60(2) - end 30 of the power relay K5
2. End 87 of power relay K5 - solenoid fuse
3. Solenoid valve fuse - X62(2) - pilot cut-out solenoid valve X41(1)
4. Pilot cut-out valve switch X2(2)- pilot cut-out solenoid valve X41(2)
5. Pilot cut-out valve switch X2(3) - frame ground (GND)
6. End B2 of ignition switch - X62(1) - power control fuse
7. End 85 of power relay K5 - X62(15)- frame grounding (GND)
8. End M of ignition switch - X62(12) - end 86 of power relay K5
Yes No

6-43
Step 5 Conductor fault in harness - ground wire short circuit.
Inspection method
forms a short circuit with the ground, and normally the resistance between any check point and normally, the
ground shall greater than 100 kΩ.
1. No.100 wire of the main power switch - X60(2) - 30 of the power relay K5
2. End 87 of power relay K5 - solenoid valve fuse - X62(2) - pilot cut-off solenoid valve X41(1)
3. End M of ignition switch - X62(12) - 86 of power relay K5
Yes No

Inspection method
Yes No

Maintenance is over
service centers.
Back
6-44
6.4.9 E9 Display panel showing nothing June 10, 2015
6.4.9 E9 Display panel showing nothing

It can not display the machine
E9 Display panel shows nothing
information.
System description
Protect the constant power end by fuse of monitoring system, control the energy power by start switch, and
if the power circuit is normal, turn on the display.
Power
Ground
Monitoring system 7.5A
Power supply system 7.5A
Fuse 50A×2
LG922D06043
6-45
June 10, 2015 6.4.9 E9 Display panel showing nothing
Component position
Ignition switch
Fuse box
Pilot cut-off valve
switch
LG922E930E06119

Step 1 Monitoring system fuse is blown
Inspection method
Unplug the fuse of monitoring system by a fuse clip, observe by visual inspection whether fuse is blown or
measure by the DIO position of multimeter whether both ends of fuse are connected.
Check if monitoring system fuse is blown
Yes No
Replace the fuse.

6-46
6.4.9 E9 Display panel showing nothing June 10, 2015

Inspection method
1. Monitoring system fuse - X62(6) - X26(1)- monitor X7(1)
2.monitoring system fuse - End 87 of power relay K4
3. Monitor X7(2) - X26(4) - frame ground
4. No.100 wire of the main power switch - X60(1) - End 30 of the power relay K4
5. End M of ignition switch - X87 (2) - X62 (12) - End 86 of the power relay K4 and K5
6. End 85 of power relay K4 and K5 - X62(15) - frame grounding
7. Power control fuse - X62 (1) - X87 (5) - End B2 of ignition switch
Yes No

Step 3 Ground fault of conductor in harness -- shorted to ground wire.
 Shutdown operation is needed.
Inspection method
1. Monitoring system fuse - X62(6) - X26(1)- monitor X7(1)
2.monitoring system fuse - End 87 of power relay K4
3. End M of ignition switch - X87 (2) - X62 (12) - End 86 of the power relay K4 and K5
Yes No

6-47
June 10, 2015 6.4.9 E9 Display panel showing nothing
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 the display fault.
1. The voltage to ground of the display X7 (1) is 24V.
2. The voltage to ground of the display X7 (2) is 0V.
3. Voltage of monitor X7(1) and X7(2) is 24V.
Is there a fault in the display?
Yes No
Replace the display.

Inspection method
Yes No
Contact local LiuGong dealers and authorized service

Maintenance is over centers.
Back
6-48
6.4.10 E10 Incorrectly displayed hydraulic oil temperature June 10, 2015
6.4.10 E10 Incorrectly displayed hydraulic oil temperature

Reducing the pump current and
Incorrectly displayed engine speed can affect the overall
E10
hydraulic oil temperature performance, 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
wire, so the hydraulic oil temperature can be displayed on the display.
Hydraulic oil temperature

sensor
Oil temperature
Oil temperature
ground
6-49
June 10, 2015 6.4.10 E10 Incorrectly displayed hydraulic oil temperature
Hydraulic oil temperature sensor parameter table

Coolant
temperatur 20 60 70 80 85 90 95 100 105 110 115
e (°C)
Resistance
3500 2401 1678 1195 1015 865.5 741.2 637.1 549.8 476.3 414
(Ω)
Component position
Front
Hydraulic oil
temperature
sensor
LG922E930E06124
6-50
6.4.10 E10 Incorrectly displayed hydraulic oil temperature June 10, 2015

Step 1 Hydraulic oil temperature sensor fault
Inspection method
Turn the knob start switch to OFF position and disconnect sensor connector.
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function (20kΩ), and measure the resistance between the sensor
connector (X43) terminals 1 and 2, comparing the result with the parameter table (normally, <4kΩ).
Whether the hydraulic oil temp sensor fails or not?
Yes No
Replace the hydraulic oil temp sensor.

Correctly tie up harness and wire:

Inspection method
1. J22 (48) of engine controller - hydraulic oil temp sensor X43 (1).
Yes No

6-51
June 10, 2015 6.4.10 E10 Incorrectly displayed hydraulic oil temperature
Step 3 Ground fault of conductor in harness -- shorted to ground wire.
Inspection method
Yes No

Inspection method
Yes No

Maintenance is over centers.
Back
6-52
6.4.11 E11 Fuel gauge unable to display correct value June 10, 2015
6.4.11 E11 Fuel gauge unable to display correct value

Fuel gauge cannot display The fuel level display is inaccurate,
E11
correct value and it brings trouble to the work.
System description
The fuel level sensor is a reed pipe type. The magnetic float density is lower than the working medium (die-
sel) 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 inner 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 to the controller
which detects the fuel level in the tank. Then, the fuel level appears on the connected display instrument.
Controller
Fuel level
Ground (ADC)
Fuel level sensor
Fuel level sensor parameter table (for the details, see the figure.)
6-53
June 10, 2015 6.4.11 E11 Fuel gauge unable to display correct value
Component position
Front
Fuel level sensor
LG922E930E06033
6-54

Step 1 Check the fuel level sensor for fault.
 High temperature and high pressure oil or water can cause personal injury! To replace 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:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level sensor
connector (X44) terminals 1 and 2 (normally, <2kΩ, for the specific resistance, see the figure).
.453
LG922E930E06034
Whether a fault developing in the fuel level sensor
Yes No
Repair or replace the fuel level sensor

Step 2 Check the harness for open-circuit

Keep away from high temperature parts (e.g. engine body) as far as possible.
6-55
June 10, 2015 6.4.11 E11 Fuel gauge unable to display correct value
Inspection method
1. Check the harness (wire No. 722 and 730) between the controller 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. Measure the resistance between the controller connector JP200 (L1) of wire harness and the sensor
connector X44 (1) (the resistance should be lower than 10Ω)
b. Measure the resistance between the controller connector JP200 (M2) of wire harness and the sensor
connector X44 (2) (the resistance shoud be lower than 10Ω)
Yes No
Connect the harness again and wrap the harness.

Step 3 Check the connector for fault.
Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the harness at the controller port JP200 (L1) and
JP200 (M2) (normally, <2kΩ, for the details, see the figure).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether a fault developing in the connector or not?
Yes No
Replace the connector.

Inspection method
Turn the start switch to the ON position and re-check it.
Yes No

Maintenance is over contact the local LiuGong dealers and authorized
service centers.
6-56
Figure: Fuel level sensor parameter table

Floater position (be subject to Output
17.5mm) resistance (Ω)
Below L1 900±9
L1-L2 825±8.25
L2-L3 750±7.5
L3-L4 675±6.75
L4-L5 600±6
L5-L6 525±5.25
L6-L7 450±4.5
L7-L8 375±3.75
L8-L9 300±3
L9-L10 225±2.25
L10-L11 150±1.5
Above L11 75±0.75
High level alarm
Floating
ball
6-57
June 10, 2015 6.4.12 E12 Wiper does not work
6.4.12 E12 Wiper does not work

Foreign matters on glass cannot be
Windshield wiper does not
E12 removed; the sight for operator is
work.
poor.
System description
Electrical circuit diagram of the wiper system is shown in the figure below: when the switch is in Gear 0,
connect No. 410 wire with No. 413 wire, and the wiper will stop working when reset to the initial position;
when the switch is on Gear 1, connect No. 413 wire to power, and the wiper will work in a gear of slow
speed; when the switch is in Gear 2, connect No. 414 wire to the power, wiper will work at the gear of fast
speed.
X63 (grey)
X62 (black)
Wiper 10A
To boom relay
Fuse 50A×2
LG922D06047
6-58
6.4.12 E12 Wiper does not work June 10, 2015
Component position
Wiper switch
Wiper motor
Fuse box
LG922E930E06127

Step 1 Check whether the wiper fuse is not blown
Inspection method
Unplug the wiper fuse by a fuse clip, observe by visual inspection whether fuse is blown or measure by the
DIO position of multimeter whether both ends of fuse are connected.
Is fuse blown?
Yes No
Replace the fuse

Step 2 Wiper switch fault
Inspection method
Disconnect connector X24, 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 is in Position 0, the resistance between pin 5 and pin 7 of switch 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.
6-59
Is the wiper switch damaged?
Yes No
Replace the wiper switch

6-60
6.4.12 E12 Wiper does not work June 10, 2015

Inspection method
1. Wiper switch X77 (1) - X24 (10) - X25 (3) - wiper motor X3 (2)
4. Wiper switch X77 (3) - spraying switch X79 (1) - X24 (9) - X63 (12) - 87A of the wiper relay K10 - X25 (4) -
wiper motor X3 (6)
5. Wiper fuse - End 30 and end 86 of wiper relay K10
6. End 85 of wiper relay K10 - X62(16) - X28(3) - door-controlled wiper switch X17(2)
7. Door-controlled wiper switch X17(1)- X28(5) - frame grounding
8. Wiper motor X3 (4) - X26 (3) - frame grounding (GND)
9. Spraying switch X79(5) - X23(14) - cleaner motor X34(2)
10. Cleaners motor X34(1) - frame grounding
Yes No

Step 4 Conductor fault in harness shorted to ground wire.
Inspection method
4. Wiper switch X77 (3) - spraying switch X79 (1) - X24 (9) - X63 (12) - end 87A of the wiper relay K10 - X25
(4) - wiper motor X3 (6)
Yes No
6-61

Step 5 Wiper motor 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 wiper motor is still off, it can be determined as the fault of wiper motor.
1. When the wiper switch is in position 0, the voltage to ground of X3 (6) is 24V, and the voltage to ground of
X3 (4) is 0V.
2. When the wiper switch is in position 1, the voltage to ground of X3 (3) is 24V.
3. When the wiper switch is in position 2, the voltage to ground of X3 (2) is 24V.
Check if wipers motor has fault?
Yes No
Replace the wiper motor

Inspection method
Operate the wiper system and check whether all actions are normal.
Yes No

Maintenance is over
service centers.
Back
6-62
6.4.13 E17 Travel alarm unable to sound June 10, 2015
6.4.13 E17 Travel alarm unable to sound

Alarm system is faulty, causing
E23 Travel alarm does not sound
potential safety hazard.
System description
The figure below is the travel alarm electrical circuit diagram. Operators can press the button of "cancel the
travel alarm" and "start the travel alarm" on the switch box. The main controller judges the moving state by
the pressure of the accelerator: the machine is moving, JP200-X3 outputs low level , the travel alarm relay
K9 close, the alarm rings with power; the machine isn’t moving, JP200-X3 doesn’t output level, the travel
alarm relay K9 open, the alarm doesn't ring.
X63 (grey)
Travel alarm 10A
Controller
Travel alarm (-)
Foot pilot
pressure switch
Travel alarm
cancellation switch
Switch box
Travel alarm
cancellation
6-63
June 10, 2015 6.4.13 E17 Travel alarm unable to sound
Component position
Front
Travel alarm
LG922E930E06132
6-64
6.4.13 E17 Travel alarm unable to sound June 10, 2015


Inspection method
1. Main controller JP200(X3) - X63(4) - End 85 of the travel alarm relay K9
2. Travel alarm X33 (2) – frame grounding (GND).
3. Main controller JP201(E1) - foot pilot pressure switch X92 (2)
4. Foot pilot pressure switch X92(1) - frame grounding (GND)
5. Travel alarm X33(1)- X63(14) - End 87 of the travel alarm relay K9
6. Main controller JP201(F1) - X26(5)- switch box X5(8)
7. Travel alarm fuse - End 30 and End 86 of travel alarm relay K9
Yes No

Step 2 Lead inside the harness is short circuited to ground.
Inspection method
forms a short circuit with the ground, and normally the resistance between any check point and normally, the
ground shall greater than 100 kΩ.
1. Travel alarm X33(1)- X63(14) - end 87 of the travel alarm relay K9
2. Main controller JP201(E1) - foot pilot pressure switch X92 (2)
3. Main controller JP201(F1) - X26(5)- switch box X5(8)
Yes No

6-65
June 10, 2015 6.4.13 E17 Travel alarm unable to sound
Step 3 Traveling alarm fault
Inspection method
Start the complete machine but do not pull up the pilot shut-off valve switch, unplug connector X92 of the foot
pilot pressure switch, and measure the voltage value of X33 (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
centers.
6-66
6.5.14 E14 A/C panel unable to display. June 10, 2015
6.5.14 E14 A/C panel unable to display.

E14 Failed A/C panel. A/C system cannot work
System description
(1) Electrical schematic diagram of A/C system, see the figure.
(2) The evaporator as arrangement schematic diagram
a. Front view
Air-mixing servo
motor
Vent
Vent servo
motor
Foot vent
Water temperature
sensor
Warm water Warm

outlet water inlet
LG922E930E06128
6-67
June 10, 2015 6.5.14 E14 A/C panel unable to display.
b. Bottom view
Inner air
sensor
Expansion
valve inlet
Ventilation motor
Fan speed control

resistance
Expansion
valve outlet
6-68
c. Rear view
Frost-preve
ntion probe Switch
Blower
motor
6-69
June 10, 2015 6.5.14 E14 A/C panel unable to display.

Step 1 Base machine power fault
Inspection method
Check whether the voltage of the mutually plugged A/C harness and base machine harness - wire 128 in the
cab is 24V with a multimeter.
Whether there is 24V voltage at wire 128
Yes No
Find out the reason according to Step 2. Check whether A/C 30A fuse is damaged.
Step 2 Wire grounding fault - failed to connect with the earthing cable.
Inspection method
Check whether the ground connection of the mutually plugged A/C harness and base machine harness – wire
210 in the cab is in good condition with a multimeter.
Is there an open circuit in the ground wire?
Yes No
Check the ground circuit of base machine harness. Find out the reason according to Step 3
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, 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.
Is A/C 30A fuse blown?
Yes No
Replace A/C 30A fuse. Find out the reason according to Step 4.
6-70
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. Visually observe whether the fuse is fused or use
a multimeter and a diode to check whether both ends of the fuse are connected.
Is A/C panel fuse damaged?
Yes No
Replace 5A fuse of the A/C panel

Step 5 A/C panel fault (inner fault).
 When replacing A/C panel, please make sure to use LiuGong parts.
Inspection method
Press the blowing rate switch, display air volume 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.
6-71
June 10, 2015 6.5.15 E15 A/C no wind or abnormal air volume
6.5.15 E15 A/C no wind or abnormal air volume

A/C blows no air or air volume
is abnormal

Step 1 Blower main relay fault (inner fault).
 When replacing the A/C relay, please make sure to use LiuGong parts.
Inspection method
Turn the multimeter to measure the resistance value between all contacts of the fan main relay according to
the table below and judge whether relay is damaged the resistance value provided.
Relay Code for both ends of wire (contact) Standard value
Unplug the relay and measure the Measure coil resistance 240±10Ω
resistance between the contacts of
the relay E-3 Contact 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

6-72
6.5.15 E15 A/C no wind or abnormal air volume June 10, 2015
Step 3 Blower motor fault.
Inspection method
Unplug the blower 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.

6-73
June 10, 2015 6.5.15 E15 A/C no wind or abnormal air volume
Inspection method
Yes No
Look for the fault of A/C system or contact local

Maintenance is over
6-74
6.5.16 E16 Poor A/C refrigeration June 10, 2015
6.5.16 E16 Poor A/C refrigeration

The refrigeration effect of A/C system
E16 Poor A/C refrigeration
is poor

Step 1 Compressor relay fault
Inspection method
Check whether the electromagnetic coil circuit of the compressor clutch relay is open with a multimeter.
Whether the compressor clutch relay fails?
Yes No
Replace the compressor clutch relay Check in accordance with Step 2.

Step 2 Inner sensor fault.
Inspection method
The inner sensor may fail and diagnose the fault of inner sensor.
Whether the inner sensor fails?
Yes No
Replace the inner sensor. Find out the reason according to Step 3
6-75
June 10, 2015 6.5.16 E16 Poor A/C refrigeration
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 and less than 3.14 MPa, 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 switch. Find out the reason according to Step 4
Step 4 Compressor clutch fault
Inspection method
Unplug the compressor clutch, and use a multimeter to check whether the compressor clutch coil is open.
Whether the compressor earthing cable 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
6-76
6.5.16 E16 Poor A/C refrigeration June 10, 2015
Step 6 A/C circuit 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 local

Maintenance is over
6-77
June 10, 2015 6.5.17 E17 Abnormal alarm of the A/C E11 - Inner air sensor line broken
6.5.17 E17 Abnormal alarm of the A/C E11 - Inner air sensor line
broken

sensor line broken

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 DTC;
3. If E11 DTC occurs, check whether the circuit of the inner sensor located in the air outlet is open with a
multimeter.
Whether the circuit of the inner sensor is open?
Yes No
Replace the inner sensor.

Step 2 Inner sensor open circuited.
Inspection method
Check whether the inner sensor to the A/C panel is open-circuited with a multimeter.
Whether the inner sensor is open circuit?
Yes No
Check fault points and repair them

6-78
6.5.17 E17 Abnormal alarm of the A/C E11 - Inner air sensor line broken June 10, 2015
Inspection method
If open circuit is not found through checking by step 1.2, it may be inner fault of the A/C panel.
Is it inner fault of the A/C panel?
Yes No

Inspection method
Yes No

Maintenance is over
6-79
June 10, 2015 6.5.18 E18 Abnormal alarm of the A/C E12 - Inner sensor short-circuited
6.5.18 E18 Abnormal alarm of the A/C E12 - Inner sensor short-cir-
cuited

Abnormal A/C alarm E12 -- Inner The service effect of A/C is poor
E18

Inspection method
seconds, the LCD will display DTCs;
3. If E12 DTC occurs, check the inner sensor located in the air outlet for short circuit with a multimeter.
Whether the inner sensor is short-circuited?
Yes No
Replace the inner sensor.

Step 2 Inner sensor short-circuited.
Inspection method
Check whether the inner sensor to the A/C panel is short-circuited with a multimeter.
Yes No

6-80
6.5.18 E18 Abnormal alarm of the A/C E12 - Inner sensor short-circuited June 10, 2015
Inspection method
If short circuit is not found through checking by Step 1 and 2, it may be inner fault of the A/C panel.
Yes No

Inspection method
Yes No

Maintenance is over
6-81
June 10, 2015 6.5.19 E19 Abnormal alarm of the A/C E15 - Water temperature sensor line broken
6.5.19 E19 Abnormal alarm of the A/C E15 - Water temperature sen-
sor line broken

Abnormal A/C alarm E15 -- The service effect of A/C is poor
E19 Water temperature sensor line
broken

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-circuited?
Yes No
Replace the water temperature sensor.

Step 2 Water temperature sensor open-circuited.
Inspection method
Check whether the water temperature sensor to the A/C panel is open-circuited with a multimeter.
Whether the water temperature is open-circuited?
Yes No

6-82
6.5.19 E19 Abnormal alarm of the A/C E15 - Water temperature sensor line broken June 10, 2015
Inspection method
If open circuit is not found through checking by step 1 and step 2, it may be inner fault of the A/C panel.
Yes No

Inspection method
Yes No

Maintenance is over
6-83
June 10, 2015 6.5.20 E20 Abnormal alarm of the A/C E16 - Water temperature sensor short-circuited
6.5.20 E20 Abnormal alarm of the A/C E16 - Water temperature sen-
sor short-circuited

Abnormal A/C alarm E16 -- Water
E20 temperature sensor short- The service effect of A/C is poor
circuited

Step 1 Water temperature sensor fault
Inspection method
seconds, the LCD will display DTCs;
3. If E16 DTC occurs, check whether the water temp sensor circuit located in the inflow side of the warm wind
radiator is short with a multimeter.
Whether the water temperature sensor is short-circuited?
Yes No
Replace the water temperature sensor.

Step 2 Water temperature sensor short-circuited.
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-circuited?
Yes No

6-84
6.5.20 E20 Abnormal alarm of the A/C E16 - Water temperature sensor short-circuited June 10, 2015
Inspection method
Yes No

Inspection method
Yes No

Maintenance is over
6-85
June 10, 2015 6.5.21 E21 Abnormal alarm of the A/C E18 - Insolation sensor short-circuited
6.5.21 E21 Abnormal alarm of the A/C E18 - Insolation sensor short-
circuited

Abnormal A/C alarm E18 --
Insolation sensor short-circuited

Step 1 Insolation sensor fault (inner fault)
 Be sure to use LiuGong parts in replacing the insolation sensor.
Inspection method
3. If E18 DTC occurs, check whether the circuit of the insolation sensor is short with a multimeter.
Yes No
Replace the insolation sensor.

Step 2 Insolation sensor short-circuited.
Inspection method
Check whether the insolation sensor to the A/C panel is short-circuited with a multimeter.
Whether the insolation sensor is short-circuited?
Yes No

6-86
6.5.21 E21 Abnormal alarm of the A/C E18 - Insolation sensor short-circuited June 10, 2015
Inspection method
Yes No

Inspection method
Yes No

Maintenance is over
6-87
June 10, 2015 6.5.22 E22 Abnormal alarm of A/C E43 - abnormal air outlet
6.5.22 E22 Abnormal alarm of A/C E43 - abnormal air outlet

Abnormal air outlets

Step 1 Air-out servo motor fault (inner 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

6-88
6.5.22 E22 Abnormal alarm of A/C E43 - abnormal air outlet June 10, 2015
Inspection method
Yes No

Inspection method
Yes No

Maintenance is over
6-89
June 10, 2015 6.5.23 E23 Abnormal alarm of the A/C E44 – Abnormal blend air door
6.5.23 E23 Abnormal alarm of the A/C E44 – Abnormal blend air
door

Abnormal blend air doors

Step 1 Air mixing ventilation door (A/M) servo motor fault (inner 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)
Step 2 Circuit fault of the servo motor of the air mixing ventilation 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 ventilation door (A/M) fails?
Yes No

6-90
6.5.23 E23 Abnormal alarm of the A/C E44 – Abnormal blend air door June 10, 2015
Inspection method
Yes No

Inspection method
Yes No

Maintenance is over
6-91
CLG920D/922D 6.5 Fault diagnosis of hydraulic system and mechanical system
June 10, 2015 6.5.1 System table of hydraulic system and mechanical system
6.5 Fault diagnosis of hydraulic system and mechanical

system
6.5.1 System table of hydraulic system and mechanical system
See the PDF of “System Table of Hydraulic System and Mechanical System”
6.5.2 H1 Excessive braking angle for swing stop
Excessive braking angle

for slewing stop
Yes
Check whether the

pressure of swing relief No Slewing relief valve fault
valve is normal.
Yes
Check whether the anti-reversing

valve is functioning properly.
No Anti-reversing valve fault
Yes
Check the swing pilot

circle for clogging
Yes Clean and replace the pilot line
No
Check whether the pilot

valve is functioning properly
No Pilot valve fault
Yes
Check whether the

swing valve element No Spring fault
spring is normal
Yes
Swing motor fault

LG922E930E06133
6-92
6.5 Fault diagnosis of hydraulic system and mechanical system CLG920D/922D
6.5.3 H2 Abnormal noise from pump mounting position June 10, 2015
6.5.3 H2 Abnormal noise from pump mounting position
Abnormal sound of
pump installation
position
Yes
Check the flywheel inside Coupling components:

for foreign matters
Yes Removal and repair
No
Check the coupling hub spline

for wear and the adjusting Replace the hub or tighten
Yes the adjusting screw.
screw for fixing the hub for
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.
6-93
June 10, 2015 6.5.4 H3 No response after engine start
6.5.4 H3 No response after engine start
When the engine is

started, all operations
are unresponsive.
Yes
Check whether the

hydraulic oil level is Add oil to the specified
No level as required
normal.
No The hydraulic Hydraulic pump fault:

pump sounds Yes
abnormally. Remove and repair it.
Check whether the
Yes
abnormal sound comes
from the hydraulic pump or
pump installation position.
Yes
The pump installation Troubleshoot by
No position sounds Yes
referring to H2.
abnormally.
Check whether the pilot Check whether any oil Pilot relief valve fault:
pressure is normal. No flows out from the pilot Yes
Repair or replace it
pump.
Pilot pump fault:

Remove and repair it.
Yes
No
Check the pilot line for Pilot valve or main control valve
No
clogging or leakage. fault: Remove and repair it.
Yes Clean the pilot line or repair it.
LG922E930E06135
6-94
6.5.5 H4 Hydraulic oil emulsification June 10, 2015
6.5.5 H4 Hydraulic oil emulsification
Hydraulic oil
emulsification
Yes
Sample the oil and Let the hydraulic

drop the sample This may be oil sit for a period
droplets onto the hot Yes due to water in of time, and
iron plate, and then the hydraulic oil. remove the water
check for bubbles. or replace the oil.
This may be Check the suction

line and the return
Yes due to air in the
line, and cut off the
hydraulic oil. air-mixed source.
LG922E930E06136
6-95
June 10, 2015 6.5.6 H5 Abnormal hydraulic oil temperature rise
6.5.6 H5 Abnormal hydraulic oil temperature rise
Abnormal hydraulic
oil temperature rise
Yes
Check whether the

hydraulic oil level is No Add oil to the specified
normal. level as required
Yes
Check the oil radiator Clean the oil radiator to

Yes
for clogging. keep the air ventilated.
No
Check whether the

fan belt tension is No
Adjust the belt tension
appropriate or not. or replace the belt.
Yes
Check whether the pressure

of the main relief valve, the
Yes Adjust the setting
port relief valve and the
pressure again.
motor relief valve is lower
than the standard value.
No
Check whether the oil return Replace the failed

No
check valve is normal. check valve
LG922E930E06137
6-96
6.5.7 H6 Swing abnormally to left and right directions June 10, 2015
6.5.7 H6 Swing abnormally to left and right directions
Rotation fault
on left and right
directions
Yes
Whether other Troubleshoot it by referring to the

operation is Yes method that for Unidirectional Swing
unresponsive or Operation Is Unresponsive.
not?
No
Check whether the Check whether the The swing valve

swing pilot Yes swing valve Yes element gets stuck:
pressure is normal. Remove and repair it.
element gets stuck.
No
Check whether the Repair or replace

swing relief valve is No the swing relief
functioning properly. valve.
No
Yes
Swing motor and

reducer fault: Repair
or replace it.
Check whether the Swing pilot valve

No
swing pilot valve is fault: Remove,
functioning properly. repair or replace it.
Yes
Clogging or leakage Yes Clean or replace

inside the pilot line the pilot line.
LG922E930E06138
6-97
June 10, 2015 6.5.8 H7 No response for single-direction swing
6.5.8 H7 No response for single-direction swing
Unidirectional
swing operation is
unresponsive.
Yes
Check whether the left

swing pilot pressure is Check the pilot line inside Pilot valve fault:
No
for clogging or leakage.
No
the same as the right Remove and repair it.
one.
Yes Yes
Clogging or
Clean or repair the pilot line.
leakage occurs.
Check whether the The swing valve element

swing valve element Yes gets stuck: remove or
gets stuck. replace it.
Swing relief valve fault:

No
Remove, repair or replace it.
LG922E930E06139
6-98
6.5.9 H8 Rotation unable to stop June 10, 2015
6.5.9 H8 Rotation unable to stop
Rotation cannot
be stopped.
Yes
Check whether the swing

Check whether the swing valve
valve element is in the neutral No No Spring fault: Remove or replace it.
element spring is normal
position.
Yes
Check whether the swing valve The swing valve element gets
Yes
element gets stuck. stuck: remove or replace it.
No
Check whether the swing Swing pilot valve fault: Remove

pilot pressure is normal.
No
Yes or replace it.
Yes
Check whether the pilot Pilot relief valve fault: Remove,
Yes
pump pressure is normal. repair or replace it.
No
Pilot pump fault: Remove and repair it.
Check whether the

Swing relief valve fault:
swing relief valve No Remove or replace it.
pressure is normal.
LG922E930E06140
6-99
June 10, 2015 6.5.10 H9 Failure to actuate unilateral travel mechanism
6.5.10 H9 Failure to actuate unilateral travel mechanism
Unilateral running
gear fails to move
completely
Yes
Whether other operation The travel valve element

Check whether the travel
is unresponsive or not? No valve element gets stuck.
Yes gets stuck: remove and
repair it.
No
Clean or replace the
Check whether the travel Travel pilot line and pilot line. Travel pilot
pilot pressure is normal. No pilot valve fault valve fault: Remove,
repair or replace it.
Yes
The travel motor
Yes Check whether the
balance valve gets
travel motor balance Yes
stuck: remove, repair or
valve gets stuck.
replace it.
No
Travel motor and reducer

fault: Remove and repair it.
Troubleshoot
according to H3
LG922E930E06141
6-100
6.5.11 H10 Travel deflection June 10, 2015
6.5.11 H10 Travel deflection
Travel deflection
Yes
Let both left and right sides

of the excavator travel at
the same time in the same Check whether the travel The travel valve element
direction+ any movement Yes Yes
valve element gets stuck. fault: remove and repair it.
on the upper part, whether
pulling one side or not?
No
Check whether the travel Travel pilot line and pilot valve
No
fault: clean, repair and replace it.
Yes
No Check whether the center Center joint fault: Remove,

joint is functioning properly.
No repair or replace it.
No
Yes
Check whether the travel Travel motor fault:

motor is functioning properly.
No Remove and repair it.
Yes
Main control valve
fault: remove, repair
or replace it.
Exchange the left pump output
hose and negative feedback Hydraulic pump
hose with the right ones, and Yes fault: Remove and
check whether the fault repair it.
phenomenon transfers.
LG922E930E06142
6-101
June 10, 2015 6.5.12 H11 Slow speed of the boom, arm or bucket
6.5.12 H11 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 Check whether both Main pump fault:,
left and right traveling No the left speed and the Yes
Remove and repair it.
speeds are normal. right speed are slow.
No
Check whether the
Check the pilot line inside Clean or repair
boom, arm or bucket No Yes
for clogging or leakage. the pilot line.
Yes None
Check whether the pilot Pilot valve fault:
valve is functioning No
properly Remove and repair it.
Check whether the Check whether the pilot Just as above-mentioned,

confluence is normal
when the boom rising or No pressure of the boom (2) No check the pilot line and pilot
the arm expanding. or the arm (2) is normal. valve.
Yes
Check whether the The confluent valve
above-mentioned valve Yes element is stuck:
element gets stuck. Removal and repair
No
Yes
Check whether the
confluent valve No Replace the
element spring is spring
functioning properly.
Check whether the Check the pilot line for Pilot valve fault: Remove
boom, arm or bucket No clogging or leakage.
None
and repair it.
Yes Yes Clean or repair the pilot line.
Check whether the Spool is stuck:

above-mentioned valve Yes
repair or replace
element gets stuck.
No
Check whether the main
relief valve and the port Relief valve fault: Remove,
relief valve are No
repair or replace it.
functioning properly.
Cylinder inside
Yes damage: Remove
and repair it.
LG922E930E06143
6-102
6.5.13 H12 Weak actions of the boom, arm or bucket June 10, 2015
6.5.13 H12 Weak actions of the boom, arm or bucket
Boom, arm or
bucket is unable
to move.
Yes
Check whether the Main relief valve fault:

main relief valve No Adjust the pressure, and
pressure is normal. repair or replace the valve.
Yes
Check whether the Port relief valve fault:
port relief valve No Adjust the pressure, and
pressure is normal. repair or replace the valve.
Yes
Check whether the cylinder Cylinder fault: Remove
No
leakage rate is normal. and repair it.
Yes Troubleshoot according to the H11 fault
LG922E930E06144
6-103
June 10, 2015 6.5.14 H13 Significantly reduced engine speed or engine stalling
6.5.14 H13 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 system
engine speed or engine Yes No Main relief valve fault
pressure is normal.
stalling, shutdown
Yes
Check whether the main pump Pump proportional

proportional valve is functioning No valve fault: Repair
properly. or replace it.
Yes
Engine or electronic
control system fault
LG922E930E06145
6-104
6.5.14 H13 Significantly reduced engine speed or engine stalling June 10, 2015
7-1
CLG920D/922D
June 10, 2015
7 Removal and Installation
7.1 Overview ........................................................................................................... 7-3

7.2 Power system................................................................................................... 7-4
7.2.1 Removal and installation of diesel engine as ............................................. 7-4
7.2.2 Removal and installation of radiator as .................................................... 7-13
7.2.3 Removal and installation of hydraulic oil cooler ....................................... 7-18
7.2.4 Removal and installation of intercooler .................................................... 7-21
7.2.5 Removal and installation of water radiator ............................................... 7-23
7.3 Undercarriage system .................................................................................. 7-25
7.3.1 Removal and installation of track roller .................................................... 7-25
7.3.2 Removal and installation of carrier roller .................................................. 7-26
7.3.3 Removal and installation of track as......................................................... 7-27
7.3.4 Removal and installation of sprocket........................................................ 7-28
7.3.5 Removal and installation of idler as and tensioner as .............................. 7-29
7.3.6 Removal and installation of revolving frame............................................. 7-30
7.3.7 Removal and installation of swing bearing ............................................... 7-32
7.4 Covering parts ................................................................................................ 7-33
7.4.1 Removal and installation of engine hood ................................................. 7-33
7.4.2 Removal and installation of counterweight............................................... 7-34
7.5 Hydraulic system ........................................................................................... 7-36
7.5.1 Removal and installation of center connector as...................................... 7-36
7.5.2 Disassembly and assembly of center connector as. ................................ 7-38
7.5.3 Removal and installation of hydraulic oil tank .......................................... 7-41
7.5.4 Removal and installation of main control valve as ................................... 7-45
7.5.5 Disassembly and assembly of main control valve as ............................... 7-48
7.5.6 Removal and installation of main pump as............................................... 7-60
7.5.7 Disassembly and assembly of main pump as .......................................... 7-63
7.5.8 Removal and installation of foot pilot valve as ......................................... 7-75
7.5.9 Disassembly and assembly of foot pilot valve.......................................... 7-78
7-2
CLG920D/922D
June 10, 2015
7.5.10 Removal and installation of hand pilot valve as...................................... 7-99

7.5.11 Disassembly and assembly of hand pilot valve as ............................... 7-102
7.5.12 Removal and installation of travel motor & reduction gear ................... 7-117
7.5.13 Disassembly and assembly of travel motor & reduction gear as .......... 7-120
7.5.14 Removal and installation of swing motor & reduction gear................... 7-164
7.5.15 Disassembly and assembly of swing motor & reduction gear .............. 7-167
7.6 Work implement ........................................................................................... 7-190
7.6.1 Removal and installation of bucket ......................................................... 7-190
7.6.2 Removal and installation of link and lever .............................................. 7-192
7.6.3 Removal and installation of arm ............................................................. 7-194
7.6.4 Removal and installation of the boom..................................................... 7-196
7.6.5 Removal and installation of work implement as...................................... 7-201
7.6.6 Removal and installation of bucket cylinder as....................................... 7-204
7.6.7 Removal and installation of arm cylinder as ........................................... 7-207
7.6.8 Removal and installation of boom cylinder as ........................................ 7-210
7.6.9 Disassembly and assembly of cylinder................................................... 7-213
7.7 A/C system .................................................................................................... 7-223
7.7.1 Removal and installation of A/C compressor as ..................................... 7-223
7.7.2 Removal and installation of A/C evaporator as....................................... 7-226
7.8 Cab .................................................................................................................. 7-234
7.8.1 Removal and installation of cab.............................................................. 7-234
7.8.2 Removal and installation of floor plate as ............................................... 7-240
7-3
CLG920D/922D 7.1 Overview
June 10, 2015
7.1 Overview
This chapter introduces the removal and installation methods for main parts of this machine.
The removal and installation of a component introduce the methods for removing and installing the compo-
nent from and on the complete machine. The disassembly and assembly of a component introduce the
method for disassembling the component into subcomponents and the method of assembly.
7-4
7.2.1 Removal and installation of diesel engine as June 10, 2015
7.2 Power system

7.2.1 Removal and installation of diesel engine as
Removal

1. Remove the negative (-) battery cable first before removal in order to avoid electric arcs.
2. When the engine operates, anti-freeze is in the high–temperature state. Make sure the diesel engine
stops working and anti-freeze 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.
Photo Steps
1. Remove the engine hood (1), and
refer to "Removal and Installation of
Engine Hood" in this chapter for
details.
1
LG922E930E07001
2. Remove three bottom plates (2), (3)

and (4).
LG922E930E07002
7-5
June 10, 2015 7.2.1 Removal and installation of diesel engine as
3. Prepare a container for receiving anti-

freeze, open water drain valve (5), and
discharge anti-freeze in the water
radiator.
5  Open water tank cover to
accelerate water discharge
time.
 The capacity of anti-freeze in

the cooling system is about 25
L. It is forbidden to directly
discharge anti-freeze to
LG922E930E07003 ground to prevent from con-
taminating the environment.
 To make sure operational

safety, first make sure the nega-
tive (-) battery cable is removed,
and then go to the next step.
6
7
4. Disconnect the negative (-) earthing
harness (6) from the positive (+)
connecting harness (7) of the starting
motor.
LG922E930E07004
5. Disconnect the connecting water hose

at the upper part of the engine:
5.1 Disconnect the engine water outlet
pipe (8);
11 5.2 Disconnect the engine vent pipe
(9);
8 5.3 Disconnect the engine water
replenishment pipe (10);
5.4 Disconnect the A/C heater water
9 intake pipe (11) and remove its fixing
support;
10
LG922D07001
7-6
6. Remove the intercooler tube (12) and

the intercooler hose (13);
12 13 7. Disconnect the intake hose (14)
connecting the turbocharger;
 After disconnecting the intake
line, the air intakes of the line
and the engine must be
masked to prevent dust and
other foreign bodies from
14
entering the air intake system
to cause engine wear.
LG922D07002
8. Disconnect the harness connecting

the engine (15).
9. Remove the harness fixing support
(16) assembled on the engine cylinder
body.
15
16
LG922D07003
10.Disconnect the frame harness from

the engine:
10.1 Disconnect the A/C compressor
17
harness connector (17);
18 10.2 Disconnect the air intake heater
harness (18);
10.3 Disconnect the connector (19)
19 connecting the engine ECM;
10.4 Remove the frame harness
20 mounting support (20);
LG922D07004
7-7
11.Remove the fan guard (21);
21
LG922D07005
12.Remove the A/C compressor (22): put

it on a counterweight.
22
LG922D07006
13.Remove the engine fan (23);
23
LG922D07007
7-8
14.Disconnect the connecting water hose

at the lower part of the engine:
14.1 Disconnect the engine water intake
hose (24);
24
14.2 Disconnect the A/C heater water
return pipe (25);
25
LG922D07008
15.Remove the right grill (26) of the

covering part and the main pump
baffle (27).
26
27
LG922D07009
7-9
16.Close the fuel shutoff valve (28) of the

oil circuit;
17.Disconnect the oil return pipe (29) and
oil inlet pipe (30) connecting the
engine and two fuel pipes (31), (32)
connecting the remote secondary
28 filter;
 Precautions:
 1. When removing the oil

return pipe on the engine, the
oil port must be plugged or
28
the oil return pipe must be
LG922D07010
fixed at a height above the fuel
liquid level in the fuel tank in
order to prevent fuel in the
fuel tank from flowing back.
29  2. After removing the fuel line,
30 the oil ports on the line and
the engine must be masked to
prevent to dust and other for-
eign bodies from entering the
32 fuel system to cause engine
31 damages.
LG922D07011  3. Meanwhile, the line must be

identified to indicate its
mounting ports.
7-10
18.Remove the engine oil filter mounting

support (33) from the main pump, and
bind the support together with the
engine oil filter (34) on the engine;
33
LG922D07012
35
LG922E930E07017
19.Lift the main pump (35) with a lifting

sling, remove flange (36) mounting
bolts, and move the main pump and
the flange outwards together so that
36 the coupling bushing is separated
35 from the engine flywheel;
(The total weight of the main pump
and flange is about: 180 kg.)
LG922E930E07018
7-11
20.Remove 4 shock absorber mounting

boles (37) on the engine bracket;
37
×4
LG922E930E07019
21.Check the components around the

engine. After confirming no impact on
hoisting, lift the diesel engine (38) out
slowly with slings and other hoisting
equipments and place it in a safe
position; (the total weight is about 630
kg, including engine and muffler etc.)
38
LG922E930E07020
7-12
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. The others are subject to gen-
eral 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:
Position Grade Tightening torque
Iron flywheel housing M10-10.9 65 N·m
Iron flywheel housing M12-10.9 115 N·m
Coupling-flywheel mounting bolts M18 350 N·m
Coupling bushing mounting bolts M16 120 N·m
Mounting bolt of shock absorber M20-10.9 550 N·m
Mounting bolt of shock absorber M24-10.9 900 N·m
 Caution: If the coupling bushing (A) is removed from the main pump, the main pump spline
shaft must be pushed until the snap spring (B) inside the coupling bushing and then locked up
(the snap ring in the coupling bushing is used for locating the assembly position of the main
pump spline shaft).
A
LG922D07013
7-13
June 10, 2015 7.2.2 Removal and installation of radiator as
7.2.2 Removal and installation of radiator as

Removal

1. Before removal, rotate the machine revolving frame to an angle suitable for removal, lower the
work implement to ground, shut down to park the machine, release accumulator pressure, open the
hydraulic oil tank cover to release pressure in the oil tank, and pump out hydraulic oil in the oil
tank.
 Precautions:
1. When the engine operates, anti-freeze is in the high–temperature state. Make sure the diesel
engine stops working and anti-freeze is cooled before removing the water radiator or opening the
water radiator cap in order to prevent possible personal injuries.
2. Clean the area around the assembly ports before removing pipelines, connectors or hoses.
3. Seal them with plugs or caps when the pipelines, connectors or hoses are removed to prevent
pollution sources from entering the hydraulic system.
4. After removing the air intake line, the air intakes of the intercooler, intercooler pipe and engine
must be masked immediately to prevent dust and other foreign bodies from entering the air intake
system to cause engine wear.
Figure Steps
1. Remove the engine hood (1); and refer to
"Removal and Installation of Engine Hood"
in this chapter for details.
LG922E930E07001
7-14
7.2.2 Removal and installation of radiator as June 10, 2015
2. Remove the plate (2) under the platform;
LG922E930E07023
3. Prepare a container for receiving anti-

freeze; open the water drain valve (3), and
discharge anti-freeze in the water radiator
(open the water tank cover to accelerate
water discharge time);
3
 The capacity of anti-freeze in the
cooling system is about 25 L. It is
forbidden to directly discharge anti-
freeze to ground to prevent from
contaminating the environment.
LG922E930E07581
4. Disconnect the line connected to the water

radiator: water intake pipe (4), vent pipe (5)
and refill hose (6).
4
LG922D07014
7-15
5. Disconnect the water outtake pipe (7) at the

lower end of the water radiator.
LG922D07015
6. Disconnect the hose (8) connected to the

cooler.
LG922E930E07030
7-16
7.2.2 Removal and installation of radiator as June 10, 2015
7. Disconnect the oil inlet pipe connector (9) of

the hydraulic oil cooler and the oil inlet tube
(10) at the bottom;
 After removing the oil inlet and out-
let pipe of the hydraulic oil cooler,
check whether the O-ring at the oil
9 port is damaged. If so, replace it
immediately to prevent oil leakages
after assembly is restored.
8. Drain hydraulic oil;
 Hold the hydraulic oil with an
LG922E930E07024 appropriate container whose
capacity is about 6 L.
10
LG922E930E07025
9. Remove the condenser (11) and diesel

radiator (12) .
11 12
LG922D07016
7-17
10.Remove the 4 mounting bolts (13) under the

13 radiator assembly;
13
LG922D07017
11.Lift and hold the radiator assembly (14) with

wire rope. Lift it out slowly and place it on a
safe position.
 Be careful not to scratch the oil port
14 flange face during the lifting the
cooler assembly to cause oil leak-
ages after assembly is restored.
LG922E930E07028
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 the general one;
• 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.
• 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;
7-18
7.2.3 Removal and installation of hydraulic oil cooler June 10, 2015
7.2.3 Removal and installation of hydraulic oil cooler

Removal

1. Before removal, rotate the machine revolving frame to an angle suitable for removal, lower the
work implement to ground, shut down to park the machine, release accumulator pressure, open the
hydraulic oil tank cover to release pressure in the oil tank, and pump out hydraulic oil in the oil
tank.
 Precautions:
1. Clean the area around the assembly ports before removing pipelines, connectors or hoses.
2. Seal them with plugs or caps when the pipelines, connectors or hoses are removed to prevent
pollution sources from entering the hydraulic system.
Figure Steps
1. Rotate the swing platforms of the machine to
an angle suitable for remove, and remove the
radiator assembly (1); refer to the "Removal
and installation of the radiator assembly" in this
1 chapter.
LG922D07018
7-19
June 10, 2015 7.2.3 Removal and installation of hydraulic oil cooler
2. Remove the upper guard (2) and the lower guard

(3) of the radiator assembly
LG922D07019
3. Remove the 4 of mounting bolts (4) beside the

hydraulic oil radiator; and then slowly lift it out
of the radiator frame and place it in a safe
position.
 Be careful not to scratch the hydraulic
4 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 leak-
ages after assembly is restored.
LG922D07020
LG922D07021
7-20
7.2.3 Removal and installation of hydraulic oil cooler June 10, 2015
Installation
• Clean the components to be assembled properly before assembly;
• 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.
7-21
June 10, 2015 7.2.4 Removal and installation of intercooler
7.2.4 Removal and installation of 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 intakes of the intercooler, intercooler pipe and engine
must be masked immediately to prevent dust and other foreign bodies from entering the air
intake system to cause engine wear.
Figure Steps
1. Rotate the swing platforms of the machine to an
angle suitable for remove, and remove the radiator
assembly (1); refer to the "Removal and installation
of the radiator assembly" in this chapter.
1
LG922D07018
2. Remove the upper guard (2) and the lower guard (3)
of the radiator assembly
LG922D07019
7-22
7.2.4 Removal and installation of intercooler June 10, 2015
3. Remove the 4 of mounting bolts(4) beside the

intercooler; and slowly lift it out of the radiator frame.
 Be careful not to scratch the intercooler
core during lifting.
LG922D07022
LG922D07023
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 leak-
ages.
7-23
June 10, 2015 7.2.5 Removal and installation of water radiator
7.2.5 Removal 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.
Precautions:
2. When the engine operates, anti-freeze is in the high–temperature state. Make sure the diesel
engine stops working and anti-freeze is cooled before removing the water radiator or opening the
water radiator cap in order to prevent possible personal injuries.
Figure Steps
1. Rotary the swing platforms of the machine to an
angle suitable for remove, and remove the radiator
assembly (1); refer to the "Removal and
installation of the radiator assembly" in this
1 chapter.
LG922D07018
2. Remove 8 mounting bolts (2) at the side of the

water radiator;
LG922D07024
7-24
7.2.5 Removal and installation of water radiator June 10, 2015
3. Hook the water radiator (3) with a steel wire rope,

and lift it out of the radiator frame.
11  Be careful not to scratch the water radia-
tor core during lifting.
LG922E930E07038
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.
7-25
June 10, 2015 7.3.1 Removal and installation of track roller
7.3 Undercarriage system

7.3.1 Removal and installation
of track roller 1
Removal
1. Support the complete machine so that the
platform forms 90° angle with the travel frame,
LG922E930E07086
3. Remove track roller mounting bolts.
LG922E930E07085
2. Loosen the filling valve (1), discharge grease

in the tensioner, and reduce track tensioning
LG922E930E07087
level.
Danger: The valve has the risk of flying out due
to high pressure grease inside. Installation
Therefore, do not loosen the filling valve 2 by The installation procedures are just opposite to
more than two turns. the removal ones.
★ Refer to the "Measurement and Adjustment
of Track Tension" in the chapter of "Testing and
Adjusting" to adjust the track tension properly.
★ Apply TONSAN 1277 thread lock sealant to
the track roller mounting bolts. The tightening
torque is 600±50Nm.
7-26
7.3.2 Removal and installation of carrier roller June 10, 2015

of carrier roller
2
Removal
1. Loosen the filling valve (1), discharge grease
in the tensioner, and reduce track tensioning
level.
Caution: 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.
LG922E930E07088
3. Loosen carrier roller mounting bolts with a

wrench, and remove the carrier roller. Take out
1 the carrier roller from the mounting hole.
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
roller. LG922E930E07089
Installation
Installation steps:
Installation sequence is just reverse to the
removal sequence.
the sprocket mounting bolts. The tightening
torque is 415±35Nm.
7-27
June 10, 2015 7.3.3 Removal and installation of track as

of track as
Removal
2
1. Move the complete machine forwards so that
the main pin (1) is located at the front section of
the sprocket.
1 LG922E930E07582
3. Squeeze out the main pin with a pin squeez-

ing machine (3).
LG922E930E07090
2. Loosen the filling valve (2) with a wrench, dis- 3

charge grease, and reduce track tensioning
level.
Caution: 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. LG922E930E07091
4. Move the complete machine forward to unfold

the track.
7-28
7.3.4 Removal and installation of sprocket June 10, 2015

of sprocket
Removal
1. Refer to "Removal of track as" section to
remove the track as. Rotate the work implement
by 90°, and jack up the complete machine with
the work implement.
1.1 Rotate the track to the sprocket (1) side.
Unfold the track.
LG922E930E07092
Installation
Installation steps:
removal sequence. 1

LG922E930E07093
2. Remove 30 sprocket mounting bolts, and

remove the sprocket.
LG922E930E07094
7-29
June 10, 2015 7.3.5 Removal and installation of idler as and tensioner as
Installation 7.3.5 Removal and installation

The installation procedures are just opposite to
of idler as and tensioner as
the removal ones.
★ Apply TONSAN 1277 thread lock sealant to Removal
the sprocket mounting bolts. The tightening 1. Refer to "Removal of track as" section to
torque is 600±50 Nm. remove the track as.
LG922E930E07095
2. Push out the idler and tensioner (1) out of the

idler bracket with a crowbar;
LG922E930E07096
7-30
7.3.6 Removal and installation of revolving frame June 10, 2015
3. Lift the idler and tensioner as (1) and move it 7.3.6 Removal and installation
forwards for removal.
of revolving frame
Removal
1. Remove the work implement as. For details,
see "Removal and installation of work imple-
ment as".
2. Remove the counterweight as. For details,
see "Removal and installation of counterweight
as".
3. Disconnect hoses (1)-(4).
• Label the disconnected hoses to prevent
mistakes during reinstallation.
LG922E930E07097
4. Lift the boom cylinder as (5) temporarily.
4. Remove the tensioner from the idler as.
2 4
1 3
5
LG922E930E07099
LG922E930E07098
5. Remove the plate (6) and the pin (7), and
remove the boom cylinder as (5).
Installation 6. Remove the opposite boom cylinder as in the
Installation steps: same steps.
removal sequence.
connecting bolts of the tensioner and idler as.
The tightening torque is 305±25 Nm.
7-31
June 10, 2015 7.3.6 Removal and installation of revolving frame
Installation
the removal ones.
• Apply TONSAN 1277 thread lock sealant to
the revolving support mounting bolts. The
7
tightening torque is 1020±100 Nm.
• The tightening torque of pin captive bolts
6 M12: 120±10 Nm.
LG922E930E07100
7. Remove bolts (8) from the center connector.

8. Disconnect hoses (9) (10) and tubes (11)
(14).
9. Label the disconnected hoses and tubes to
prevent mistakes during reinstallation.
10. Lift the platform as temporarily.
11. Remove 40 mounting bolts and remove the
revolving frame as.
10
11 9 13
12 14
8
LG922E930E07101
7-32
7.3.7 Removal and installation of swing bearing June 10, 2015
7.3.7 Removal and installation Installation

of swing bearing
the removal ones.
Removal • Apply TONSAN 1277 thread lock sealant to
1. Remove the revolving frame as. For details, the revolving support mounting bolts. The
see "Removal of revolving frame". tightening torque is 1020±100 Nm.
2. Remove 40 mounting bolts (1) to remove the • When installing the revolving support, the
revolving support. tape mark S on the inner ring of the revolv-
ing support needs to face the right side.
Inner race race soft-zone
Outer race race soft-zone
1
Machine moving forward
LG922E930E07102
LG922E930E07104
3. Lift the revolving support (2).

Weight of the revolving support: 445 Kg.
LG922E930E07103
7-33
CLG920D/922D 7.4 Covering parts
June 10, 2015 7.4.1 Removal and installation of engine hood
7.4 Covering parts

2
of 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 LG922E930E07106
engine hood.
4. After laying the engine hood flat, remove 4
1. Lower and shut down the work implement. bolts (3) mounting the engine hood.
2. Open engine hood (1).
LG922E930E07107
LG922E930E07105
5. Lift down the engine hood, and put it on flat
3. Remove the pin (2) connecting the engine ground covered by foam cardboard.
hood and the mast with pliers.
7-34
7.4 Covering parts CLG920D/922D
7.4.2 Removal and installation of counterweight June 10, 2015

of counterweight
Removal
Before the removal of the counterweight, move
the machine to the level ground to guarantee
there is no heavy sway while lifting the counter-
weight, and avoid the personal injury.
1. After removing the engine hood, stably lift the
counterweight with a steel wire rope and a lifting
LG922E930E07108
appliance to prevent it from falling down during
removal.
Installation
The installation sequence is just opposite to the
removal sequence.
• Engine hood mounting bolt M10
The tightening torque is 52 ± 7Nm.

• Install and adjust the engine hood: fasten
four bolts of the engine hood hinge. Adjust
the engine hood lock if the engine hood
cannot buckled due to displacement.
LG922E930E07109
2. Remove 4 counterweight mounting boles M30

(1) and washers with a torque wrench.
7-35
CLG920D/922D 7.4 Covering parts
June 10, 2015 7.4.2 Removal and installation of counterweight
Installation
removal sequence.
• The tightening torque of the counterweight
mounting bolts M30: 4, 1850±150Nm. The
bolt thread shall be coated with adhesives
(Tonsan 1242, JB/T7311-2008).
1
• 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.
LG922E930E07110
2. Fix the counterweight so that the longitudinal
3. Lift and move away the counterweight, and clearance between the counterweight and the
put it in a flat and safe position. revolving frame and the door, and the clearance
 Do not knock the counterweight against is in the range of 15±3mm.
3. The clearance between the outer profile
the engine or radiator.
planarea of the door and the outer profile
The counterweight weighs 4300 kg.
planarea of the counterweight in the transverse
direction of the complete machine is within the
range of 5±3 mm;
4. The outer profile of the revolving frame is
aligned with the outer profile of the counter-
weight.
LG922E930E07111
7-36
7.5.1 Removal and installation of center connector as June 10, 2015
7.5 Hydraulic system

7.5.1 Removal and installation 1
of center connector as
Removal
 2
Before removing hydraulic lines, lower the work
implement to the ground completely, shut down
the engine, screw the key to the KEY ON posi- 3
tion, operate all hydraulic control levers several
LG922E930E07112
times to release the residual pressure from the
hydraulic system, and then press the exhaust 2. Remove four travel pipes (4), remove oil
button of hydraulic oil tank breather valve to return pipes (5) and remove pilot pipes (6).
release the internal pressure from the oil tank.
 Before removing the lines, connectors

5 4
or hoses, make mark to prevent mis-
takes during assembly. Clean the
periphery of the assembled oil port if
necessary, and put an oil receiving plate
to receive oil.
6
 Seal them with plugs or caps when the
lines, connectors or hoses are in disas-
sembling state to prevent pollution
sources from entering the hydraulic LG922E930E07113
system.
3. Remove T-clamps (7).
1. Remove two pilot pipes (1); remove four 4. Remove stop plates (8).
travel pipes (2) and remove two oil return pipes
(3).
7-37
June 10, 2015 7.5.1 Removal and installation of center connector as
9
LG922E930E07114 LG922E930E07116
5. Pre-tighten the center connector with a sling

and a lifting appliance. Installation
removal sequence.
Tightening torque of center connector

mounting bolts M16-10.9: 305±25 Nm
Tightening torque of annular seal con-

nectors with O-rings: G3/8: 75±5 Nm; G3/4:
165±15 Nm
LG922E930E07115
6. Remove four captive bolts (9), and lift down

the center connector body.
Lifting weight: about 33 kg.
7-38
7.5.2 Disassembly and assembly of center connector as. June 10, 2015
7.5.2 Disassembly and assem-

bly of center connector as. 3
Disassembly
 Choose a clean location. Lay rubber
plates or cloth, etc. for removal, and be
careful not to damage parts.
1. Remove four bolts (1) and washers (2).
 Be careful to fix the center connector to

prevent hard objects from scratching LG922E930E07118
the sealing surface of each oil port.

3. Remove the sealing cover O-ring (4).
 Be careful not to damage the O-ring.

1
2 4
LG922E930E07117
2. Remove the cover (3).

LG922E930E07119
 Be careful not to damage the inner O-
4. Remove the snap ring (5) from the spindle (6).
ring while taking out the cover.
 Be careful not to damage the mounting
surface.
7-39
June 10, 2015 7.5.2 Disassembly and assembly of center connector as.
6 8
LG922E930E07120 LG922E930E07122
5. Remove the stop ring (7). 8. Remove the seal rings (12) (14) and dust ring
(10) from the center connector body.
7  Be careful not to damage the sealing

surface of the connector body.
 When the seal rings cannot be taken

out, destroy the seal rings first and then
take them out, and replace them with
new seal rings during reinstallation.
12
LG922E930E07121
6. Extract the spindle (6) out of the center con-

nector body (8) with a puller.
7. Remove the bushing (9). 14
 Hook the claw end of the puller to the

flange surface, and push the spindle out
10
of the cover.

LG922E930E07123
While taking out the bushing, be careful
not to damage the sealing surface of the
spindle.
7-40
7.5.2 Disassembly and assembly of center connector as. June 10, 2015
9. Remove four plugs (11) at the end of the spin- Assembly

dle (6).
The assembly sequence is just opposite to the
 Protect the O-ring (13) from being removal sequence. Pay attention to the assem-
bumped. bly of the following items.
1. Repair sections damaged during removal,
11 and prepare replacement parts in advance.
2. Thoroughly clean each part with cleaning oil,
and blow them dry with compressed air.
3. Clean working oil must be applied to the spin-
13 dle section and the center connector body
before assembly.
4. Seals such as seal O-ring, oil seal shall be
replaced in principle.
5. Prepare torque wrenches used for mounting
bolts and oil plugs at each section, and tighten
LG922E930E07124 them to the torques specified in the table below.
Tightening
Name Specifications
torque
Bolt M10×25-8.8-Zn.D 52±6N·m
Plug G1/2 110±10N·m
7-41
June 10, 2015 7.5.3 Removal and installation of hydraulic oil tank
7.5.3 Removal and installation of hydraulic oil tank

Removal

Before removing hydraulic lines, lower the work implement to the ground completely, shut down
the engine, screw 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 loosen the hydraulic oil tank
cover to release the internal pressure from the oil tank.
 Before removing the lines, connectors or hoses, make mark to prevent mistakes during
assembly. Clean the periphery of the assembled oil port if necessary, and put an oil receiving
plate to receive oil.
 Seal them with plugs or caps when the lines, connectors or hoses are in disassembling state
to prevent pollution sources from entering the hydraulic system.
Photo Steps
1. Rotate the revolving frame, and
evacuate a removal and installation
space for fuel tank and main control
valve bottom plates.
LG922E930E07125
7-42
7.5.3 Removal and installation of hydraulic oil tank June 10, 2015
2. Remove two fuel tank bottom plates (1).
LG922E930E07126
3. Place a barrel below the oil drain port of

the tank, remove the drain plug (2) and
drain the oil completely, and then
reinstall the drain plug back.
2
LG922E930E07127
4. Open the right door(3) of the engine

hood
5. Remove the dipstick (4), and remove the
pilot valve gp (5).
LG922D07049
7-43
June 10, 2015 7.5.3 Removal and installation of hydraulic oil tank
5
LG922D07050
6. Open engine hood (6).

7. Remove the front cover (7).
6 7 8. Remove the oil return pipe (8)
9. Remove the pump oil return pipe (9).
10.Remove the tube(10)
LG922D07051
9
8
10
LG922D07052
7-44
7.5.3 Removal and installation of hydraulic oil tank June 10, 2015
11.Remove 5 oil suction tube flange

mounting bolts (12), and remove 6 fuel
tank mounting captive bolts (13).
13
12
LG922E930E07132
12.Penetrate through the lifting eyes, and lift

and move the fuel tank to a clean and
safe place with a sling and a lifting
appliance.
Lifting weight: 173kg.
LG922E930E07133
Installation
• The tightening torque of the mounting bolts is: M16-10.9: 305±25Nm.
• The threads of mounting bolts shall be coated with Tonsan 1277 before installation.
• Refill hydraulic oil.
7-45
June 10, 2015 7.5.4 Removal and installation of main control valve as
7.5.4 Removal and installation main control valve bottom plates.
of main control valve as

the engine, screw the key to the KEY ON posi-
hydraulic system, and then press the exhaust
button of hydraulic oil tank breather valve to
release the internal pressure from the oil tank. LG922E930E07125

to receive oil.

sources from entering the hydraulic
system.
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank and
7-46
7.5.4 Removal and installation of main control valve as June 10, 2015
2. Remove the fuel tank bottom plates (1). 4. Remove the front cover plate (3).
1
3
LG922E930E07126 LG922E930E07134
3. Place a barrel below the oil drain port of the 5. Remove the bottom plate (4) under the main
tank, remove the drain plug (2) and drain the oil control valve.
completely, and then reinstall the drain plug
back.
2
4
LG922E930E07135
LG922E930E07127
7-47
June 10, 2015 7.5.4 Removal and installation of main control valve as
6. Remove the return tube (6); remove the pilot 8. Shift the main control valve out with lift equip-
hose (7) and the working port hose (8); ment such as a sling.
Lifting weight: about 220kg.
8
7
LG922E930E07136
LG922E930E07138
7. Remove the 3 captive bolts (10) of the main

control valve. Installation
removal sequence.
• Tightening torque of main control valve as
mounting bolts:
M12-10.9: 120±10Nm?
• The tightening torque of the pilot hose is:
M16×1.5: 26±2Nm
10
LG922E930E07137
7-48
7.5.5 Disassembly and assembly of main control valve as June 10, 2015
7.5.5 Disassembly and assem- though the removal is available based on the
structure. Prepare clean cleaning oil, working oil
bly of main control valve as and grease in advance.
Related drawings
Please refer to the structure drawing relating to Disassembly
the introduction of the main control valve in the  The number in the () after a part name
section "Structural function and service". The
represents a part number in the struc-
numbers involved below are subject to the part
ture drawing.
numbers in the structure drawing.
1. Place the control valve on an operation plat-
form.
Precautions
 Perform removal in a clean place. Do not
1) As hydraulic elements are precisely
damage the flange face.
machined parts, select an especially clean place
to carry out removal and installation.
2) In addition to such handling of the control
valve, be careful enough not to let dust and sand
intrude inside.
3) When removing the control valve from the
base machine, seal every interface with a cover.
Before removal, confirm again such covers are
completely installed, and thoroughly clean the
outside of the whole component as. Operation
should be performed on an appropriate opera-
tion platform. Before the operation begins, the
platform should be covered with clean paper LG922E930E07139
sheets or rubber plates.

4) The force support in carrying and moving the 2. The removal of the main spool: the travel
control valve should act on the solid positions of (301), bucket (304), rotation (305), optional
the body and should never act on the projecting (309), arm 2 (306), boom 2 (307) and rotation
positions such as the spool and spring cover. Be priority (311).
careful of the operation.
2.1 Loosen the inner hexagon bolt (273), and
5) Although various tests (such as the overflow remove the spring cover (201 or 202) and O-ring
properties test, internal leakage test and pas- (261).
sage loss test) can be carried out after the
2.2 Remove the spool, spring, spring holder
removal and assembly of elements, these must
(332), stopper (335 or 339) and bolt with liners
be carried out on a hydraulic test device. Do not
(336) from inside the valve body in the spool gp
perform removal in a place where test adjust-
state.
ments can’t be done due to restrictions, even
7-49
June 10, 2015 7.5.5 Disassembly and assembly of main control valve as
 When removing the spool gp from the

valve body, be careful not to damage the
valve body.
LG922E930E07142
3. Removal of boom 1 spool (303):

LG922E930E07140
3.1 Loosen the inner hexagon bolt (273), and
remove the spring cover (201) and O-ring (261).
3.2 Remove the boom 1 spool (303), springs
(320 and 328), spring holder (332), stopper
(335) and bolt with liners (336) from inside the
valve body A (101) in the spool gp state.

valve body A (101), be careful not to
damage the valve body.
3.3 Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such as
an aluminum plate) between the bench vice and
LG922E930E07141
the spool so that the boom 1 spool (303) is fixed.
Remove the bolt with liners (336) from the spool
2.3 Use a bench vice containing a shield over gp, and disassemble the spring (320 and 328),
the jaw to sandwich a protection plate (such as stopper (335) and spring holder (332).
an aluminum plate) between the bench vice and 3.4 After the removal of 3 items above, do not
the spool so that the spool is fixed. Remove the perform further removal of the boom 1 spool
bolt with liners (336) from the spool gp, and dis- (303).
assemble the spring, stop (335 or 339) and
spring holder (332).
7-50
LG922E930E07143 LG922E930E07144
4. Removal of arm 1 spool (302): 5. Removal of straight travel spool (308):

4.1 Loosen the inner hexagon bolt (273), and 5.1 Loosen the inner hexagon bolt (273), and
remove the spring cover (201) and O-ring (261). remove the spring cover (201) and O-ring (261).
4.2 Remove the arm 1 spool (302), springs (320, 5.2 Remove the straight travel spool (308),
328), spring holder (332), stopper (335) and bolt springs (322 and 323), spring holder (332), stop-
with liners (336) from inside the valve body B per (335) and bolt with liners (336) from inside
(102) in the spool gp state. the valve body A (101) in the spool gp state.
 When removing the spool gp from the  When removing the spool gp from the
valve body B (102), be careful not to valve body A (101), be careful not to
damage the valve body. damage the valve body.
4.3 Use a bench vice containing a shield over 5.3 Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such as the jaw to sandwich a protection plate (such as
an aluminum plate) between the bench vice and an aluminum plate) between the bench vice and
the spool so that the arm 1 spool (302) is fixed. the spool so that the straight travel spool (308) is
Remove the bolt with liners (336) from the spool fixed. Remove the bolt with liners (336) from the
gp, and disassemble the spring (320 and 328), spool gp, and disassemble the spring (322 and
stopper (335) and spring holder (332). 323), stopper (335) and spring holder (332).
4.4 After the removal of 3 items above, do not 5.4 After the removal of 3 items above, do not
perform further removal of the arm 1 spool perform further removal of the straight travel
(302). spool (308).
7-51
LG922E930E07145 LG922E930E07146
6. Removal of bypass stop valve (310): 7. Removal of spring covers (204.205.206)

6.1 Loosen the inner hexagon bolt (273), and • Loosen the inner hexagon bolt (273), and
remove the spring cover (203) and O-ring (262). remove the spring covers (204.205.206)
6.2 Remove the bypass stop spool (310), and O-ring (264).
springs (372 and 373), spring holder (331), stop- • When removing the bucket spool cover
per (337) and bolt with liners (333) from inside (206), first loosen the block (258) before
the valve body B (102) in the spool gp state. removing the spool cover from the valve
body B (102). Remove the plunger (211)
after removing the spool cover.
valve body B (102), be careful not to
damage the valve body.
6.3 Use a bench vice containing a shield over
the jaw to sandwich a protection plate (such as
an aluminum plate) between the bench vice and
the spool so that the bypass stop spool (310) is
fixed. Remove the bolt with liners (333) from the
spool gp, and disassemble the spring (372 or
373), stopper (337) and spring holder (331).
LG922E930E07147
8. Removal of main relief valve (601) and inter-

face relief valves (602.604):
• Remove the main relief valve (601) and
interface relief valves (602. 604) from valve
body.
7-52
• Main relief valve (601)

• Interface relief valve (602)
• Interface relief valve (604)
LG922E930E07150
9. Removal of lock valve selector pair (252):

• Loosen the inner hexagon bolt (252-171),
LG922E930E07148
and remove the lock valve selector pair
8.1 After the relief valves are removed from the (252) and O-ring (252-161).
valve bodies, do not perform further removal of • After the lock valve selector pair (252) is
the relief valves. removed from the valve body, do not per-
form further removal of the lock valve
selector pair.
252-171
LG922E930E07149
252-161
LG922E930E07151
7-53
LG922E930E07152 LG922E930E07154
10. Removal of negative control relief valve

(610)
• Remove the negative control valve (610)
267 266 269 265 231 253
from the valve body.
• After the negative control valve (610) is Pis
removed from the valve body, do not per-

form further removal.
Dr
P AR R
2-2 211 232

LG922E930E07155
12. Removal of logic control valve (251), rotary

logic valve gp (254) and arm 2 logic valve gp
(256):
12.1 Loosen the inner hexagon bolt (251-120),
and remove the logic control valve (251) and O-
rings (251-112.-113).
LG922E930E07153
12.2 Remove the rotary logic valve gp (254) and
11. Removal of arm regeneration stop valve arm 2 logic valve gp (256) from the valve body.
(257):
12.3 After the logic control valve is removed
Remove the bushing (257-253), spring (257- from the valve body and the logic valve gp are
231), spring holder (257-231), spool (257-211) removed, do not perform further removal.
and valve bushing(257-211) from the valve body
B (102).
7-54
13. Removal of check valve:

13.1-CP1,C2,CCb,LCb,LCo,LCk,LCa,LCAT2
LG922E930E07156
LG922E930E07159
13.2-CMR1,CMR2
• Remove the block (553), and then remove
the cone valve (512) and spring (521).
LG922E930E07157
251-112 251-101 LG922E930E07160
13.3-CRa,CRb
13.4-CCk,CCo
251-113 251-120 13.5 Remove the block (550), and then remove
LG922E930E07158 the steel ball (541), spring (543) and spring
holder (542).
7-55
LG922E930E07161 LG922E930E07162
14. Removal of flange (209) Removal after inspection

• Loosen the inner hexagon bolt (971), and Thoroughly clean all the removed parts with
remove the flange (209) and O-ring (165). clean mineral oil, and inspect them after they
15. Removal of plate (210): are dried by compressed air. Place all parts on
• Loosen the inner hexagon bolt (274), and clean paper or cloth.
remove the plate (210) and O-ring (165). Inspection of control valve
16. Removal of orifice plug for signal oil circuit: 1) Inspect the entire surface of each part. No
• Except special circumstances, do not gen- burrs, rough edges, drag marks, galling,
erally remove the block (151) and orifice scratches or other defects are allowed.
plug (156). 2) Confirm that the seal groove faces of the
17. Removal of valve body: valve body and valve block are smooth. Defects
17.1 Except special circumstances, do not gen- such as impurities, deformations, pits and corro-
erally remove the anchor bolt of the valve body sion are not allowed.
B (102). 3) If there are deformations and pits on the valve
17.2 As the plugs unrecorded in the above pro- seat surface of the check valve of the valve body
cedures are used for technological holes and and valve block, eliminate them in the abrading
valve body sanitary holes, do not remove them method.
except special circumstances.
 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 a spring in case of a break or defor-
7-56
mation. Assembly
6) When the relief valve acts ineffectively, repair The number in the () after a part name rep-
it according to the removal and assembly of the resents a symbol in the structure drawing.
relief valve.
Precautions in assembling O-ring seals
7) Replace all seals and O-rings with new ones.
1) Note that the seals must have neither forming
defects nor the scars generated in use.
Inspection of relief valve 2) Apply grease or working oil in the positions of
1) Make sure the spool and valve seat head seal the seals and similarly shaped seals to ensure
surface of each valve have no defects and the sufficient lubrication.
mating surfaces are in uniform contact. 3) Do not stretch the seals to permanent defor-
2) Make sure the spool and valve seat of the mation such that they cannot recover.
main valve are easily and freely slid by hand. 4) When installing an O-ring, do not install it in a
3) Make sure the spool outer circumferential sur- distorted way. A distorted O-ring is difficult to
face and valve seat inner circumferential surface naturally recover after being installed, which is
have no drag marks and galling. the cause of oil leakage.
4) Make sure the springs have no breaks, defor- 5) For the mounting bolts of all parts, fix them
mations or abrasion. with a tool such as a torque wrench according to
5) Make sure the damping holes of the spool the mounting torque as shown in Maintenance
and valve seat of the main valve are not blocked Criteria.
by impurities. 1. Installation of check valve:
6) Replace O-rings with new ones. 1.1 Install the cone valves (511.512.513.514)
7) When minor damage is found in the above and springs (521.522.523).
inspection, it can be eliminated in the abrading Install O-ring (561) in the plug (551.552), and
method. fasten it in specified torque.
8) When a defective part exists, replace the
relief valve by gp.
 The following is the assembly of combi-
nation of cone valve, spring and plug
used.
Cone Installatio
Spring Plug
valve n site
511 521 551 8 places
512 522 553 2 places
513 523 552 2 places
514 521 551 2 places
7-57
valve body (251-101) of logical control valve,

Inner Mounting fasten it in specified torque with hex bolt (251-
Plug
hexagon torque
No. 120) and the mounting torque is 49-65N·m.
spanner (Nm)
6. Installation of negative control relief valve
(551) 12mm 230~260
(610):
(552) 12mm 230~260
Install the negative control relief valve (610) in
(553) 10mm 130~150
the valve body, fasten it in the specified torque
1.2 Install the steel ball (541), spring holder shown in the following, and the mounting torque
(542) and spring (543): is 69-78N·m.
• Install an O-ring (166) on the plug (550), 7. Installation of arm regen stop valve (257):
fasten it in specified torque, and the mount- Install the valve bushing (257-212), spool (257-
ing torque is 25-29N·m. 211), spring holder (257-232), and spring (257-
2. Mounting plate (210): 231) on the valve body (102). Install the O-ring
• Install the O-ring (165) on Valve body B (257-265) on the bushing (257-253), fasten it in
(102), fasten the hex bolt (274) in the spec- specified torque, and the mounting torque is 69-
ified torque, and the mounting torque is 98- 78N·m.
120N·m. 8. Installation of lock valve selector valve (252):
• When the orientation of the board is down- Install the O-ring (252-161) on the lock valve
ward, change the orientation of the control selector valve (252), fasten it in specified torque
valve. with hex bolt (252-171), and the mounting
torque is 10-14N·m.
3. Installation of flange (209):
9. Installation of main relief valve (601) and port
• Install an O-ring (165) on the flange (209),
relief valve (602, 604);
fasten the hex bolt (971) in the specified
torque, and the mounting torque is 49-
65N·m. Install the main relief valve (601) and port relief
4. Installation of logical control valve (251) and valve (602, 604) on the valve body, and fasten it
rotary logical valve as (254): in the following specified torque.
4.1 Install the rotary logical valve gp (254) on the

Mounting
valve body B (102). Tool
torque
4.2 Install the O-ring (251-112.-113) on the Main relief
Wrench 32mm 69~79N·m
valve body (251-101) of logical control valve, valve (601)
fasten it in specified torque with hex bolt (251- Interface Wrench 32mm
relief valve or socket 69~79N·m
120) and the mounting torque is 49-65N·m.
(602) wrench 32mm
5. Installation of the logical control valve (251) Interface Wrench 36mm
and arm 2 logical valve gp (256). relief valve or socket 120~140N·m
(604) wrench 36mm
5.1 Install arm 2 logical valve gp (256) on the
valve body A (101).
5.2 Install the O-ring (251-112.-113) on the
7-58
10. Installation of straight travel spool (308): spool gp on the valve body A (101).
10.1 Use the bench vice provided with shield on  While installing spool gp on valve body
the vice jaw, sandwich guard plate (aluminum
A (101), do it slowly and prudently.
plate, etc.) between the bench vice and spool,
and fasten the intermediate part of the straight  Never push the spool into the valve
travel spool (308). Install the spring holder (332), body forcibly.
spring (322, 323), and stopper (335), fasten the 12. Installation of arm 1 spool (302):
bolt with liner (336) in specified torque, and the
12.1 Use the bench vice provided with shield on
mounting torque is 16-18N·m.
 Before installing the bolt with liner (336), plate, etc.) between the bench vice and spool,
apply #262 thread seal on it. and fasten the intermediate part of the arm 1
spool (302). Install the spring holder (332),
The straight travel spool (308) will deform if it is
spring (320, 328), and stopper (335), fasten the
sandwiched improperly, so do not clip the bench
vice too tightly.
10.2 Upon the assembly of item ① , install the
spool gp on the valve body A (101).  Before installing the bolt with liner (336),
apply #262 thread seal on it.
 While installing spool gp on valve body
The arm 1 spool (302) will deform if it is sand-
A (101), do it slowly and prudently.
wiched improperly, so do not clamp bench vice
 Never push the spool into the valve tightly.
body forcibly. 12.2 Upon installation of item ① , install the
11. Installation of boom 1 spool (303): spool gp on the valve B (102).
11.1 Use the bench vice provided with shield on  While installing spool gp on valve body
B (102), do it slowly and prudently.
and fasten the intermediate part of the boom 1  Never push the spool into the valve
spool (303). Install the spring holder (332), body forcibly.
spring (320, 328), and stopper (335), fasten the 13. Installation of main spool:
Travel (301), bucket (304), swing (305), backup
(309), arm 2 (306), arm 2 (307) and swing prior-
ity (311).
 Before installing the bolt with liner (336), 13.1 Use the bench vice provided with shield on
apply #262 thread seal on it. the vice jaw, sandwich guard plate (aluminum
The boom 1 spool (303) will deform if it is sand-
and fasten the intermediate part of each spool.
wiched improperly, so do not clamp bench vice
Install the spring holder (332), spring, and stop-
tightly.
per (335 or 339), fasten the bolt with liner (336)
11.2 Upon the assembly of item ① , install the
7-59
in specified torque, and the mounting torque is 15. Installation of cover:

16-18N·m. 15.1 Install the spool cover (204, 205 & 206)) on
 Before installing the bolt with liner (336), the side opposite to spring gp of the spool, fas-
ten the hex bolt (273) in specified torque, and
the mounting torque is 25-34N·m.
The boom spool will deform if it is sandwiched
improperly, so do not clamp bench vice tightly.  Verify that the O-ring (264) has been
13.2 Upon installation of item ① , install the installed on the spool cover
spool gp on the valve A (101) and valve B (102). (204.205.206).
15.2 Installation of bucket spool (206):
 When installing the spool gp on the
Install the plunger (211) in the bucket spool
valve A (101) and valve B (102), do it
cover (206). Install O-ring (561) on the plug
slowly and prudently.
(258), and fasten it in specified torque. After fas-
 Never push the spool into the valve tening it, install the bucket spool cover (206) in
body forcibly. the same way as that of item ① , and the mount-
ing torque is 150-180N·m.
14. Installation of bypass stop spool (310):
15.3 Install spring cover (201, 202 & 203) on the
14.1 Use the bench vice provided with shield on
spool spring gp, fasten it in the specified torque
with hex bolt (273), and the mounting torque is
25-34N·m.
and fasten the intermediate part of bypass stop
spool (310). Install the spring holder (331), Verify that the spring cover (201.202.203) has
spring (372, 373), and stopper (337), fasten the been provided with O-ring (261).
 Before installing the bolt with liner (333),

The bypass stop spool (310) will deform if it is
sandwiched improperly, so that protect the valve
body from being clamped too tightly with bench
vice.
14.2 Upon installation of item ① , install the
spool gp on the valve B (102).
 While installing spool gp on valve body

B (102), do it slowly and prudently.
 Never push the spool into the valve forc-

ibly.
7-60
7.5.6 Removal and installation of main pump as June 10, 2015

of main pump as
Removal

hydraulic system, and then press the exhaust LG922E930E07125
2. Remove the fuel tank bottom plates (1).

takes during assembly. Clean the 1
to receive oil.

system. LG922E930E07126
1. Rotate the revolving frame, and evacuate a 3. Place a barrel below the oil drain port of the
removal and installation space for fuel tank and tank, remove the drain plug (2) and drain the oil
main control valve bottom plates. completely, and then reinstall the drain plug
back.
7-61
June 10, 2015 7.5.6 Removal and installation of main pump as
5
6
2
7
8
LG922E930E07127 LG922E930E07164
4. Remove engine hood (3); remove plate (4). 6. Remove the oil drain (9) of the main pump;
remove pilot hose (10), remove pilot pump suc-
tion tube (11) and remove 2 high-pressure oil
pipes (12).
3
4
9
10
LG922E930E07163
12
5. Remove oil filter (5); remove plate (6) and (7);

remove engine oil filter holder (8); pull up har- 11
ness connected to the pump. LG922E930E07165
7. Remove suction tube (13).

7-62
7.5.6 Removal and installation of main pump as June 10, 2015
13
LG922E930E07166 LG922E930E07168
8. Lift up the main pump with sling and hoisting Installation

equipment, and remove 12 bolts on the mount-
Install the main pump in the reverse sequence
ing flange (14).
of removal.
Pay attention to the following technical require-
ments during installation:
The tightening torque of the main pump

mounting screw M20-10.9 is: 600±55Nm,
and apply the thread locker (Tonsan 1277)
14
on the screw thread before installation.
Tightening torque on the thread con-

nector of the angel with O-ring: G1/4:
37.5±2.5Nm; G3/8: 75±5Nm; G3/4:
165±15Nm.
Tightening torque on the thread con-

LG922E930E07167
9. Lift out the main pump and flange.

nector of 24° cone with O-ring: M16×1.5:
Lifting weight: 127 kg.
26±2Nm.
7-63
June 10, 2015 7.5.7 Disassembly and assembly of main pump as
7.5.7 Disassembly and assembly of main pump as

Part drawing of main pump
Part number involved in the chapter is based on the following drawing.

% ;

: =

<
$

%

$
LG922E930E07169
7-64
7.5.7 Disassembly and assembly of main pump as June 10, 2015
The disassembly of main pump as

is described in three parts in the fol-
lowing.
1. Disassembly of pump body
2. Disassembly of adjuster
3. Disassembly of pilot pump
1 Disassembly of pump body
1. Select the disassembly site.
 Select the cleaning site.

LG922E930E07170
Cover the operation platform with rubber plate or
cloth, etc., never collide the parts and protect 5. Unscrew the hex bolt with washer to remove
them from damage. the gear pump (04).
2. Remove the rubbish, rusting, etc. on the
pump surface with cleaning oil, etc.
3. Remove the oil plug (468) on the connector
where oil leaks to release all oil in the pump
housing (271).
 Remove the oil plugs on the front pump

and the rear pump.
4. Dismantle the hex bolt to remove the adjuster
and dismantle the hex bolt with washer to
remove PTO unit (05).
For the pump without PTO unit, dismantle hex
LG922E930E07171
bolt (414) to remove the lower cover (326).
6. Unscrew the hex bolts (401) connected to
 For the disassembly of adjuster, refer to
swashplate supporting platform (251), pump
the service and maintenance specifica- housing (271) and oil distributor (312).
tions for adjuster.
 For the disassembly of PTO unit, refer to

the service and maintenance specifica-
tions for PTO unit.
7-65
 While separating pump body and oil dis-

tributor, remove the first gear (116) at
the same time.
LG922E930E07172
7. Put the regulator on the operation platform

horizontally with the fitting surface downward,
and separate the pump housing (271) and oil LG922E930E07173
distributor (312). 8. Pull out the cylinder body (141) from pump
housing (271) straightforwards based on the
 While the fitting surface of the regulator
drive shaft (111.113), and meanwhile remove
is downwards, rubber plate, etc. must
the plunger valve (151.152), return plate (153),
be laid on the operation platform so as
sphere bushing (156), and return spring (157).
to protect the fitting surface from colli-
sion.  Protect the sliding surface of cylinder
body, sphere bushing, shoes, and
swashplate from being damaged.
LG922E930E07174
7-66
9. Dismantle hex bolt (406) to remove the cap 11. Remove the shoe plate (211) and swash-
(F) (261). plate (212) from the pump housing (271).
 A hole (M6 bolt) used for pulling out is

provided on the cap (F), so the cap can
be pulled out easily after a bolt is
installed.
 Because oil seal is installed on the cap

(F), protect the oil seal from being dam-
aged during removal.
LG922E930E07177
12. Knock the fitting flange part of the swash-

plate supporting platform (251) on the pump
housing side gently to separate the swashplate
supporting platform and the pump housing.
13. Remove the plate (313.314) from the oil dis-
tributor (312).
Remove link stopper (L) (534), link stopper (s)
LG922E930E07175
(535), servo plunger (532) and tilt pin (531) from
10.Knock the rear end of the drive shaft
the pump housing (271) in accordance with the
(111.113) gently so as to separate the drive
necessity. What’s more, remove the needle
shaft from swashplate supporting platform (251).
bearing (124) from the oil distributor (312).
 While removing tilt pin, protect the head

of the tilt pin from being damaged and
remove it with clamp.
 Because anaerobe is applied on the

cooperating part of tilt pin and servo
plunger, protect the servo plunger from
being damaged.
 Except for considering the bearing life

of needle bearing, try not to disassem-
ble it.
LG922E930E07176
 Never unscrew the hex bolts on oil dis-

7-67
tributor and swashplate supporting plat- (630), hex nut (801.802), and adjusting
form randomly. Otherwise the flow set screw (924).
already will change.
 Never loosen these bolts or nuts. If they
 While carrying out the 7th operation, are loosened, the pressure—flow set
there is falling off, so pay attention to it. already will change.
LG922E930E07179
LG922E930E07178
4. After removing the cap (C) (629), remove the
2. Disassembly of regulator outer ring spring (625), inner ring spring (626)
For the part number involved in the following, and spring holder (C) (624) from the compensa-
refer to the part drawing of regulator in the main tor part, and pull out the regulating ring (Q)
pump as introduction of "structure function and (645), guide spring (646) and spring holder
maintenance". (644) from the pilot part.
1. Select one disassembly site.
 It is easy to remove the regulating ring
 Select one cleaning site. by using M4 bolt (Q) (645).
 In order to protect the parts from being

damaged, rubber plate or operation-
used cloth, etc. shall be laid on the oper-
ation platform.
2. Wash out the dust, rust, etc. on the surface of
regulator with cleaning oil.
3. Dismantle hex bolt (438), and remove the cap
(C) (629).
 The cap (C) (629) has been provided

with adjusting wheel (C) (627), adjusting
bolt (C) (628), locknut (630), hex nut LG922E930E07180
7-68
5. Remove hex screw (436438), and remove the 7. After removing lock ring (858), remove center
pilot cover (641); after removing pilot cover plug (614) and adjusting plug (615).
(641), please take out the pin (898) and Pf bush-
 It is easy to remove center plug (614)
ing (631) from the compensator, and then
and adjusting plug (615) with M6 bolt.
remove the set spring (655) from the pressure
regulator part.
LG922E930E07183
8. Remove lever (2) (613), but do not pull out pin

LG922E930E07181
(875).
6. Remove backup ring (814), spring holder

 It can make the operation easier to use a
pair of tweezers.
(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. Pro-
tect the reset spring from losing.
LG922E930E07184
9. Push out pin (874), and remove feedback

rod (611).
Push out pin (874) (pin diameter φ4) with slimsy
steel bar, and meanwhile, avoid hitting rod (1)
LG922E930E07182
(612).
7-69
3. Disassembly 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.
LG922E930E07185
10. Remove lever (1) (612), but do not pull out 1

pin (875).
11. Remove pilot plunger (643) and spool (652).
12. Remove plunger bushing (622), compensa-
tor plunger (621) and compensator rod (623).
These are the complete operating steps.
LG922E930E07187
 During removal of plunger bushing

2. Place the pilot pump shaft end (2) down-
(622), it can be extruded from the com- wards.
pensator rod (623) end on the opposite
side to plunger bushing (622).
 Because input shaft of pump is more
protuberant than fitting surface, it is
best to provide supporting objects on
the two ends of the fitting surface.
LG922E930E07186
LG922E930E07188
7-70
3. Remove four mounting screws (3) on the 5. Put the upper cover aside. Remove O-ring
pump cover from the upper end. carefully.
 The damaged O-ring cannot be reused.
2ශാ
LG922E930E07189
4. Pull out the upper cover (4) of pilot pump LG922E930E07191
upwards slowly and gently. 6. Grasp one end of driven gear, and pull out the
 Be careful not to damage the mounting driven gear (5) straight up slowly.
surface.  Mark the direction and make sure to pull

it out from the fitting direction of driven
gear.
 Protect supporting shaft on two ends of
4 gear and the fitting surface matched

with it from damage.
LG922E930E07190
LG922E930E07192
7-71
7. Grasp one end of drive gear, and pull out the Assembly
driven gear (6) straight up slowly.
Precautions:
 Mark the direction and make sure to pull 1. Repair sections damaged during removal,
it out from the fitting direction of drive and prepare replacement parts in advance.
gear. 2. Clean out each component with cleaning oil
thoroughly, and blow it to dry with compressed
 Protect supporting shaft on two ends of
air.
gear and the fitting surface matched
3. Assembly must be carried out after the slide
with it from damage.
part and bearing are applied with clean working
oil.
4. Seals such as seal O-ring, oil seal shall be
6 replaced in principle.
(1) Assembly of pump body

The assembly sequence is just opposite to the
removal sequence. Pay attention to the assem-
bly of the following items.
LG922E930E07193
7-72
Mounting torque table (2) Assembly of regulator

Notice: apply clean hydraulic oil on component
Mountin surface to get lubrication effect before assem-
Specifi g bly.
Parts name Name (mm)
cations torque
(N·m) 1. Select the assembly site.
Hex bolt M5 6.9 B=4  Select one cleaning site.

(Texture
SCM435)
M6 12 5  In order to protect the parts from being
M8 29 6 damaged, rubber plate or operation-
M10 57 8 used cloth, etc. shall be laid on the oper-

ation platform.
Hex.
M12 98 10
wren 2. Install compensating rod (623) into compen-
M14 160 12 sating hole of housing (601).
3. Snap the pin (875) installed on lever (1) (612)
M16 240 14
into the slot of compensating rod (623), and then
M18 330 14
snap lever (1) (612) into pin (876) embedded on
M20 430 17 housing (601).
PT heavy
bolt
Rc1/16 6.9 4  Please make sure that spool (652) and
(Texture valve bushing (651) can not get stuck in
Rc1/8 10 5
S45C) housing (601), and they can slide neatly.
Note: twine
it with Rc1/4 17 6 Ditto Pay attention to the installation direction of spool
sealing tape (652).
1.5-2 circles Rc3/8 34 8 5. During installation of feedback rod (611),
Rc1/2 49 10 insert it after aligning pin (874) to the pin hole on
feedback rod (611).
ROH oil
G1/4 36 6
plug  It is easy to operate to insert a part of
G3/8 74 8
pin (874) into feedback rod (611) in
(Texture advance.
G1/2 110 10 Ditto
S45C)
G3/4 170 14  Pay attention to the direction of feed-
G1 190 17 back rod (611) and do not make mistake.
G11/4 270 17
On the occasion where pumps are in series,

components of front pump and rear pump shall
not mix together.
7-73
6. Install pilot plunger (643) into the hole for pilot 8. Align pin (876) pressed into center plug (614)
plunger (643) of housing (601). to pin hole of lever (2) (613), install it into center
plug (614), and then install lock ring (858).
 Make sure that pilot plunger (643) can
not be stuck in housing (601), and it can
slide neatly.
LG922E930E07196
9. Install adjusting bushing (615), and then

LG922E930E07194 install lock ring (858).
 Note not to install the adjust plug (615)

7. Snap pin (875) pressed in lever (2) (613) into into the mounting hole of the center
the slot of pilot plunger (643), and then install plug (614).
lever (2) (613).
 At this time, shake feedback rod (611) to
make sure there is no serious waggle
and no failure such as getting stuck.
LG922E930E07195
LG922E930E07197
7-74
10. Install reset spring (654) and spring holder 12. Install spring holder (Q) (644), pilot spring
(653) into the hole of spool (652), and then (646) and regulating wheel (Q) (645) in the pilot
install backup ring (814) on spool (652). hole, and install spring holder (C) (624), internal
spring (626) and external spring (625) in the
compensating hole.
 Pay attention to the orientation of spring

holder (Q) (644).
LG922E930E07198
11. 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 respec- LG922E930E07200
tively. 13. Install adjusting screw (C) (628), regulating

 Make sure the compensating plunger wheel (C) (627), locknut (630), hex nut (801),
and hex positioning screw (924) installed on
(621) and pin (898) are not stuck and
cover (C) (629) together on housing (601), and
they can move flexibly.
fasten them with hex bolts (438).
11.1 Upon installation of pilot valve (641), install
and fasten it with hex bolt (436), (438).
LG922E930E07201
LG922E930E07199
7-75
June 10, 2015 7.5.8 Removal and installation of foot pilot valve as
(3) Assembly of pilot pump 7.5.8 Removal and installation

The assembly sequence is opposite to that of
disassembly.
of foot pilot valve as
Mounting torque: Removal
S/N Name
Specifica
tions
Tightening
torque

1 Bolt M8X60 17N.m implement to the ground completely, shut down
2 Bolt M8X50 17N.m the engine, screw the key to the KEY ON posi-

to receive oil.

system.
1. Remove bottom plate (1) under foot pilot.
7-76
7.5.8 Removal and installation of foot pilot valve as June 10, 2015
3. Remove 2 connectors (3).
LG922E930E07202
2. Remove 6 pilots (2). LG922E930E07204
4. Remove step (4) with cross screwdriver;

remove floor mat (5) and rubber pedal (6).
5
4
LG922E930E07203
LG922E930E07205
7-77
June 10, 2015 7.5.8 Removal and installation of foot pilot valve as
5. Remove 4 bolts with wrench to remove pedal Installation

(7).
Install foot pilot valve in the steps opposite to
that of removal.
Tightening torque of connector:

36±2Nm;
Tightening torque of hose connector:

26±2Nm;
7
LG922E930E07206
6. Remove 4 captive bolts (8) and then remove

foot pilot valve upwards.
LG922E930E07207
7-78
7.5.9 Disassembly and assembly of foot pilot valve June 10, 2015
7.5.9 Disassembly and assembly of foot pilot valve

Part drawing of foot 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
52
52 213
213
501
521 215
215
311
423 214 311
420 335
52 224 335
52 501 214
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
52 336 211 131 153
52 471 471 225 103
201 213
220
225
431 421 151
413
52 201
52 412
112
220 151
412
431 413 131
103
134
102
163
153
LG922E930E07208
7-79
June 10, 2015 7.5.9 Disassembly and assembly of foot pilot valve
S/N Part No. S/N Part No.

101 Housing 301 Slide valve
102 Housing 311 Spring seat
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 Grease fitting 412 Shaft bushing
210 Grease fitting 413 Cam shaft
211 O-ring 420 Cam
212 O-ring 423 Positioning screw
213 O-ring 431 Seat
214 Push rod 471 Positioning screw
215 Washer 472 Locknut
217 Washer 473 Hex bolt
218 Spring seat 501 Rubber sleeve
220 Hex bolt 520 Pedal
224 Piston 521 Step bushing
225 Steel ball 522 Hex bolt
271 Hex screw
7-80
Disassembly 1. Clean the pilot valve with white kerosene.
Special tool  All connectors are sealed with plugs.

For removing bushing 2. Fix the pilot valve on the bench vice with buf-
fer plate (the copper plates or other soft plates).
Remove the step cover (521) from step (520).
&HQWHUKROHDOORZDEOH EHORZɎ
Remove it from the upward side.
521
520
(1) There shall be a capacious site to place the

removed components and parts. Prepare a sta-
ble operation platform where components and LG922E930E07210
parts will not fall off and roll during operation. 3. Loosen the hex bolt (522) with the inner hexa-
(2) Prepare tools and related data. gon spanner, and remove the pedal (520).
(3) All components and parts have been pro-
cessed precisely. Operating with caution, handle
with care and do not crash or drop the compo-
nents.
(4) Do not consider that all components and
parts are solid and firm. During removal, the
excessive beat, pry and cut will lead to trimming,
deformation and damage, which causes unable
to assemble, oil leak as well as performance
reduction. Therefore, operate with cautions and 522
patience.
(5) No corresponding disposal after removing, or LG922E930E07211
random placement in removing midway, will

cause rusted components and parts because of
humidity and impurity. When the operation must
be interrupted, pay attention to adopting the
measures of rust protection and dust prevention.
7-81
4. Loosen the hex bolt (473) with the inner hexa- 6. Unscrew positioning screw (423) with inner
gon spanner, and remove the seat (431). hexagon spanner.
 As it is coated with anaerobe #241, the

torque to loosen is large.
431
473
423
LG922E930E07212
5. Remove rubber bushing (501) from valve cap

(201) from the upper side. LG922E930E07214
7. Align the round rods (below φ8) with the one

end of the cam shaft (413), and then beat it with
501
hammer to remove it.
201
413
LG922E930E07213
LG922E930E07215
7-82
8. Unscrew locating screw (471) and locknut 10. Remove valve cap (201).
(472) on the cam (420), and remove them in
 Record the position relationship
pair.
between the valve cap and the buffer
 Record the position relationship housing (102).
between the cam and valve cap (201).
 During removal, please note the push
 During removal, please note the push rod (214) and push rod bushing (202)
rod (214) may be ejected. may be ejected because of the elastic
forces of the buffer springs (336), (337).
(The push rod bushing may not be ejected from
buffer housing because of the sliding resistance
420
of the O-ring (212))
472
471
201
102
LG922E930E07216
9. Unscrew the hex screw (271) with the inner

hexagon spanner.
LG922E930E07218
11. Remove push rod (214) from plug (202).
271  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 plug can pop.
LG922E930E07217
7-83
13. Remove the plunger (224) from the buffer

housing.
214
202  Record the position relationship
between the plungers and the buffer
housing holes.
224
LG922E930E07219
12. Remove plug (202) together with lubricating

oil cup (203) and NHU oil cup (210).

between the plug and the buffer hous-
ing. LG922E930E07221
 During removal, please note the plunger

may be ejected because of elasticity of
the buffer spring.
202
203
210
LG922E930E07220
7-84
14. Remove the buffer springs (336), (337) from 16. Take out the steel ball (225) with magnet,
the buffer housing. etc.
 Record the position relationship  Keep the steel balls well. Do not lose
between the buffer spring and the buffer them.
housing hole.
225
336
337
LG922E930E07224
LG922E930E07222
17. Loosen the hex bolt (220) with the inner
15. Remove the spring seat (218) from the buf- hexagon spanner.
fer housing.

between the spring holder and the buf-
fer housing hole.
220
218
LG922E930E07225
LG922E930E07223
7-85
18. Remove the buffer housing (102). 20. Remove the pressure reducing valve gp and
Record the position relationship between the reset spring (335) from the housing.
buffer housing and the housing (101).  Record the position relationship with
 During removal, please note the pres- the housing hole.
sure reducing valve gp can be ejected
because of the elastic force of the reset
spring (335).
335
102
335
101 LG922E930E07228
LG922E930E07226
19. Remove the O-ring (211) and the O-ring

(213) from the valve body.
211
213
LG922E930E07229
LG922E930E07227
7-86
21. Place the valve cap (201) on the platform 23. Removal of Pressure Reducing Valve GP.
horizontally, then align the special tool 1 to the Please vertical upright the slide valve (301) and
bushing (412), knock it gently with the hammer, place it on the flat operation table, depress the
and remove the bushing. spring holder (311), and then remove the 2
round washers (215) with the head of a small
straight screwdriver.
 Be careful not to damage the surface of

the slide valve.
201
 The depressing scope should not be
more than 4mm for the spring holder.
311
LG922E930E07230
301
22. Fix the cam gp on the bench vices, loosen
the locknut (472) with spanner, and remove the
locknut and locating screw (471).
 Neutral position must be adjusted to

assemble the locating screw. If it is not
necessary to replace the position screw, LG922E930E07232
keep it in the cam gp form in following 24. Separate washer (215) of the slide valve
process. (301), spring holder (311), spring for secondary
pressure setting from washer (313) with spring
(324).
471  Keep it well in the gp form until assem-
bling.
472  Washer (215) is used for presetting and

adjustment of spring for secondary
pressure setting; the thickness of each
slide valve is different. It may also not
be used.
LG922E930E07231
7-87
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.
215 324
313
202
LG922E930E07233
25. Remove lubricating oil cup (203) from plug

(202).
LG922E930E07235
27. Remove seal O-ring (212) from plug (202).

203
212
202
LG922E930E07234
202
LG922E930E07236
7-88
28. Fix the housing (101) on the bench vice with 30. Take out the steel ball (194) from the hous-
buffer plates (the copper soft plate, etc.), and ing(101). (Only for PVD8PC)
then loosen the oil plug (153) with inner hexa-
 Remove the steel ball with magnet.
gon spanner. (Only for PVD8PC)
101 101
194
153
LG922E930E07239
LG922E930E07237
29. Pull out the valve seat (191) from the hous-
ing (101). (Only for PVD8PC)
212
202
LG922E930E07236
7-89
Cleaning of components and parts Assembly

• Put all components and parts into a coarse Precautions:
cleaning container with white kerosene, (1) The same as removal, ready the operation
and clean them. (Coarse cleaning) platform, tools and related data.
• Cleaning all components and parts in dirty (2) During removal, give the same attention to
oil initially, will damage components. Clean normal precautions.
after components and parts are fully (3) During assembly, remove all flitters and for-
steeped, and impurity and grease are eign matters of all parts. In addition, confirm that
floated. there are no flashes, scratches, impact marks,
• The unclean white kerosene will damage etc. on the components and parts. If there is
components and parts and reduce the per- above-mentioned situation, please remove it
formance after reassembly, therefore keep with oil stone.
the white kerosene clean completely. (4) In principle, replace with new products for
• Put all components and parts into a clean- the O-ring and NHU seal ring.
ing container with white kerosene, and (5) When installing the O-ring and NHU seal
clean while rotating them until the inside is ring, pay attention not to damaging them. (For
clean (after cleaning operation). Clean the easy assembly, please apply little grease)
white kerosene adhering on components (6) When assembling components and parts,
and parts with clean cone screw. please use grease to prevent dropping.
• If drying with compressed air, the compo- (7) Fasten the bolts, etc. according to mounting
nents and parts can be damaged and torque as shown in assembly sectional diagram.
rusted because of impurity and moisture in (8) After finishing assembling, all connectors
compressed are, so do not use it. shall be sealed with plugs to prevent impurity.
Rust protection of components and parts.
• Apply antirust agent on components and 1. Fix the housing (101) with buffer plates (the
parts. copper plates and other soft materials) on the
• After cleaning, placing them without rust bench vice, and install the steel ball (194) into
prevention will result in rust. And the func- the housing (101). (Only for PVD8PC)
tion will not be played fully after reassem-
 Attract the steel balls to the weak mag-
bling.
nets, or install them with tweezers, etc.
7-90
101
194
153
LG922E930E07240
LG922E930E07242
2. Install the valve holder (191) into housing
4. Install washer (313), washer (217), spring
(101).
(324) for secondary pressure setting, and spring
(Only for PVD8PC)
holder (311) to the slide valve (301) in
sequence.
101  The washer 2 is used for presetting and
adjustment of spring for secondary
191 pressure setting. The thickness of each
slide valve is different. It may also not
be used.
LG922E930E07241
301
3. Install oil plug (153) according to the specified 313 324
torque. 217
(Only for PVD8PC)
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.
7-91
 Make the acute angle side (no arc side) 6. Install the reset spring (335) into valve body.
of washer 1 face upward. Be sure not to  Install it according to the position before
force to install the slide valve head or removal.
install improperly.

335
 Make the acute angle side (no arc side)

of washer 1 face upward. Be sure not to
force to install the slide valve head or
install improperly.

LG922E930E07246
7. According to above No.4 item, install the

pressure reducing valve gp of gp form into the
valve body.
 Install it according to the position before

311
removal.
215
301
LG922E930E07244
LG922E930E07247
Acute angle side

 8. When installing pressure reducing
valve gp, note not let the lower end of
slide valve to excessive impact the
valve angle.
7-92
10. Install the buffer housing (102) and housing

(101) together with hex bolt (220), and fasten
them according to the specified torque.
Note the valve body corner

removal.
 The two hex bolts (220) shall be equably

screwed into the buffer housing (102) to
keep buffer housing is fastened in paral-
lel.
9. Install the O-ring (211) and O-ring (213) on

the valve body.
213 220
211
102 101
LG922E930E07250
11. Attract the steel ball (225) to the weak mag-

net, or install it into the buffer housing (102) with
tweezers, etc.
LG922E930E07249
225
102
LG922E930E07251
7-93
12. Install the spring seat (218) into buffer hous-  Note not to make it engage with the buf-
ing.
fer housing (336).
removal. 337
218
LG922E930E07254
15. Install piston (224).

LG922E930E07252
Install it according to the position before
13. Install the buffer spring (336) into buffer
removal.
housing.
 Install it according to the position before 224

removal.
336
LG922E930E07255
LG922E930E07253
14. Install the buffer spring (337) into buffer

housing.

removal.
7-94
16. Install O-ring (212) onto the plug (202). 18. Install lubricating oil cup (203) into push rod
bushing.
212
203
202
LG922E930E07256
17. Install NHU oil cup (210) into push rod bush- LG922E930E07258
ing. 19. Install the push rod (214) into the push rod
bushing.
 When installing NHU seal ring, pay
attention to the direction.  The push rod surface shall be applied
with hydraulic oil before installing.
 It is easier to install it when NHU seal
ring is applied with a layer of grease  Do not force to insert the NHU seal ring
before installing NHU seal ring. to prevent damaging the lips.
210
214
LG922E930E07257 LG922E930E07259
7-95
20. According to (15) (16) (17) (18) items, the 22. Install the cover to the buffer housing.
push rod gp shall be installed into buffer housing
in the gp form.
removal.
 Note the cover may be ejected because

of the elastic force of the buffer springs
(336), (337).
LG922E930E07260
21. Compress the bushing (412) on the valve

cap (201) with special tool 1, and then knock it
with hammer to press it into the cover.
LG922E930E07262
 When compressing the bushing, note

not to knock out the inner side of cover.
201
412
LG922E930E07261
7-96
23. Install and fasten the hex bolt (271) accord- 24. Install the cam (420) on the cover.
ing to the specific torque.
 The cover should be installed in the hor- removal.
izontal state without deflection.
 Install the locating screw (471) to the

cam (420), and install the locknut (472) 420
temporarily.
271
LG922E930E07265
25. Press the cam (420); meanwhile insert the

camshaft (413) into the cam from outside.
LG922E930E07263
420
413
471 472
LG922E930E07266
LG922E930E07264
7-97
26. The surface of the hex locating screw (423) 28. Adjust the height of the locating screw (471),
shall be applied with the thread locker #241 or parallel the cam (420) upside with the cover
other appropriate objects. underside, and turn the cam right and left. After
confirm that the cam will not be loose in the neu-
tral position, install and fasten the locknut (472)
according to the specified torque.
 Adjust the 4 push rods (214) to an

appropriate position with locating
screw. When turning over the locating
screw, the control lever shall be loose in
423
the neutral position and acute move-
ment will happen when starting the
engine and attention shall be paid to
this.
LG922E930E07267
27. Install and fasten the hex locating screw

(423) according to the specified torque.
423
LG922E930E07269
LG922E930E07268
7-98
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. 501
 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.
LG922E930E07271
31. Install the seat (431), and install and fasten

the hex bolt (473) according to the specified
torque.
431
473
LG922E930E07270
30. After inserting the upper end of rubber cover

(501) into cam, insert the lower end into the slot
of cover.
 Before the rubber bushing lower end is

inserted into the cover groove, spray LG922E930E07272
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.
7-99
June 10, 2015 7.5.10 Removal and installation of hand pilot valve as
32. Install the pedal (520), and install and fasten 7.5.10 Removal and installation
the hex bolt (522) according to the specified
torque. of hand pilot valve as
Removal of hand pilot valve as-lh.

522
520
LG922E930E07273  Before removing the lines, connectors
33. At last, install the pedal cover (521) on the or hoses, make mark to prevent mis-
pedal (520). takes during assembly. Clean the
to receive oil.

521 sources from entering the hydraulic
system.
1. Pull out rubber jacket (1) of pilot valve, unplug
wire (2), remove locknut (3) of control lever, and
then remove the control lever.
LG922E930E07274
7-100
7.5.10 Removal and installation of hand pilot valve as June 10, 2015
3. Remove the 4 fixing bolts (5) from hand pilot.
1 5
3 2
LG922E930E07275
2. Remove four mounting bolts (4) on handrail LG922E930E07277
box, and remove cover of handrail box. 4. Pull out hand pilot slightly, and remove 6 pilot
pipes (6).
5. Remove the hand pilot valve.
4
LG922E930E07276
6
LG922E930E07278
7-101
June 10, 2015 7.5.10 Removal and installation of hand pilot valve as
Installation of hand pilot valve-lh.

• Install the hand pilot valve-as according to opposite steps of removal. Wherein tightening torque of
connector: 36±2Nm;
• Tightening torque of hose connector: M18×1.5: 37±2Nm.
Removal and installation of hand pilot valve-rh

By referring to removal and installation of hand pilot valve-lh, remove and install hand pilot valve-rh.
7-102
7.5.11 Disassembly and assembly of hand pilot valve as June 10, 2015
7.5.11 Disassembly and assembly of hand pilot valve as

Part drawing of hand pilot valve
The 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 accor-
dance with the corresponding type.
The part number involved in the section shall be based on the following drawing.
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
Type PV48K1
7-103
June 10, 2015 7.5.11 Disassembly and assembly of hand pilot valve as
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
Type PV48KC1
(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. There-
fore, please operate with caution and patience.
(3) Suggest continuous operating. If the operation is interrupted, please adopt the rust-proof and dust-proof
measures.
7-104
Disassembly 5. Rotate the connector (301) to the left with

clamp and then loosen it.
1. Clean the pilot valve with white kerosene.
 Seal the connectors with plugs.

 When the elastic force of the reset
spring (221) is large, the cover (151), the
2. Fix the pilot valve on the bench vive.
push rod bushing (211) and the push
3. Remove the ripple protection cover (501).
rod (212) may be ejected at the time of
 Do not damage the ripple protection unscrewing the connector (301). When
cover (501). pulling out the connector, they may also
be ejected out.
501
301
212
211
LG922E930E07281
LG922E930E07283
4. Clamp distance between the adjusting nut

(312) and the disk (302) with spanner. Remove
adjusting nut and disk.
312
302
LG922E930E07284
LG922E930E07282
7-105
6. Remove the cover (151).
151 101
LG922E930E07286
LG922E930E07285
8. Pull out the push rod (212), push rod bushing

7. The push rod bushing (211) may be blocked
(211), the pressure reducing valve gp and reset
in the valve body (101) because of the weak
spring (221) from the valve body (101).
reset spring (221) and the O-ring slide resis-
tance, and please remove it with a straight  Record the position relationship of the
screwdriver. valve body holes.
 Utilize the bushing peripheral groove
under the condition of the bushing (211)
not being damaged result from deflec-
tion.
 Note the push rod bushing (211) may be

ejected because of the elastic force of
the reset spring (221). 221
LG922E930E07287
9. Keep the interface plate (111) upward, and fix

the pilot valve on the bench vice with the copper
plate.
10. Loosen the oil plug (293) with inner hexagon
spanner.
(Only for PV48KC1)
7-106
111
293
292
LG922E930E07288 LG922E930E07290
11. Pull out the valve seat (291) from the inter-
Hook the valve seat and pull it backward as
face plate (111). shown in the following figure.Do not damage
the junction surface of the steel ball.
(Only for PV48KC1)
Steel ball
Valve
seat
291
LG922E930E07289
12. Remove the steel ball (292) with the magnet

or other similar objects from the interface plate
(111). (Only for PV48KC1)
7-107
13. Loosen the hex bolt (125) with the inner

hexagon spanner.
122
125
LG922E930E07294
LG922E930E07292
16. For removal of the pressure reducing valve,
depressing the spring holder (216) to compress
14. Remove the interface plate (111) O-ring the secondary pressure spring (241) and mean-
(122) from the valve body (101). while make the spring holder (216) crosswise a
15. Pull out the bushing (131) from the valve bit and pass via the bigger hole side, and then
body (101). remove the slide valve (201).
Then separate the slide valve (201), the spring
holder (216), the secondary pressure spring
(241) and the washer (217).
• Be careful not to damage the surface of the
slide valve (206).
• The room for further compressing of the
spring holder (216) is no more than 6 mm.
• Keep it well in the gp form until reassembly.
LG922E930E07293
7-108
17. When installing the spring (246) and spring

holder (218) of two segmented breaking,
131
remove it from the push rod (212).
216
241
LG922E930E07295
206
217
LG922E930E07297
18. Pull out the push rod (212) from push rod
bushing (211).
LG922E930E07296
211 212
LG922E930E07298
7-109
19. Remove the O-ring seal ring (214) and seal Precautions for cleaning the com-
ring (213) from the push rod bushing (211) with
ponents:
small straight screwdriver or other tools.
(1) Put components and parts into a cleaning
container filled with white kerosene and clean
214 them roughly.
(2) Put components and parts into a cleaning
container filled with white kerosene, rotate and
clean them until insides of them are completely
clean. Wipe up white kerosene adhering to com-
ponents and parts with clean rag after cleaning.
(3) Components and parts need soaking suffi-
ciently, and clean them after impurities and
grease float.
(4) Unclean white kerosene can damage com-
LG922E930E07299
ponents and parts cause degradation of their
performance after assembled, so it shall guaran-
tee the cleanness of white kerosene.
(5) Impurities and moisture in compressed air
can cause rust, therefore do not dry them with
compressed air.
213
LG922E930E07300
7-110
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) During assembly, remove all flitters and foreign matters of all parts. In addition, confirm that there are no
flashes, scratches, impact marks, 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 lit-
tle lubricating grease for easy installation and smoothness)
(4) When assembling components and parts, use grease to prevent dropping.
(5) After finishing assembling, all connectors shall be sealed with plugs to prevent impurity.
The figure below shows tightening torque value of mounting torque of bolts, etc. Measure mounting
torque value with torque wrench.
Thread
Functional Mounting torque
Tool Size (mm) specificatio
parts (N·m)
n
Inner hexagon spanner 6 Hex bolt M8 20.6±1.5
Inner hexagon spanner
Only (PV48KC1 5 ROH oil plug G1/8 11.8±1.0
specification)
22 Adjusting nut M14
Wrench 68.6±4.9
32 Disk M14
Special clamp is shown in
figure 24 Fitting M14 47.1±2.9
LG922E930E07283.
7-111
1. Place mounting surface of interface plate

(111) upward and fix the pilot valve with the cop-
per board. 125
2. Install bushing (131) and O-ring (122) on
valve body (101).
122
111
LG922E930E07303
4. Fix hex bolts (125) with an inner hexagon

spanner according to specified torque.
 While installing, screw them in pairs

alternately and slowly.
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 posi-

tion, when assemble the spring pin (126)
in the hole of the valve body(101).
 The gasket(121) shall be replaced with a

new one.
LG922E930E07304
5. Install the steel ball (292) into the interface

plate (111) with magnet. (PV48KC1)
126
LG922E930E07302
7-112
6. And then install the valve seat (291) into the

interface plate (111). (Only for PV48KC1)
293
292
LG922E930E07307
8. Install washer 2(217), secondary pressure

LG922E930E07305 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
291 spring holder (216) is no more than 6

mm.
LG922E930E07306
7. Fix the oil plug (293) as per specified torque

with an inner hexagon spanner. (Only for
PV48KC1)
201 217 241 216
LG922E930E07308
7-113
10. Install O-ring (214) onto the oil plug (221).
214
221
LG922E930E07309
9. Install the reset spring (221) into the valve LG922E930E07311
body (101). Install pressure reducing valve gp 11. Install the seal ring (213) onto the push rod
into the valve body (101). bushing (211).
 Install it according to the position before  Please install the seal ring (213) in lip
removal. direction as shown in the figure below.
211
213
221
101
LG922E930E07310 LG922E930E07312
7-114
12. Install the push rod (212) into the push rod
bushing (211).
If there is a spring (246) and a spring holder
(218) used for two segmented breaking, install
246
them onto the push rod (212).
 Apply working oil onto the surface of

the push rod (212).
Push rod bushing
Sealing
LG922E930E07314
Push 13. Install push rod gp into the valve body (101).
rod Apply working oil
• 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 con-
nectors (301) temporarily at the same time.
 Be careful not to leave the slide valve  Pay attention to the popup of the push
tilted (201), otherwise, it will cause dam- rod bushing gp and the cover (6).
age to the hole of the valve body (101).
211
214
212
221
101
LG922E930E07316
LG922E930E07313
7-115
151 25
LG922E930E07317 LG922E930E07319
14. Install the (151) . 16. Install disk (302) on the connector (301).
15. Install the connectors (301) onto the valve  Adjust the 4 push rods (212) to an even
body (101) according to specified torque with
contacting position, and then install
clamp.
screws. If the screws are over screwed,
it may cause the base machine malfunc-
tion because the control lever placed in
the neutral position may produce sec-
ondary pressure. So pay special atten-
tion to the adjustment of to screwing
position of disc (302) screws.
301
LG922E930E07318
302
LG922E930E07320
7-116
17. The method for installing the adjusting nut 19. Install ripple protection cover (501).
(312) is that clamp opposite sides of the disc
 Be careful not to break ripple protection
(302) with wrench and fix the adjusting nut (312)
cover (501).
as per specified torque.
20. Add antirust to each port, and then install the
 While installing, do not move the disc
plug.
(302).
501
312
302
LG922E930E07323
LG922E930E07321
18. Apply grease onto swing parts of connectors

(301) and the top of the push rod (212).
301
LG922E930E07322
7-117
June 10, 2015 7.5.12 Removal and installation of travel motor & reduction gear

of travel motor & reduction
gear
Removal
1

times to release the residual pressure from the LG922E930E07324
hydraulic system, and then press the exhaust 3 Remove the oil return pipe (2).
button of hydraulic oil tank breather valve to 3.1 Remove two high-pressure pipes (3).
release the internal pressure from the oil tank. 3.2 Remove pilot pipe (4).
 Attach the identification label to each
pipe to prevent wrong installation in the
subsequence procedures. 2

or hoses, make mark to prevent mis- 3
necessary, and put an oil receiving plate 4
to receive oil.

lines, connectors or hoses are in disas- LG922E930E07325

system.
1. Refer to the method for the removal of the
track as for removing the track as.
2. Remove four M16 bolts (1), and then remove
plate of travel motor.
7-118
7.5.12 Removal and installation of travel motor & reduction gear June 10, 2015
4. Unscrew 30 bolts (5), and remove sprocket. 6. Remove 30 mounting bolts (6).
7. Remove travel motor.
Lifting weight: about 275kg.
LG922E930E07326
5. Bind travel motor with sling, adjust the rope to

the centre-of-gravity position, and straining it LG922E930E07328
with lifting equipment slowly.
LG922E930E07327
7-119
June 10, 2015 7.5.12 Removal and installation of travel motor & reduction gear
Installation 3. Clean bolt hole, apply thread locker Tonsan

1277 to mounting bolt, tighten the bolt timely,
1. Install the travel motor in track beam, and the
and apply corresponding pretightening force to
motor oil port shall orient the frame side.
the bolt in symmetrical cross strengthening
method.
Tightening torque: 305±25Nm
LG922E930E07327
2. Clean bolt hole, apply thread locker Tonsan

1277 to mounting bolt, tighten the bolt timely,
LG922E930E07330
and apply corresponding pretightening force to
the bolt in symmetrical cross strengthening 4. Tighten pilot pipe, oil return pipe and two
method. high-pressure pipes.
Tightening torque: 305±25Nm Tightening torque of M16 pilot pipe:

26±2Nm
Tightening torque of M22 oil return

pipe: 47±2Nm
Tightening torque of M36 high pressure

tube: 126±6Nm
LG922E930E07329
7-120
7.5.13 Disassembly and assembly of travel motor & reduction gear as June 10, 2015
7.5.13 Disassembly and assem-

bly of travel motor & reduction
gear as
Relevant part drawing
Numbers involved in the section are subject to
numbers in the following drawing.
LG922E930E07331
5. Tighten plate mounting bolts of travel motor.
Tightening torque: 305±25Nm
LG922E930E07332
7-121
June 10, 2015 7.5.13 Disassembly and assembly of travel motor & reduction gear as
Section C-C
Section B-B
Section A-A
travel motor and reduction gear
Assembling drawing of
7-122
Part drawing for reduction gear 21 12

31 22
3
2 21
5
42 27 23
9
23 33
4 43
30
1
37
42
29 20 19
17 22 7
13 35
6 8
12 36
15
34
25
LG922E930E07334
7-123
Parts drawing of hydraulic motor 139

135
112
113 171
326 167
109 103
337 357 341
150 115
324 355 106
116 105
366 352
328 397 368 107
301
325 111
358 104
379
352 110
368 114
383
110
382 145
380 358
384
359 385 337
326
108 132
398
149
343 151
354
102
399 366
323
363
2 325
355 217
357 217 328
209 211 220 385
209 336
384 324
217 217 201 382
211
208 208 381
220 206 191
359
211 211 203 380
201 162
206 161
219 219
205
203 210 202
205 210
204 202 204
LG922E930E07335
7-124
Part list of swing motor & reduction gear

S/N Part name S/N Part name S/N Part name
1 Hub 106 O-ring 219 Shoe
2 Shaft 107 Plunger seal 220 Thrust plate
3 Fixed flange 108 Rear cover flange 301 Propelling steel ball
4 RV gear A 109 Valve rod 323 Thrust plate
5 RV gear B 110 Plug 324 Washer
6 Axle gear 111 Spring seat 325 Shaft bushing
7 Support gear 112 Plug 326 Plunger
8 Cover 113 Valve 327 Spring
9 Camshaft 114 Spring 328 Spring
12 Shim 115 Spring 330 Friction plate
13 Washer 116 O-ring 336 Matching plate
15 Connecting sleeve 132 O-ring 337 Oil seal
17 Pin 135 Plain pin 341 O-ring
19 Hex screw 139 Bolt 343 O-ring
Elastic snap ring for Elastic snap ring for
20 145 Hex plug 346
holes holes
Deep groove ball
21 Angle bearing 149 Hex plug 352
bearing
Deep groove ball
22 Cone bearing 150 Hex screw 354
bearing
23 Needle bearing 151 O-ring 355 Rolling needle
Spring backup ring
25 161 Hex plug 357 Plunger
used on rod
27 O-ring 162 O-ring 358 Shoe
29 O-ring 167 O-ring 359 Hinge
30 O-ring 171 Valve rod 363 Dowel pin
31 Floating seal ring 193 Spring 366 Spring
33 Plug 201 Steel ball 368 Valve
34 Fixed pin 202 Filter 379 Valve bushing
35 Hex screw 203 Plug 380 Spring stop dog
36 Steel ball 204 Plunger 381 Plug
37 Washer 205 Plug 382 Snap ring
42 Dowel pin 206 O-ring 383 Spring
43 O-ring 208 O-ring 384 O-ring
102 Drive shaft 209 Steel ball 385 O-ring
103 Swashplate 210 Strainer 397 O-ring
104 Cylinder body 211 Hex plug 398 Supporting ring
105 Plunger 217 Nameplate 399 Supporting ring
7-125
Special tool 3. Press-in tool
1. Pre-tightening clamp of bearing
LG922E930E07338
LG922E930E07336 Quantity 1
Quantity 1
4. Press-in tool (I)
2. Fixing clamp
LG922E930E07339
LG922E930E07337 Quantity 1
Quantity 2
7-126
5. Press-in tool (II) 7. Press-in tool (IV)
LG922E930E07340 LG922E930E07342
Quantity 1 Quantity 1
6. Press-in tool (III) 8. Cusp chisel
LG922E930E07341 LG922E930E07343
7-127
9. Bar 11. Sling
11.8
LG922E930E07344 LG922E930E07346
10. Aluminum bar 12. Inserting clamp (I)
LG922E930E07345 LG922E930E07347
7-128
13. Inserting clamp (II) 15. Lifting clamp
LG922E930E07348 LG922E930E07350
14. Press-in tool (III) 16. Pull-up clamp
LG922E930E07349 LG922E930E07351
7-129
17. Plugging tool 1. Remove valve gp from rear flange [301].

2. Remove O-ring [208], [209], [210] and support
ring [211], [217].
 The removed O-ring cannot be re-used
LG922E930E07352
Quantity 1
Disassembly LG922E930E07353
Precautions
3. Remove 12 hex screws [343].
1) Before disassembly, make a judgment about
spot check item and anomalous nature of abnor-
mal spot, and then disassemble it in the disas-
sembly sequence.
2) During disassembly, operate in accordance
with after mentioned disassembly steps in clean
site.
3) Lay rubber and plastic gasket on the working
platform.
4) Be sure to mark junction surface of each com-
ponent during disassembly.
5) Do not bump and lose components during
disassembly, and settle the removed compo- LG922E930E07354
nents.
6) Once the seal component is removed, Even if
you think there is no injury or abrasion, it must
be replaced in principle, and it is not allowed to
deform the component.
7-130
4. Remove relief valve gp from spindle [2]. 9. Remove 12 hex screws [33].
 Drive shaft [102] may be removed

together with relief valve.
LG922E930E07357
LG922E930E07355
10. Install 2 lifting rings (PF1/2) in threaded hole
of plug [33] on the cover.
11. Tighten the lifting ring, and then lift cover [8].
5. Remove valve plate of valve gp [109], dowel
pin [341] and ball bearing [150] from relief valve  If it is difficult to take off the cover
gp. because of O-ring or other reasons,
6. Remove 2 O-ring [29] and O-ring [2] from knock it on gently with plastic hammer.
spindle. 3. Remove O-ring from the cover.
 The removed O-ring cannot be re-used  The removed O-ring cannot be re-used
4. Release gear oil.

• Waste oil container (about 8L)
LG922E930E07356
7. Overturn GM as cover upwards.

8. Remove 3 plugs [33]. LG922E930E07358
The disassembly of travel as and reduction gear

7-131
is divided into three parts in the following, includ-

ing:
(1) Disassembly of brake valve
(2) Disassembly of hydraulic as
(3) Disassembly of reduction gear
(1) Disassembly of brake valve

1. Remove [323].
1.1 Remove 2 plugs [301] from cover flange.
Remove O-ring [336] from each plug.
• When relief valve is installed on spindle,
remove 2 plugs [324] already unscrewed. LG922E930E07360
• The removed O-ring cannot be re-used.

3. Removal of check valve.
3.1 Remove plug [326] from cover flange [301].
• When relief valve is installed on spindle,
remove 2 plugs [326] already unscrewed.
LG922E930E07359
2. Remove 2 springs [328], check valve [325]

and spool [323] from cover flange [301].
LG922E930E07361
• Protect outside surface of spool [301] and
actuating surface of cover flange [323].
• Spool and cover flange are matched, so
cover flange gp must be replaced when any
part is replaced.
7-132
4. Remove 2 springs [330] and valve [327]. 6. Remove spool [363] from relief valve [301].
Protect relief valve [301] and valve [327] from 6.1 Remove the O-ring [355] from plug [357]
bump.
 The removed O-ring cannot be re-used.
4.1 Remove O-ring [337] from plug [326].
LG922E930E07364
LG922E930E07362
7. Remove inner components from relief valve
[301].
5. Remove spool [363]. 7.1 Remove 2 plugs [380] from relief valve [301].
5.1 Remove plug [357] from relief valve [301]. 7.2 Remove the O-ring [359] from plug [380]
• When relief valve [301] is installed on spin-  The removed O-ring cannot be re-used.
dle [2], remove plug [357] already
unscrewed.
LG922E930E07365
LG922E930E07363
7-133
8 Remove piston [381] from relief valve [301]. 10. Remove 2 steel balls [385] from relief valve
[301].
 Actuating surface of piston cannot be
bumped.
• Piston and relief valve are matched, so
relief gp must be replaced when any part is
replaced.
LG922E930E07368
11. Remove safety valve gp.

11.1 Remove plug [204] from valve bushing
LG922E930E07366 [202].
11.2 Remove the O-ring [210] from plug [204]
9. Remove 2 bolts [382] from cover flange [301].
9.1 Remove O-rings [383] [384] from plug
[382].
• Removed O-ring cannot be reused.
LG922E930E07369
LG922E930E07367
7-134
12. Remove SHIM [205] from plug [204]
LG922E930E07372
LG922E930E07370
13. Remove spring stop dog [203], spring [206]

and valve [201] sequentially.
LG922E930E07373
14 Remove piston seal [220] from valve [201].

14.1 Disassemble another safety valve in the
same steps.
LG922E930E07371
7-135
2. Remove O-rings [135] [139] from plug [112].

piston seal
valve
LG922E930E07374
(2) Disassembly of hydraulic as

1. Disassemble parking brake. LG922E930E07376
1.1 Remove piston [112] from cavity of spindle

3. Remove components in the assembly.
[2] by compressed air.
3.1. Overturn GM as to the assembly side.
• If compressed air is pumped too rapidly,
3.2 Release hydraulic oil in the assembly cavity.
piston [112] may fly out from flange [2], and
it may lead to injury, so put a protective 3.3 Remove cylinder [104] from the cavity of
cap, etc. on the thrust plate [112] to protect spindle [2] by two hands holding it.
operator. • While overturning assembly side, place an
oil container below it to make hydraulic oil
• Compressed air (3-5kg/cm2)
flow into the container.
• Air gun
• Before removing cylinder body, turn it
clockwise and anticlockwise for 2 or 3
times, and remove it from swashplate, oth-
erwise, some piston may fall into the cavity
of spindle.
• To oil collecting container.
LG922E930E07375
7-136
5. Remove swashplate [103] from the cavity of

spindle [2].
LG922E930E07377
4. Remove the cylinder body [104]. LG922E930E07379
4.1 Remove piston gp [105, 106], thrust plate

[107], thrust steel ball [108], washer [111], and 5
6. Pull out drive shaft [102] from the spindle
ejector rods [151]
(bearing [149] is pulled out together with drive
• Cylinder body, piston gp, thrust plate, etc.
shaft [102]).
cannot be supplied separately, and they
• Oil seal cannot be taken out together.
can be purchased together as a whole
6.1 Remove 2 fulcrum shafts [167] and 2 pins
when needed.
[171] from spindle [2].
 It is easy to pull out the drive shaft [102]

to knock the top of drive shaft on the
reduction gear gently with plastic ham-
mer firstly before pulling it out. If it is
knocked heavily, the drive shaft [102]
may fly out suddenly.
LG922E930E07378
7-137
8. Disassemble the cylinder body.

8.1 The cylinder body is placed on operation
platform, and the press-in clamp is placed on
washer [110].
8.2 Press the press-in clamp by compressing it
slowly, and remove spring backup ring [145]
from backup ring slot with backup ring pliers.
• Pressure load is beyond 200kg
(19.60Mpa).
• Before pressing in again, make sure to line
up the axes of press-in metal clamp (1),
LG922E930E07380
washer [110] and cylinder body. Protect the
cylinder body from being bumped.
Infiltrate 2 oil-way by compressed air, and • Apply a layer film on the cylinder body to
remove piston gp and spring [193] from the cav- protect the surface of cylinder body [104]
ity of spindle [2]. from scratch.
• Piston [161] and piston shoe [162], as a • Never remove spring [114] from the cylin-
whole, cannot be supplied separately, and der until making sure to replace the spring
only the piston gp can be supplied. [114].
• If compressed air is pumped too rapidly,
piston [112] may fly out from spindle [2],
 Loosening the compressed spring [114]
and it may lead to injury, so put a protective rapidly may make it fly out and lead to
cap, etc. on the thrust plate [112] to protect injury, So relax the compression slowly.
operator.
• (3~5kg/cm2).
• Air gun.
LG922E930E07382
9. Remove spring backup ring [145], washer

LG922E930E07381 [110], spring [114] and washer [110].
7-138
LG922E930E07385
LG922E930E07383
3. Remove the sleeve.

3.1 Remove sleeve [15] from drive shaft [102].
1. Remove sun gear.
1.1 Remove steel ball [36] and input gear [6]
from sleeve [15].
LG922E930E07386
LG922E930E07384
4. Remove support flange.
4.1 Turn the turntable to the top and bottom
2. Remove gear bracket.
position, and make spindle [2] upwards.
2.1 Remove spring backup ring [25] from each
4.2 Fix housing [1] and spindle [2] with fixed
drive shaft [9] of planetary carrier.
tool.
2.2 Remove gear bracket [7] from each drive
4.3 Turn the turntable to the top and bottom
shaft [9] of planetary carrier.
position, and make support flange [3] upwards.
 Use the cusp of pliers to remove backup 4.4 Remove 3 spring backup rings [20] and 3
ring, and the backup ring may fly out, so washers [13] from support flange [3].
pay attention to it.
7-139
4.5 Grind off the fullering bulge on the holes of 6

dowel pins [34] on support flange [3] with air-
actuated grinding head.
4.6 Place clamps for pulling out the pin, screw
stud into dowel pin [34], screw the nut and pull
up dowel pin [34] until the upper end of dowel
pin [34] sprays to the lower end surface.
• Before removing support flange [3], the
housing [1] and spindle [2] must be fixed by
fixed tool, otherwise the spindle [2] may fall
on the operation platform.
• Make position mark on washer [20] and
support flange [3] with oil pen, so that the
reassembly can be operated in accordance
with the marked position.
• Please wear protective glasses and face
mask while grinding off fullering bulge in
the hole.
LG922E930E07387
7-140
5. Unscrew 3 hex screws [6] slowly and remove • Protect ball hearing [21] from being dam-
them. aged while removing it, and knock the end
5.1. Remove support flange [3] from spindle [2]. face of pin with hammer and cusp chisel at
• Binder is applied in threaded hole of hex the position of trisection or quartering posi-
screw [19]. It is difficult to loosen it, so tion, so as to knock out ball bearing [21].
unscrew the hex screw [19] slowly. • While ball bearing [21] coming out the
• Make marks for the alignment of support housing, ball bearing [21], reduction gear
flange [3] and spindle [2] on support flange gp and pin may drop, so place rubber pad
[3]. under operation platform to avoid bumping.
• Reduction gear gp consists of reduction gp,
 Install them by aligning mark line during
planetary carrier drive shaft, gasket, and
reassembly.
components in roller bearing can not be
supplied separately, so please purchase
them as a set when they are needed.
LG922E930E07388
6. Remove the fixed clamp LG922E930E07389
6.1 Turn the operation platform to top and bot-

tom direction, and make the spindle upwards.
• Remove 2 fixed clamps. Dismantle the Hammer
spindle and screw 2 lifting rings, and then
lift spindle [2] from housing [1]. Sharpen punch
 Protect the main bearing from being

bumped while lifting the spindle. Pin
6.2 Remove gear gp, ball bearing [21] and pin Ball bearing
[17] of reduction gear with lifting ring.
6.3 Knock cusp chisel with hammer so as to
knock bearing [21] out from housing [1], and
remove reduction gear gp and pin [17]. LG922E930E07390
7-141
7. Remove ball bearing [21]. 8. Remove components in spindle [2].

7.1 Remove floating seal [31] from the housing. 8.1 Remove floating seal [31] from the housing.
7.2 Overturn the turn table to top and bottom 8.2 Remove the outer ring of cone bearing [22]
direction. from spindle [2].
7.3 Knock ball bearing [21] in the housing with
hammer and cusp chisel, and then remove it.
• While ball bearing [21] coming out the
housing, ball bearing [21] may drop, so
place rubber pad under operation platform
to avoid bumping.
Hammer
Sharpen punch
LG922E930E07392
9. Remove the outer ring of cone bearing [22]

Ball bearing from support flange [3].
9.1 Remove 3 outer ring of cone bearing [22]
LG922E930E07391
from support flange [3].
LG922E930E07393
7-142
10. Remove oil seal [132].  The removed ball bearing [149] cannot
10.1 Remove oil seal [132] from the spindle
be reused.
referring to the following drawing.
• Compressor
• The removed oil seal [132] should not be
• Keeper [II]
used again.
• Screwdriver (small size)
• Hammer
• Remove ball bearing [149].
• Place the keeper [II] on operation platform, Oil seal
and insert the drive shaft [102] in keeper
[II].
• Press the ball bearing [149] from the end of
drive shaft [102] with compressor.
• Never remove ball bearing [149] if it is not
to be replaced.
LG922E930E07394
7-143
Assembly
Precautions
(1) Operation shall be carried out in clean site.
(2) It is prohibited to wear fabric gloves during assembly.
(3) Sealing elements such as O-ring and floating SEA, etc. must be replaced while parts damaged during
assembly are repaired.
(4) The removed hex screw [19] must be replaced, and then conduct the assembly.
(5) Each component must be cleaned thoroughly and be blown to dry with air gun.
(6) Parts of hydraulic as, such as motion parts and slide contact surface, etc. must be applied grease [level
NAS9] with good cleanliness before assembly.
(7) During the installation of bolt and plug in refixation position, the torque of torque wrench shall be subject
to the specified value shown in the following table.
Part Thread Quant Tightening torque kgf-m (N-

Name
number dimension ity m)
19 Hex screw M24(P3.1) 3 72.3±11(708.5±107.8)
33 Plug PF1/2 3 10±2(98.1±19.6)
35 Hex screw M12(P1.75) 12 10.4±1.6(102±15.7)
202 Valve bushing PF1 2 25±5(245±49.0)
204 Plug PF1/2 2 10±2(98.1±19.6)
324 Plug M36(P1.5) 2 45±9(441±88.2)
326 Plug M36(P1.5) 2 26±4(255±39.2)
343 Hex screw M16(P2.0) 12 25.7±4(252±39.2)
346 Plug PF1/4 2 3±0.5(29.4±4.9)
352 Plug PF1/4 2 3±0.5(29.4±4.9)
354 Hex screw NTPF1/16 8 1.0±0.25(9.8±2.45)
357 Plug PF1/2 2 10±2(98.1±19.6)
380 Plug PF3/8 2 6±1(58.8±9.81)
382 Plug PF1/8 2 1.5±0.25(14.8±2.45)
398 Hex screw PF1/8 4 1.25±0.25(12.3±2.45)
7-144
(1) Assembly of control valve  The hole of relief valve and spool
1. Assemble check valve.
periphery may be damaged because of
1.1 Install O-ring [337] on plug [326]. contact, after the assembly, interior of
1.2 Install spring [330] and spring [327] on plug GM as may leak oil, and then the perfor-
[326], apply lubricant on the spring [330] and mance may be poor, so pay attention to
valve [327], and then fix the spring. this point.
1.3 Screw a plug [326] on the installed relief • Apply lubricant on O-ring [337].
valve [301], and then tighten it in specified
torque.
• Apply lubricant on O-ring [337].
• Apply seal on the plug [326].
• Screw the plug [326] with torque wrench.
Tightening torque 26±4kgf-m

(255±39.2N-m)
LG922E930E07360
3. Install check valve [325] and spring [328] on

the plug [324], screw the plugs [324] (two) in the
relief valve [301], and tighten them in specified
torque.

LG922E930E07361 (441±88.2N-m)
• The relief valve [301] is in the relief valve
2. Assemble the spool. gp, so the whole of relief valve gp must be
2.1 Insert the spool [323] in relief valve [301]. replaced if one of the above-mentioned
2.2 Install O-ring [336] in plug [324]. component is needed to be replaced.
• Apply hydraulic oil on spool [323], and then
insert it in relief valve [301].
 Axes of relief valve shall be aligned to

the axes of spool during the installation
of spool. Protect the hole of relief valve
and spool periphery from being dam-
aged by contact.
7-145
LG922E930E07359 LG922E930E07364
4. Assemble 2-speed control valve [363], and 5. Install plug [324] on relief valve [301] and
install O-ring [355] in plug [357]. tighten it in specified torque.
4.1 Put the spring [366] on spool [363] and then Tightening torque 10±2kgf-m
insert the spool [363] in the hole of relief valve
(98.1±19.6N-m)
[301].
• Apply lubricant on O-ring [355].
• Apply hydraulic oil on spool [363].
• Axes of relief valve shall be aligned to the
axes of spool during the installation of
spool. Protect the hole of relief valve and
spool periphery from being damaged by
contact.
 The hole of relief valve and spool

periphery may be damaged because of
contact, after the assembly, interior of
LG922E930E07363
GM as may leak oil, and then the perfor-
mance may be poor, so pay attention to
this point.
7-146
6. Assemble the internal parts of relief valve gp. insert it in relief valve [301].
• Install steel ball [385] in relief valve [301]; • Axes of relief valve shall be aligned to the
• Install O-ring [383] and [384] in plug [382]; axes of spool during the installation of
• Apply lubricant on O-ring [383] and [384]. spool. Protect the hole of relief valve and
spool periphery from being damaged by
contact.
• The hole of relief valve and spool periphery
may be damaged because of contact, after
the assembly, interior of GM as may leak
oil, and then the performance may be poor,
so pay attention to this point.
 The relief valve [301] and piston [381]

compose the relief valve gp, so the
whole of relief valve gp must be
replaced if one of the above-mentioned
LG922E930E07368
components is needed to be replaced.
7. Install plug [382] on relief valve [301] and

tighten it in specified torque.
Tightening torque 1.5±0.25kgf-m

(14.8±2.45N-m)
LG922E930E07366
9. Install plug [380] in relief valve [301], and

screw up the plug [380] in specified torque.
Tightening torque 6±1kg-m

LG922E930E07367
(58.8±9.81N-m)
• Assemble safety valve.
8. Insert piston [301] into relief valve [301], and
• Install O-ring [208], [209], [219] and backup
install O-ring [359] in to the plug [380].
ring [211], [217] in the valve bushing [202].
• Apply hydraulic oil on spool [323], and then
• Install O-ring [210] in plug [204].
7-147
• Apply lubricant on O-ring [383] and [384].

11. Install valve [201], spring [206], spring stop
dog [203] in the valve bushing [202], and tighten
the plug [204] in specified torque.
• Apply hydraulic oil on the periphery of valve
[201], and then install it in the valve bush-
ing [202].
• During the installation of valve bushing, the
axes of valve bushing shall be aligned to
the axes of valve. Protect the valve seal
from being damaged by contact.
LG922E930E07365
(98.1±19.6N-m)
• The pressure of the component to be
10. Install the shim [205] in plug [204], and
removed is debugged, so the whole of
install piston seal [220] in the valve [201].
safety valve gp shall be replaced if one of
 Shim shall be removed during disas- the above-mentioned components is
sembly because the pressure is needed to be replaced.
adjusted by the shim, and if any inner
part is needed to be replaced, the whole
valve body must be replaced.
 The piston seal [220] is composed of O-

ring and seal ring, apply lubricant on the
O-ring and seal ring, and then install O-
ring and seal ring on the valve [201].
LG922E930E07371
LG922E930E07370
7-148
LG922E930E07372
LG922E930E07370
• In order to avoid falling off, apply grease on
both face of the shim, adhere it to the plug
(2) Assembly of reduction gear and hydraulic as
and then install the plug in the valve sleeve.
During the reassembly after component replace-
ment, two parts require the intermittent adjust-
ing. Bearing pretightening adjusting and washer
S adjusting Make sure whether the following
components are replaced with new ones before
assembly.
Rplacement
Perform adjustment according
to the "[A]Adjusting
BALLBEARING" in this
chapter
Rplacement
Perform adjustment according to
the "[B] radial clearance of
LG922E930E07371
TAPER BEARING D" in this
chapter
Rplacement
Perform adjustment
according to the "Drive A Adjust the ball bearing
shaft assembly ball
bearing 21 of connecting
housing" in this chapter
According to the "B Replacement

Rplacement of radial clearance of cone
Speed reduction spindle
bearing D"in this chapter
assembly
LG922E930E07395
 When the above components are

assembled after verification, they must
be used after being adjusted one by
one. If components are used without
7-149
adjustment, it may lead to poor opera-

tion and early damage of GM as.
BALL Hammer
Press-in tool
The following operation is carried out without BEARING
replacement.
HUB
1. Reassemble the housing [1].
1.1 The housing [1] is lifted in operation platform
with the opening upwards, and tighten 3 screws
uniformly.
1.2 Install the periphery of ball bearing [21] into
the housing [1] by compressor and hammer.
LG922E930E07396
1.3 Install floating seal [31] in the housing [1]
with press-in clamp [I] [II].
3. Assemble housing [1] and spindle [2].
 The O-ring of floating seal [31] cannot
3.1 Install two lifting ring on the symmetric posi-
be applied with lubricant. tion of the spindle [2].
• Install the floating seal in housing in the fol- 3.2 Hitch the hook, and put the spindle [2] in the
lowing sequence: press-in clamp [I], float housing [1] slowly.
seal, and then use the press-in clamp [II]. 3.3 Remove lifting ring, fix the housing [1] and
Press the press-in clamp [II] until it contacts spindle [2] with 2 fixed clamps in symmetric
the press-in clamp [I]. positions.
3.4 Overturn the operation platform and make
2. Assemble spindle [2]. the cover upwards.
2.1 Use press-in clamp [II], [III] to install the
 Overturn it in 180 degree.
floating seal [31] in the floating seal slot of spin-
dle [2].
 The O-ring of floating seal [31] cannot

be applied with lubricant.
• Install the floating seal in housing in the fol-
lowing sequence: press-in clamp [III], float
seal, and then use the press-in clamp [II].
Press the press-in clamp [II] until it contacts
the press-in clamp [III].
• Check and make sure that the O-ring is
installed in housing [1] correctly.
LG922E930E07397
3.5 Align the periphery of cone bearing [22]

7-150
(three) to the periphery hole on spindle [2], and

then install them. Hammer
4. Assemble reduction gear as and install it in
the spindle [2]. Press-in tool
4.1 Install the sling (II) in the center hole of
reduction gear gp. ANGOI AR BALL
4.2 Lift and hold the reduction gear as and align BEARING
it to the position on spindle [2], and install the

reduction gear gp in spindle [2] slowly.
4.3 Install pin [17] (24 pins) in the slot pin
between reduction gear A [4], B[5] and housing
LG922E930E07399
[1].
 Apply gear oil on each pin.

6. Assembly the support flange [3].
6.1 Install the support flange [3] in ball bearing of
spindle [2].
• Assemble it in accordance with the joint
mark on the spindle [2], support flange [3]
and planetary carrier drive shaft.
LG922E930E07398
5. Assemble steel ball gp [21].

5.1 Install the steel ball gp [21] in housing [1],
and knock the press-in tool with hammer to
compress the ball bearing. LG922E930E07400
5.2 Install 3 cone bearing peripheries.

7. Assemble dowel pin [34] and tighten hex
 Knock the periphery with hammer to
screw.
verify that the ball bearing is installed
7.1 Apply Loctite on the thread position of screw
into the housing.
[19], and put the washer in three holes.
7.2 Tighten 3 hex screws, 20kgf-m.
7.3 Insert dowel pin in the hole with force gun
driving them.
7-151
7.4 Drive the dowel pins into pin hole one by If the following part is to be replaced,
one. • S pin as
• If there is oil or grease on pin and hex • Reduction gear as
screw, degrease them with degreasant, Adjust it referring to "[B] Adjust axial clearance
and then dry them. of cone bearing", and then carry out the follow-
• Never mistake the direction and position of ing operation.
periphery.
• Compressed air 5~6kgf/cm² If no component is required to be replaced,
carry out the following operation directly.
8. Assemble spring backup ring and washer.
8.1 Install washer S [13] in support flange.
8.2 Install spring backup ring [20] in spring
backup ring slot in the support flange [3].
• During the assembly of 3 washers S [13]
and spring backup ring [20], align the
marks made during the disassembly of
support flange [3], and then install them in
the same position as that before disassem-
bly.
LG922E930E07401
7.5 Tighten 3 hex screws with the tightening

torque of 72.3±11kgf-m.
LG922E930E07402
9. Reassemble the gear bracket.

LG922E930E07388
9.1 Install 3 gear brackets [7] on planetary
drive shaft R [9] .
• During the assembly of 3 gear brackets,
align the marks made during the disassem-
7-152
bly, and then install them in the same posi- 10.2 Install oil seal [132] in the oil seal hole on
tion as that before disassembly. spindle [2].
 Apply white vaseline or lubricant on the

lip of oil seal [132].
11. Assemble drive shaft [102].
11.1 Install oil bearing [102] in the drive shaft
[169].
 Wear leather glove, and then install the

bearing.
 Ensure that the cone of ball bearing is

compressed to the seat.
LG922E930E07386
9.2 Install 3 spring backup rings [25] in the

spring backup ring slot of planetary drive shaft
[9].
 The spring backup ring may fly out.
• Make the side of sharp corner on spring

backup ring upwards.
• Retainer pliers
LG922E930E07403
12. Install piston as ([161] [162]).

12.1 Springs [193] is installed in piston as [161
[162] and the piston hole in the spindle [2].
12.2 Install it in the spindle [2].
 The spring is adhered by grease.
 Apply hydraulic oil on external diameter

of piston gp.
LG922E930E07385
13. Assemble the fulcrum shaft [167].

10. Assemble oil seal.
13.1 Insert 2 pins [171] in spindle [2].
10.1 Turn GM as.
13.2 Install two fulcrum shafts [167] on the pins.
7-153
 Apply grease on the junction surface of der body [104] can be seen clearly. Install spring
backup ring in the slot and then release the
fulcrum shaft.
pressure.
 Cover the drive working surface of the

cylinder body with plastic film.
 The spring backup ring may fly out.
• Refer to the left figure for how to install

washer [110], and spring backup ring [145].
LG922E930E07381
14. Assemble the cylinder body

14.1 Install the washer [110], spring [114], and
washer [10] in the drive shaft hole of cylinder
body [104].
14.2 Place the cylinder body [104] on the com- LG922E930E07382
pressor to compress the spring.
LG922E930E07383
14.3 Place keeper [I] on the last washer, switch

it on and press the pressure head until the
backup ring slot in the drive shaft hole of cylin-
7-154
15. Assemble the motor as.

15.1 Insert 5 needle rollers [151] in the pin of
cylinder body [104].
15.2 Install washers in each end surface of 5
rollers.
15.3 Install thrust steel ball [108] on washer
[111].
15.4 Install piston as [105] [106] in the thrust
plate [107].
 Soak the components as a whole in

hydraulic oil.
LG922E930E07404
16. Assemble the assembly components.

16.1 Lift the motor as with sling [I], and then
install it in the spindle [2].
16.2 Upon the installation, remove the sling [I].
16.3 Upon the assembly of drive shaft [102],
swashplate [103], pile force plate [153], pile
force steel ball [108], washer [111], thrust plate
[107], needle roller bearing [151], cylinder body
[104], and piston as, install the lifting clamp on
LG922E930E07378 the drive shaft lengthways.
 Fit the fulcrum shaft hole on swashplate

15.5 Insert the above components in the hole of [103] and fulcrum shaft.
cylinder body [104].
 Avoid bumping while installing it into
the spindle [2].
 Upon the installation of motor as, turn

the cylinder body with hands to ensure
that it cannot stagnate, remove it to
check and then install it again.
7-155
Assemble the assembly in accor-

Sling (I)
dance with the following steps after
the adjustment.
1. Install safety valve in relief valve gp [301].
2. Tighten the safety valve in specified torque.
Tightening torque: 25±5kgf-m
LG922E930E07405
LG922E930E07406
3. Tighten 12 hex screws [343] in specified

torque.
Tightening torque: 25.7±4kgf-m

3.1 Install O-ring [355] in plug [357] and tighten
the plug in specified torque.
Tightening torque: 10±2kgf-m

7-156
• Grease and hydraulic oil
LG922E930E07407
LG922E930E07356
4. Pour hydraulic oil on the spindle [2], install O-

ring [27] [29] in the slot, fit the faces on the spin- 6. Apply grease on O-ring [135] [139], and then
dle [2], do not apply grease on it, and insert 2 install them in the O-ring slot of piston [112].
pins [42] in the spindle [42]. Align the relief valve 6.1 Install piston [112] in the spindle.
[301] to pin [42] hole and install it on spindle [2].
• Hydraulic oil is about 1.7L.
 O-ring [112] contacts pin DLE [112], and
knock the piston [112] with plastic ham-
mer gently to install piston [112]
smoothly and uniformly.
 Protect O-ring [112] from being dam-

aged.
LG922E930E07355
5. Install ball bearing [150], dowel pin [341], ball

bearing [109], and 12 springs [113] on the relief
valve [301].
 Apply hydraulic oil on ball bearing, and

LG922E930E07376
apply grease on the plate and 12

7. Install the cylinder body [115] into spindle [2],
springs.
7-157
and then install return plate [116] to the cylinder 9. Tighten 12 hex screws [35] in specified
body [104]. The operation shall be carried out in torque.
order. 9.1 Pour the gear oil in housing [1].
 Cylinder body is required to be soaked Tightening torque: 10.4±1.6kgf-m
in hydraulic oil before installation. • Gear oil 5.4L
 Never mistake the installation sequence
of cylinder body [115] and return plate
[116], otherwise the brake torque may
reduce.
LG922E930E07357
LG922E930E07377
8. Install the O-ring [43] on plug and then tighten

the plug [33] in specified torque. (3 gear oil
ports)
 Tightening torque: 25±5kgf-m
LG922E930E07408
7-158
10. Install sleeve [15] on the drive shaft. Maintenance limit

10.1 Install sun gear [6] on sleeve l[15], and then Carry out the disassembly and stop check of
put the steel ball [36] in the hole of sun gear [6]. GM as in accordance with the following stan-
 Apply grease on steel ball [36]. dard. Use each component prudently, and espe-
cially there cannot be any scar on the moving
11. Install O-ring [30] in the slot of cover [8].
part and the top and bottom of the parts contact-
 Apply grease on O-ring [30]. ing the moving parts.
12. Lift mounting cover [8] on spindle [2] with 1. Seal components
sling, lifting ring and plastic hammer. Once seal components (O-ring, oil seal, and
floating seal) are removed, they must be
 Protect the O-ring [30] from being
replaced with new ones even if there is no scar.
bumped.
2. Handling standard of wearing part
• Container (about 8L)
2.1 Replace all components with obvious scar
on the surface.
2.2 Component with the following conditions
shall be replaced.
LG922E930E07384
LG922E930E07358
7-159
Standard
Part value Permissible value
Part name Symptom
number (Standard (Judgment value)
size)
Spindle as
(2)
Spindle
(3) • Major damage is on the
Support flange
(19) appearance.
Screw
(34) • Abnormal wear
Dowel pin
(37)
Washer
Reduction gear gp
(4) Reduction gear A • Uneven wear on
(5) Reduction gear B reduction gear surface
(9) Planetary wheel • Rotation of planetary
(12) drive shaft wheel drive shaft is not
(22) Shim smooth, and it is clamped
(23) Cone bearing and stagnated.
Needle bearing
• Abnormal wearing is on
(13) Washer
the end face.
• Abnormal wearing is on
(20) Spring retainer
the end face.
• The surface peels off.
(21) Ball bearing
• Uneven wear
• No scar is allowed to be
on the moving part of
spool [323]
• The clearance between
relief valve and spool
[323] is too obvious
• No scar is allowed to be
Relief valve • Diameter • Diameter
on the moving part of
(301) assembly clearance clearance
piston [381]
Relief valve 10~20µm 25µm
• The clearance between
relief valve and piston
[381] is too obvious
• The contact surface of
valve [327] is damaged.
• The contact surface of
valve [227] is too deep.
• Surface with damage
(323) Spool
• Surface with wearing
• Surface with damage
(381) Piston
• Surface with wearing
7-160
• Contact face of OLL seal

(102) Drive shaft [132] is worn.
• Spline is worn.
• The contact face is
(103) Swashplate
sintered and clenched.
• Spline is worn. Diameter Diameter
• Internal diameter surface clearance clearance
is worn. 28~45µm 50µm
(104) Cylinder body
• There is scar on the
contact surface of plate
[109]
• The axial clearance Clearance Clearance
between piston [105] and 0.05mm 0.15mm
Piston gp shoe [106] is wide
(105)
Piston • Abnormal wearing is on
(106)
Shoe the shoe.
• Uneven wear is on the
shoe.
• End face of periphery is
(107) Thrust plate
worn.
• Uneven wear is on the
contact part between
(108) Pile force steel ball
return plate [107] and ball
surface
• The contact surface is
(109) Thrust plate burnt and catches uneven
wear.
• Two end faces catch Brake Brake torque
uneven wear. torque • 398 N·m a little
(115) Friction plate
• The specified torque • .398N·m few
(116) Phase plate
cannot be caught. above (40.6kgf·m)
• Sintering (40.6kgf·m)
• With indentation
(149) Ball bearing
• Peeling off
(150) Ball bearing
• Uneven wear
(363) Spool • Surface damage and
(201) Valve uneven wear
• Damage is on the seat
surface.
(202) Valve bushing • Clearance between valve
bushing and valve is
wide.
7-161
Adjustment
[A] Adjustment of ball bearing Torque lench
The ball bearing [22] must have proper pretight-

ening force to satisfy its life cycle requirement, Special nut
and the replacement of any one component Asjusting jig
influencing the pretightening force of ball bear- Hub
ing must be carried out in accordance with the Spindle
following steps.
• Ensure that all adjustments are correct
during the reassembly of the assembly.
Incorrect adjustment may lead to earlier Depth micro-meter
damage.
B
• Components influencing the pretightening A
C
force of the bearing include: housing [1],
spindle gp and ball bearing [21]. Hub
Spindle
• Ensure to adjust the pretightening force as
follows:
Tool: Asjusting jig
• Adjust clamp used for pretightening force of LG922E930E07409
ball bearing 1. Install the adjusting clamp used for pretight-

• Depth indicator ening force of ball bearing on spindle [2], and
• Torque wrench then tighten the nut in tightening torque specially
• Socket wrench (30mm) set to 12±2kgf-m, so as to compress the ball
bearing installed in the housing.
2. Measure the size of "A" with depthometer
from the measuring hole on the adjusting clamp
used for pretightening force of ball bearing.
3. The "B" size of adjusting clamp used for pre-
tightening force of ball bearing is known, so cal-
culate the "C" size of clearance.
• “C”=“A”-“B”
• A = measured value B = clamp thickness
size C = clearance required
7-162
E surface
HOLD FLANGE
LG922E930E07410
4. Determine size "D" of support flange [3].

5. In accordance with the measuring result of (2)-(4), adjust the support flange [3] following the steps
below.
• Size "C" of support flange [3] is required to be measured.
• "D" = "C" ±0.02, size "D" is adjusted to the equation size.
(a) If the actual size "D" of support flange [3] is less than the specified size, Cut surface E of support
flange [3] to the specified size.
(b) If the actual size of support flange [3] is within the tolerance, use it in the current situation.
(c) If the actual size "D" of support flange [3] is more than the specified size, Replace new spindle gp [3].
Measure and adjust size "D" of support flange [3] again.
6. Remove Adjusting clamp used for pretightening force of ball bearing from spindle [2].
[B] Adjust the axial clearance of cone bearing.
 If the aftermentioned components are required to be replaced, reselect the thickness of washer
to adjust the axial clearance of cone bearing [22]: housing [1], spindle gp, reduction gear gp
and spring backup ring.
 Ensure that all adjustments are correct during the reassembly of the assembly. Incorrect
adjustment may lead to earlier damage.
• If any above mentioned component is required to be replaced, the axial clearance is required to be
adjusted again.
• The steps to adjust the axial clearance of cone bearing are as follows:
7-163
Tool:
• Press-in tool (IV)
Retainer(IV) • Hammer
• Thickness gauge
Taper roller bearing
1. For the press-in toll (IV) on the periphery of
cone bearing [22] on the planetary drive shaft [9]
RV gear ass’y compressed in the reduction gear as, knock it
gently with hammer.
2. Assemble the thinnest washer [13] in support
flange [3].
LG922E930E07411
3. Knock the periphery of washer [20] gently
with hammer and press-in tool (IV).
 Ensure that the reduction gear gp has

been installed into the spindle.
4. Install spring backup ring [20] in the slot of
support flange [3].
5. Measure the clearance between spring
backup ring [20] and cone bearing [22] with
depth gauge.
6. Verify whether the thickness of spring backup
ring is correct or not:
• Max.= thickness of plug gauge+ thickness
S of washer installed
• Min.= thickness of plug gauge + thickness
S of washer installed - 0.05
7. Select another washer S in the following table
to install in the gap between washer S and
spring backup ring.
7-164
7.5.14 Removal and installation of swing motor & reduction gear June 10, 2015
Table of clearance adjustment com- 7.5.14 Removal and installation

ponents of swing motor & reduction
Washer [13]
gear
Removal

t LG922E930E07412

Mark of category size t or hoses, make mark to prevent mis-
E 3.30~3.35 takes during assembly. Clean the
F 3.35~3.40 periphery of the assembled oil port if
G 3.40~3.45 necessary, and put an oil receiving plate
H 3.45~3.50 to receive oil.
I 3.50~3.55  Seal them with plugs or caps when the

J 3.55~3.60 lines, connectors or hoses are in disas-
K 3.60~3.65 sembling state to prevent pollution
L 3.65~3.70 sources from entering the hydraulic
M 3.70~3.75 system.
N 3.75~3.80 1. Remove oil filler pipe (1).
O 3.80~3.85 1.1 Remove hose (2) of main oil filler;
P 3.85~3.90 1.2 Remove the oil return pipe (3).
Q 3.90~3.95
R 3.95~4.00
S 4.00~4.05
T 4.05~4.10
U 4.10~4.15
7-165
June 10, 2015 7.5.14 Removal and installation of swing motor & reduction gear
3. Remove the bottom plate (5).
1
3
2
5
LG922E930E07413
LG922E930E07415
2. Remove 2 pilot pipes (4) of time delay valve. 4. Remove block (6).
LG922E930E07414 LG922E930E07416
7-166
7.5.14 Removal and installation of swing motor & reduction gear June 10, 2015
5. Remove the grease hose (7) on the bottom of

swing motor reduction gear.
LG922E930E07419
LG922E930E07417
Installation
Installation is in the reverse order of removal.
6. Remove 12 captive bolts (8); apply lubricant
on pin (9), and then remove it. • Mounting bolt M24-10.9, tightening torque:
600±55Nm.
• Clean the threaded hole before the installa-
tion, and apply thread locker (Tonsan
1277) on the thread of bolt.
• Check whether the hydraulic oil is enough.
Tightening torque of M16 pilot pipe:

8 26±2Nm
9 Tightening torque of M22 oil return

pipe: 47±2Nm
Tightening torque of M30 high pressure

LG922E930E07418
pipe: 126±6Nm
7. Lift the motor with rope and lifting equipment,

Tightening torque of M36 oil filter pipe:
137±6Nm
and then place it on a clean and safe position.
Lifting weight: 217kg.
8. Cover the installing port of the motor with
paperboard after it is lifted, so as to avoid for-
eign matters falling into the port.
7-167
June 10, 2015 7.5.15 Disassembly and assembly of swing motor & reduction gear
7.5.15 Disassembly and assembly of swing motor & reduction gear

Cross-section view of swing motor & reduction gear
Section of Motor
452 122 123 121 111 743 742 702 712 472 983 303 488 401 355 351
124 162 469
114 A 052
301
151 161
443
171
491
101
A 163
985
391
390
444
984
131
451
706 (051-1)
707 051
(031-1) 033 031

(031-1)
LG922E930E07420
7-168
7.5.15 Disassembly and assembly of swing motor & reduction gear June 10, 2015
Section of reduction gear

401 102 801 926 402 922 202 230 231 602 104
930
Plugged for transportation
802
601
287
912
390
391
211
204
201 210
285
403
915 903
283 Plugged for transportation
905
904
925 913 910 286 203 282 909 284
LG922E930E07421
7-169
Special tool 3. Install the clamp used for oil seal.
1. Remove the clamp used for bearing (401).
Φ215
118
Φ185
10
180
200
LG922E930E07424
LG922E930E07422
2. Remove the clamp used for bearing (402).
Φ155
Φ95
41
60
LG922E930E07423
7-170
4. Special tool used to remove brake plunger
14
85
75
30
15
35
.5
12
R
100
30
14
44
M16
8
M16
贯通
4
8
LG922E930E07425
Disassembly
The chapter introduces the disassembly of
swing motor & reduction gear in two parts,
including:
(1) Disassembly of swing motor
 Choose a clean location. The disassem-

bly platform shall be covered by rubber
plate or cloth, etc. in order to protect
components from being damaged.
7-171
1. Disassembly of swing motor 4. Loosen pressure-reducing valve (051) and

Remove the motor in accordance with the fol- remove it from valve body (303).
lowing sequence. The number in the brackets  O-ring may be destroyed while loosen-
following the component name is the symbol
ing pressure-reducing valve, therefore,
shown in the installation profile view.
be sure to replace the O-ring.
1. Tie the periphery of motor with steel wire
rope, lift it by crane, and then clean it with color-
less 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) down-
LG922E930E07427
wards, and then fix it on the operation platform
which is easy to be disassembled. At this time,
make the mark at the junction position between 5. Remove ROMH oil drain plug (469) from
motor body (301) and valve body (303). valve body (303), and then remove spring (355)
and plunger (351).
 Protect the plunger valve seat from

being damaged.
LG922E930E07426
LG922E930E07428
7-172
6. Unscrew hex bolt (401), and then remove 7. Remove the brake spring (712) from the
valve body (303) from motor body (301). brake plunger.
• 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
side of cylinder.)
When prying the junction surface with screw-
LG922E930E07430
driver, protect the junction surface from being
damaged.
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 verti-
cally.
LG922E930E07429
LG922E930E07431
7-173
9. Level the motor again, and then pull out the  The spline may destroy oil seal during
cylinder (111) from drive shaft (101). Pull out the
the removal of drive shaft, so twine the
plunger (121), plate (123), plate spring and
spline part of drive shaft with plastic
plunger (124) in sequence.
adhesive tape before the removal.
Protect the revolving mating surface of cylinder
and plunger, etc. from being damaged.
When it is difficult to remove the plunger,
remove it in the 12th operation step.
LG922E930E07434
LG922E930E07432
10. Remove friction plate (742) and metal plate

(743) of separator from motor body (301).
LG922E930E07435
12. Carry out the following operation steps in

accordance with the requirements.
Drive out the inner ring of cylindrical roller bear-
ing from drive shaft with press machine.
LG922E930E07433
 The inner ring of cylindrical roller bear-
ing can also be knocked by hammer and
steel bar, but it is needed to knock the
11. Remove drive shaft (101) and plunger (124). inner ring uniformly and protect the
7-174
bearing from being damaged. 2. Disassembly of reduction gear

1. Lift the reduction gear with lifting device, and
 The removed bearing cannot be reused.
then lay the drive shaft on the level ground.
13. Knock the outer ring of cylindrical roller bear- Drain the gear oil from oil drainage port on the
ing gently with hammer and steel bar from one a gear.
side of housing of oil seal (491), so as to remove
2. Loosen hex screw (602) and remove the
it from the motor body (301).
motor.
 The removed bearing cannot be reused. 3. Remove No. 1 sun gear (211).
4. Remove No. 1 planetary carrier gp.
 Collect the gear oil with clean container,

and check the oil for wear powder.
Punch press
Drive shaft
14. Remove the cylindrical roller bearing (444)

from valve body (303) with sliding weight bear-
LG922E930E07438
ing detacher.
 The removed bearing cannot be reused.
LG922E930E07439
LG922E930E07437
7-175
5. Removal of No. 1 planetary carrier gp. 10. Remove circlip (913) from drive shaft (201).
 It is not required to disassemble No. 1  Mark the gear and pin to avoid mistake
steering carrier further hereto, so please during the installation.
check the components in accordance
with the guidance mentioned by mainte-
 If No.2 spring pin (282) is removed,
never reuse it.
nance criteria.
6. Lift the gear ring (202) and remove it.
7. Remove No. 2 sun gear.
8. Remove No. 2 planetary carrier gp.
LG922E930E07441
LG922E930E07440
9. Removal of No. 2 planetary carrier gp.
 It is not required to disassemble No. 2

planetary carrier gp hereto.
Check the components carefully in accordance
with the guidance mentioned by maintenance
criteria. We recommend to replace No. 2 plane-
LG922E930E07442
tary carrier gp in set as possible as you can. But
if the replacement of some part is inevitable,
please operate in accordance with the following
steps.
1) Remove the most inside
• Spring pin (910) and No. 2 spring pin (282).
2) Remove No.2 planetary gear (203) from the
side.
7-176
12. As it is shown in the figure, remove bearing

seal ring (915) and the bearing (401) from the
drive shaft bearing.
13. Remove oil seal (401) from the housing
(102).
 While removing the drive shaft, protect

it from being damaged.
 If the bearing seal (915) and oil seal

(801) are removed, never reuse them.
LG922E930E07443
11. Place the reduction gear erectly. Support the

periphery of housing, make the drive shaft sur-
face downward, and knock the center of shaft
with plastic hammer to remove the shaft from
the housing.
 Hereto, check the drive shaft, and if

there is no abnormality, it is not
required to disassemble it further. LG922E930E07444
Check the components carefully in accordance

with the guidance mentioned by maintenance
criteria. We recommend to replace in set as pos-
sible as you can. But if the replacement of some
part is inevitable, please operate in accordance
with the following steps.
7-177
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 fol-
lowing points.
1) Protect the components from being damaged.
2) Before the assembly, please check each
component in accordance with maintenance cri-
teria.
3) Each component shall be cleaned with deter-
gent and then blow it to 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. in the tightening torque shown in the follow-
ing table with torque wrench.
7) If liquid filling material is required, Peel the
surface of the component with knife or similar
objects. and grind the surface with oilstone.
7-178
Table of specification and tightening torque of bolt
Tightening torque: N- Applicable part

Bolt size Name
m number
M20 Hex bolt 431 401
Pressure reducing
M33xP1.5 177 051
valve
M30xP1.5 ROMH oil drain plug 334 469
PF1/4 ROM oil drain plug 36 467
12mm Hex bolt 102N-m 602
10mm Plug 65N-m 901
If it does not conform to the above part number, please refer to the assembly profile view.
7-179
(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 cylin-
drical 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 One side of the output shaft
pin of cylindrical roller bearing.
3. Install the inner ring of cylindrical roller bear-
ing (444) into the drive shaft (101) in the shrink-
on method. 5. Knock it gently with hammer and steel bar to
4. Install the oil seal (491) in the motor body install the cylindrical roller bearing (443) on the
(301) with tool. motor body (301).
 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.
 Knock it uniformly to protect the periph-

ery from being damaged.
LG922E930E07447
LG922E930E07445
7-180
6. Install the drive shaft on the motor body (301). 7. Place the motor body (301) flatly, and then
insert the plunger (124).
 Install it carefully to protect the sealing
part of oil seal from being damaged.  Revolve the side with big chamfer of
plunger into the motor body.
 Twine the spline of shaft with plastic
adhesive tape.  Apply a layer of grease on it in order to
avoid it falling off from the junction sur-
face.
LG922E930E07448
LG922E930E07449
8. Assemble the plate (123) and plate spring,

and then assemble them and piston gp (121,
122).
LG922E930E07450
7-181
9. Install the plunger gp (121, 122) assembled 10. Place the motor body (301) again with the oil
on plate (123) on the cylinder (111), and install it seal downward, and then install separator metal
together with drive shaft (101) cooperatively. plate (743) and friction plate (742) on the motor
body in sequence.
Install 4 separator metal plates and 3 friction
plate in total.
LG922E930E07451
LG922E930E07453
LG922E930E07452
LG922E930E07454
7-182
11. Install O-ring (706) (707) in the motor body 13. Install brake spring (712) in brake plunger
(301). (702).
 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.
LG922E930E07457
14. (This step can be implemented only when

LG922E930E07455
removing cylindrical roller bearing (444).
Install the outer ring of the cylindrical roller bear-
12. Install the brake plunger (702) in the motor ing (444) into valve body (303) while knock it
body (301). 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.
LG922E930E07456
LG922E930E07458
7-183
15. Install valve plate (131) into valve body 16. Install valve body (303) on motor body (301),
(303), and then into O-ring. and then tighten it with hex bolt.
 Apply a thin layer of grease on joint sur-  Pay attention to installation direction of
face of valve plate. (Prevent falling off) 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.
LG922E930E07459
LG922E930E07461
LG922E930E07460
7-184
17. Install plunger (351) and spring (355) into (2) Assembly of reduction gear
valve body (303), and then install ROMH oil 1. Assembling the drive shaft assembly
drain plug (469) equipped with O-ring (488) into 1) Install bearing seal (915) into drive shaft
valve body (303). (201).
 Check whether the plunger moves 2) Apply the grease inside of bearing (401), and
smoothly. press it into drive shat.
 Before assembly, apply the grease on

both sides of bearing.
LG922E930E07462
18. Install pressure-reducing valve (051) into LG922E930E07464
valve body (303).
LG922E930E07465
LG922E930E07463
7-185
3) Apply the grease on the bearing. 4. Lift up drive shaft assembly with threaded
hole in front end of drive shaft, and then install it
into housing.
 Use the seal on external surface.
(LOCKTITENO.222)
 Do not install forcibly, and do not dam-

age the lip of oil seal carefully with the
clamp in 5.3.4.
LG922E930E07466
Grease
LG922E930E07468
LG922E930E07467
2. Place the housing (102) on horizontal opera-

tion platform
3. Install oil seal (801) in front of housing (102)
with the clamp.
LG922E930E07469
7-186
5. Lift the reduction gear erectly, and make drive 9. No. 2 planetary carrier gp.
shaft downward. 1) Install thrust washer (286).
6. Install the bearing with clamp (402). 2) Insert planetary gear (203).
7. Install the circlip (913). 3) Gently knock No. 2 pin (282) into planetary
8. Fill the grease into housing from grease filler. gear with plastic hammer.
 Test the installation depth of drive shaft

from bearing surface with the clamp
according to the requirements in 5.3.4.
LG922E930E07471
LG922E930E07470
LG922E930E07472
LG922E930E07443
7-187
4) Install spring pin (910) into No. 2 planetary 10. Apply liquid seal on the joint surface of hous-
carrier gp (230), and knock on two ends of ing (102).
spring pin tightly. 11. Install No. 2 planetary carrier gp into housing
 Please refer to installation essentials (102).
LG922E930E07473 LG922E930E07475
LG922E930E07474 LG922E930E07476
7-188
12. Install gear ring (202) into housing (102). 14. Install No.1 sun gear (211).
Fix gear ring with four screws temporarily, and 15. Temporarily remove the bolt, and apply liq-
pay attention to using washer when screwing, in uid seal on the installation surface of housing
case of damage the housing. (102).
13. Install No. 1 planetary carrier gp. 16. Install rear housing (104) to gear ring (202),
and tighten hex bolt.
17. Fill gear oil into reduction gear from the filler,
temporarily install the dipstick, and test gear oil
capacity.
LG922E930E07440
LG922E930E07438
LG922E930E07439
LG922E930E07477
7-189
LG922E930E07478
7-190
7.6.1 Removal and installation of bucket June 10, 2015
7.6 Work implement raping bar.

 It needs the coordination of two per-
sons, one person hammers the pin out
of bucket of pin hole from one end of the pin with
copper hammer and raping bar, and the
Removal
other person holds the pin on the other
1. Start the engine, and operate the machine to end.
make bucket back lie on the ground. Shutdown
the engine.  The pin weighs 21.5 Kg.
 Put the pad between the bucket and  O-ring is installed between bracket of
ground. arm and the bucket, which needs to be
removed and put at safe place.
LG922E930E07479
2. Remove captive bolt and nut (1). LG922E930E07481
3. Remove captive bolt and nut (2).
1
2
LG922E930E07480
4. Remove the pin (3) with copper hammer and

7-191
June 10, 2015 7.6.1 Removal and installation of bucket
5. Remove the pin (4) with copper hammer and 6. Start the engine, lift and swing the boom, and
raping bar. then remove the bucket (5).
 It needs the coordination of two per-

sons, one person hammers the pin out
of pin hole from one end of the pin with
copper hammer and raping bar, and the
other person holds the pin on the other
end.
5
 The pin weighs 28.5 Kg.
 O-ring is installed between bracket of

arm and the bucket, which needs to be
removed and put at safe place.
LG922E930E07483
Installation
Installation steps:
removal sequence.
• Tightening torque of captive bolts (2) and
(4) of the pin, M20: 600±55Nm, and the dis-
4
tance between sleeve and its nearest nut is
1-1.5mm.
• Clean thread part of bolt and nut before
LG922E930E07482
assembling bolt, and apply thread locker
TONSAN 1277 on thread surface.
• Clean the pin hole and pin surface prior
before installation.
• If it’s difficult to knock the pin, 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.
7-192
7.6.2 Removal and installation of link and lever June 10, 2015
7.6.2 Removal and installation 3. Remove captive bolt and nut (1).
4. Remove captive bolt and nut (2).
of link and lever
Removal
1. Remove the bucket. See "Removal and
installation of bucket" for details.
2. Retract arm cylinder, retract boom cylinder to
make work implement drop until arm bracket is 1
on the ground, select proper state to place
sleeper between link (1) and arm, and place
sleeper between cylinder body of bucket cylin-
der and arm during the process.
2
LG922E930E07485
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 lifting equip-
ment and sling.
6. Remove left lever (3).
 There are adjusting washers between

the lever and link, and between the lever
and arm bracket, and it is necessary to
LG922E930E07147
remove and put them at safe place.
LG922E930E07486
7-193
June 10, 2015 7.6.2 Removal and installation of link and lever
7. Place a sleeper between right lever and arm,

knock on little end of the pin (4) with copper
hammer and rapping bar, push the pin (4) to
right lever, and remove the pin (4). 6
bucket cylinder and link, and between
the link and lever, and it is necessary to
remove and put them at safe place.
8. Tighten the piston rod and the cylinder body
with wire rope. 5
LG922E930E07488
10. Remove the link (7), and convey it to safe

place for storage.
7
LG922E930E07487
9. Rotate right lever (5) and drop its end on the

ground, and take off the sleeper. Knock little end
of the pin (6) with cooper hammer and rapping
rod, push the pin (6) to the direction of right
LG922E930E07489
lever, and remove the pin (6) and right lever (5)
at the same time.

the lever and arm bracket, and it is nec-
essary to remove and put them at safe
place.
7-194
7.6.3 Removal and installation of arm June 10, 2015
Installation 7.6.3 Removal and installation

of arm
removal sequence.
• Tightening torque of captive bolts (1) and Removal
(4) of the pin: M20: 600±55Nm, and the dis-
tance between sleeve and its nearest nut is 
1-1.5mm. Before removal oil pipe, open the arm and
bucket completely, keep the distance between
the bucket and the ground about 300~400mm,
shut down the engine, operate the lever to
relieve pressure, release the pressure of the
• Clean the pin hole and pin surface prior to
accumulator, and loosen the hydraulic oil tank
assembly.
cover to release the pressure in the hydraulic oil
• If it’s difficult to knock the pin, then adjust
tank.
the installation position of the lever and link
1. Remove the bucket. See "Removal and
cylinder and knock it again.
installation of bucket" for details in this chapter.
• Do not damage or lose dust ring and
2. Remove link and lever. See "Removal and
adjusting washer during the installation.
installation of link and lever" for details in this
chapter.
3. Remove bucket cylinder. See "Removal and
installation of bucket cylinder" for details.
4. Start the engine, stretch the arm cylinder to
the longest, operate boom cylinder, and put
down work implement to make arm bracket fall
on the ground.
 The pad needs to be placed between the

arm and ground.
7-195
June 10, 2015 7.6.3 Removal and installation of arm
1
LG922E930E07490
LG922E930E07491
5. Lift up arm cylinder with lifting rope and lifting

10. Remove lifting rope on the cylinder.
equipment.
11. Install the pin (2) into pin hole, and lift the
6. Remove the bolt, nut and plate (1) with span-
arm (5) with lifting rope and equipment through
ner.
the pin (2).
7. Remove the pin (2) with copper hammer and
12. Remove captive bolt, nut and plate (3) of
rapping rod.
boom bracket hinge pin.
 There is adjusting washer between arm 13. Remove hinge pin (4) with copper hammer
cylinder and arm, and it needs to take it and rapping rod.
down and place it at safe place. 14. Slowly put the arm on the ground with the
sling.
8. Start the engine, retract arm cylinder piston  The sleeper needs to be placed between
rod, and fasten piston rod with wire rope in case
the arm and ground.
of stretching out.
 Do not release the pressure
9. Lift arm cylinder to certain space with lifting

equipment, place the sleeper between arm cyl-
inder body and the boom, and put arm cylinder
on the sleeper.
7-196
7.6.4 Removal and installation of the boom June 10, 2015
15. Start the engine, and lift and awing the boom 7.6.4 Removal and installation
to remove the arm.
of the boom
Removal

Before removal oil pipe, open the arm and
5
2 bucket completely, keep the distance between
3
the bucket and the ground about 300~400mm,
shut down the engine, operate the lever to
relieve pressure, release the pressure of the
accumulator, and loosen the hydraulic oil tank
cover to release the pressure in the hydraulic oil
4
tank.
LG922E930E07492
 Clean the area around the assembling
Installation ports before removing pipelines, con-

nectors.
removal sequence.  Seal them with plugs or caps when the
The tightening torque of captive bolts of lines, connectors or hoses are in disas-
the pin:
• M12: 120±10Nm
system.
• M20: 600±55Nm
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.
• Clean the pin hole and pin surface prior to 2. Release residual pressure in hydraulic oil line.
assembly.
(See release of residual pressure in hydraulic oil
• If it’s difficult to knock the pin, then adjust line in "Testing and Adjusting")
7-197
June 10, 2015 7.6.4 Removal and installation of the boom
(arm assembly includes arm, bucket, link, lever

and pin)
 The sleeper needs to be placed between

arm and ground.
LG922E930E07493
3. Remove hydraulic hose (1) on both ends of

bucket cylinder with inner hexagon spanner, and
pay attention to wrapping the connector with LG922E930E07495
towel or cloth for protection, to prevent oil

splashing. Fasten the hose on boom tube with 5. Start the engine, and swing the machine till
the strap. there is enough space for removing the boom.
 Hold hydraulic oil leaked from the line
with oil bucket to prevent contaminating
the ground.
LG922E930E07496
1
LG922E930E07494
4. Refer to "Removal and installation of the arm"

in this chapter, to remove arm assembly (2),
7-198
6. Operate the machine to place the boom on

the ground.
 The pad needs to be placed between

boom bracket and ground.
3
4
LG922E930E07498
10. Lift boom cylinder-lh (5) with lifting rope and

equipment.
LG922E930E07497
11. Push boom cylinder and hinge pin (6) of
boom to the position that does not affect the
7. Disconnect the connection of grease line (3) moving of boom cylinder (5) with copper ham-
and boom cylinder. mer and rapping rod.
8. Remove fixed sleeve (4) between boom cylin-
der and boom hinge pin and its accessory bolt
and pin.
6
 There is adjusting washer between
sleeve and cylinder, and it needs to take
it down and place it at safe place.
5
9. Remove fixed sleeve, bolt and nut on the side
of boom cylinder-rh with the method in article 8.
LG922E930E07499
12. Start the engine, retract piston rod of boom

cylinder-lh, and fasten piston rod with wire rope
to prevent it stretching out. Lower boom cylin-
der-lh to revolving frame, and place the sleeper
between the cylinder and frame.
13. Lower the boom cylinder-rh (7) with the
7-199
June 10, 2015 7.6.4 Removal and installation of the boom
same method.
14. Lift the stretching part on both ends of boom

bracket pin of lifting rope and equipment.
9 9
8
7
LG922E930E07501
18. Remove fixed plate (10) of boom and frame

hinge pin and its accessory bolt and washer.
LG922E930E07500
15. Release residual pressure in hydraulic oil

line. (See release of residual pressure in
hydraulic oil line in "Testing and Adjusting")
16. Disconnect the harness (8) and fix it on the
boom with strap.
17. Disconnect the connection between hose (9)
and boom tube.
10
 Wrap the connector with towel or cloth
to prevent oil splashing. LG922E930E07502

with oil-holding equipment to prevent
the contamination.
7-200
19. Remove boom and frame hinge pin (11) with Installation
special tools.
20. Operate lifting equipment to remove the removal sequence.
boom.
The tightening torque of captive bolts of
the pin:
• M12: 120±10Nm
• M20: 600±55Nm
• The distance between the sleeve and the
nearest nut is 1~1.5mm.
11
LG922E930E07503 • Clean the pin hole and pin surface prior to
assembly.
7-201
June 10, 2015 7.6.5 Removal and installation of work implement as

of work implement as
Removal
1. Remove the bucket. See "Removal and 1
installation of bucket" for details in this chapter.
2. Start the engine, operate the machine to
make arm cylinder and bucket cylinder retract
completely, and operate boom cylinder to make
work implement fall on the ground.
LG922E930E07505
5. Lift boom cylinder-lh (2) with lifting rope and

equipment.
6. Push boom cylinder and hinge pin (3) of boom
to the position that does not affect the moving of
boom cylinder-lh (2) with copper hammer and
rapping rod.
7. Start the engine, retract piston rod of boom
cylinder-lh, and fasten piston rod with wire rope
to prevent it stretching out. Lower boom cylin-
LG922E930E07504
der-lh to revolving frame, and place the sleeper
between the cylinder and frame.
8. Lower the boom cylinder-rh (4) with the same
3. Remove fixed sleeve (1) between boom cylin-
method.
der and boom hinge pin and its accessory bolt
and pin.
 There is adjusting washer between

3
sleeve and cylinder, and it needs to take
it down and place it at safe place.
4. Remove fixed sleeve, bolt and nut on the side
of boom cylinder-rh with the method in article 2.
2
LG922E930E07506
7-202
7.6.5 Removal and installation of work implement as June 10, 2015
9. Release residual pressure in hydraulic oil line. 12. Remove fixed plate (7) of boom and frame
(See release of residual pressure in hydraulic oil hinge pin and its accessory bolt and washer.
line in "test and adjustment")
10. Disconnect the harness (5) and fix it on the
boom with strap.
11. Disconnect the connection between hose (6)

and boom tube.
 Wrap the connector with towel or cloth

to prevent oil splashing.

7
with oil-holding equipment to prevent
the contamination. LG922E930E07509
13. Remove the boom and frame hinge pin (8)

with special tools (9).
6 6
5
LG922E930E07507
9
LG922E930E07510
LG922E930E07508
7-203
June 10, 2015 7.6.5 Removal and installation of work implement as
14. Install arm bracket pin back into arm Installation

bracket.
15. Use two sets of lifting equipment for coordi- removal sequence.
nation, one lifts stretching part on both ends of
boom bracket pin, the other lifts stretching part The tightening torque of captive bolts of
of arm bracket pin, and operate two sets of lifting the pin:
equipment to remove work implement assembly • M12: 120±10Nm
(10). • M20: 600±55Nm
• Clean the pin hole and pin surface prior to
10
assembly.
LG922E930E07511
7-204
7.6.6 Removal and installation of bucket cylinder as June 10, 2015
7.6.6 Removal and installation  Separate the cylinder from the arm with
of bucket cylinder as sleeper, and avoid direct touch and

bump to cause appearance wear.
Removal

hydraulic system, and then loosen the hydraulic
oil tank cover to release the internal pressure
from the oil tank.
 Before removing the lines, connectors LG922E930E07512
or hoses, make mark to prevent mis- 3. Retract bucket cylinder, and fix piston rod with
takes during assembly. Clean the wire rope to prevent it from stretching out.
to receive oil.

system.
 Use more lifting points as many as pos-

sible. Lifting ring is not allowed to bear
shear force, and if there is no appropri-
LG922E930E07513
ate lifting point, wide lifting rope able to
bear enough weight must be used.
1. Refer to "Removal and installation of bucket"
and "Removal and installation of link and lever"
in this chapter for the removal of bucket, link and
lever.
2. Operate the machine to lower arm end to the
ground.
7-205
June 10, 2015 7.6.6 Removal and installation of bucket cylinder as
4. Disconnect hydraulic hose (1) on both ends of 7. Knock the little end of pin with copper bar and
bucket cylinder. take it out.
 Wrap the connector with towel or cloth Never stand at receding side of the pin, other-
wise, the sudden falling of the pin will cause per-
to prevent oil splashing.
sonal injury.
5. Remove captive bolt of bucket cylinder pin
8. Take down bucket cylinder and horizontally
plate, and take down the plate (2).
place it on the sleeper.
LG922E930E07514
LG922E930E07516
6. Lift bucket cylinder with strap and lifting

equipment.
 Be sure to fix piston rod in the shortest

and safe state, and then lift it.
LG922E930E07515
7-206
7.6.6 Removal and installation of bucket cylinder as June 10, 2015
Installation Precautions:
Welding is not allowed on the cylinder, and the 1) Please clean the pin hole and pin surface
cylinder can not be ground wire for welding, in before installation.
case of electric arcs between piston rod and cyl- 2) If it’s difficult to knock the pin, adjust the
inder head, and piston and cylinder body dam- installation position of the bucket and knock it
aging parts. again.
Installation sequence is just reverse to the 3) Protect the seal ring from damage during
removal sequence installation.
• The tightening torque of pin captive bolts: 4) Fill grease after finishing installation.
M12: 120±10Nm. 5) Check the surface of piston rod, and it is not
• Clean bolt hole before installation, and allowed to have tape, paint, concrete, etc. to
apply thread locker TONSAN 1277 on adhere on the surface of piston rod in case of
thread surface. damaging seal ring during action.
• Tightening torque of captive bolt of the oil 6) Any dirt is not allowed to enter into hydraulic
pipe flange: system during removal and installation of
M10: 73.5±3.5Nm; hydraulic cylinder. Oil port shall be sealed in reli-
able 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.
7-207
June 10, 2015 7.6.7 Removal and installation of arm cylinder as
7.6.7 Removal and installation 1. Lift arm cylinder steadily with nylon strap and
lifting equipment.
of arm cylinder as
Removal

hydraulic system, and then loosen the hydraulic
from the oil tank.
LG922E930E07517

to receive oil.

system.

7-208
7.6.7 Removal and installation of arm cylinder as June 10, 2015
2. Remove captive bolt of piston rod pin, and 5. Remove two hydraulic hoses (2) with arm cyl-
remove the plate (1). inder.
3. Knock the little end of pin with copper bar and 6. Disconnect grease hose (3);
take it out. 7. Remove captive bolt of piston rod pin, and
 Never stand at receding side of the pin, remove the plate (4).
otherwise, the sudden falling of the pin

will cause personal injury.
3
4
1
LG922E930E07520
LG922E930E07518
8. Knock the little end of pin with copper bar and
take it out.
4. Operate the machine to make arm bucket pis- Never stand at receding side of the pin, other-
ton rod retract completely, and fix piston rod with wise, the sudden falling of the pin will cause per-
wire rope to prevent it stretching out. sonal injury.
 Be sure to fix piston rod in the shortest 9. Slowly lift arm cylinder and place it on the
sleeper.
and safe state, and then lift it.
LG922E930E07519 LG922E930E07521
7-209
June 10, 2015 7.6.7 Removal and installation of arm cylinder as
Installation Precautions:
Welding is not allowed on the cylinder, and the 1) Please clean the pin hole and pin surface
cylinder can not be ground wire for welding, in before installation.
case of electric arcs between piston rod and cyl- 2) If it’s difficult to knock the pin, adjust the
inder head, and piston and cylinder body dam- installation position of the bucket and knock it
aging parts. again.
Installation sequence is just reverse to the 3) Protect the seal ring from damage during
removal sequence: installation.
• The tightening torque of pin captive bolts: 4) Fill grease after finishing installation.
M12: 120±10Nm. 5) Check the surface of piston rod, and it is not
• Clean bolt hole before installation, and allowed to have tape, paint, concrete, etc. to
apply thread locker TONSAN 1277 on adhere on the surface of piston rod in case of
thread surface. damaging seal ring during action.
• Tightening torque of captive bolt of the oil 6) Any dirt is not allowed to enter into hydraulic
pipe flange: system during removal and installation of
M10: 73.5±3.5Nm. hydraulic cylinder. Oil port shall be sealed in reli-
7-210
7.6.8 Removal and installation of boom cylinder as June 10, 2015

of boom cylinder as
Removal

the engine, screw the key to the KEYON posi- 1
hydraulic system, and then loosen the hydraulic LG922E930E07522
from the oil tank.
2. Remove the captive bolt of piston rod pin and
 Before removing the lines, connectors take down the sleeve (2).
or hoses, make mark to prevent mis- 3. Remove grease line (3).
to receive oil.
 Seal them with plugs or caps when the 3

system. 2

LG922E930E07523
1. Fix boom cylinder (1) with nylon strap and
travel crane.
7-211
June 10, 2015 7.6.8 Removal and installation of boom cylinder as
4. Knock the little end of pin with copper bar and 6. Disconnect hydraulic hose (4) of boom cylin-
take it out. der.
 Never stand at receding side of the pin,

otherwise, the sudden falling of the pin
4
will cause personal injury.
LG922E930E07526
7. Remove captive bolt of boom cylinder body

LG922E930E07524
pin, and take pin plate out (5).
8. Remove boom cylinder body pin (6).
5. Operate the excavator to make boom cylinder
piston rod retract completely. Fix piston rod with
wire rope to prevent it from stretching out. Place
a wood block on lower part of boom cylinder to
lower the cylinder gently. 6
LG922E930E07527
LG922E930E07525
7-212
7.6.8 Removal and installation of boom cylinder as June 10, 2015
9. Lift boom cylinder as out and place it on Installation

sleeper.
Welding is not allowed on the cylinder, and the
 Be sure to fix piston rod in the shortest cylinder can not be ground wire for welding, in
and safe state, and then lift it. case of electric arcs between piston rod and cyl-
inder head, and piston and cylinder body dam-
aging parts.
removal sequence:
• The tightening torque of pin captive bolts:
M12: 120±10Nm.
• Clean bolt hole before installation, and
apply thread locker TONSAN 1277 on
thread surface.
• Tightening torque of captive bolt of the oil
pipe flange:
LG922E930E07528
M10: 73.5±3.5Nm;
Precautions:
1) Please clean the pin hole and pin surface
before installation.
2) If it’s difficult to knock the pin, adjust the
installation position of the bucket and knock it
again.
3) Protect the seal ring from damage during
installation.
4) Fill grease after finishing installation.
5) Check the surface of piston rod, and it is not
allowed to have tape, paint, concrete, etc. to
adhere on the surface of piston rod in case of
damaging seal ring during action.
6) Any dirt is not allowed to enter into hydraulic
system during removal and installation of
hydraulic cylinder. Oil port shall be sealed in reli-
7-213
June 10, 2015 7.6.9 Disassembly and assembly of cylinder
7.6.9 Disassembly 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 cylin-
ders 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
7-214
7.6.9 Disassembly and assembly of cylinder June 10, 2015
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
10 Oil pipe group B 31 Dust ring
11 Clamp group 32 C-bushing
12 Pressing 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 Hex bolt
21 Steel wire snap ring
7-215
Disassembly
Preparations
1. Keep the operation area clean and tidy.
Fixed device
2. Estimate the total weight of the hydraulic cyl-
inder 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 mat-
ter.
 Protect the hydraulic cylinder assembly 5. Fix the piston rod with the pin hole and the flat
(piston rod in particular) from damage. part of piston rod lifting eye.
1. Drain the oil from cylinder. 6. Remove the piston nut.
2. Fix the hydraulic cylinder. 6.1 Remove the setscrew.
2.1 Remove the pipe and other interferential There are two chisel seams at the outside of set-
objects before the fixation. screw; they’re used for riveting on the cushion
2.2 Fix the hydraulic cylinder on the vertical or head. Remove the riveting parts with hand drill,
horizontal position. and then remove the setscrew.
2.3 Locate with he pin hole of the cylinder bot- 6.2 Remove the steel ball from setscrew.
tom. 6.3 Remove the piston nut.
3. Remove the cover.
The screw thread type: remove it with hook
spanner.
4. Pull out the piston rod
4.1 Affirm that the pipes, etc. have been
removed.
4.2 Prepare the appliance to collect the hydrau-
lic oil from the hole of telescope side (the cover
side).
4.3 Pull out the piston rod to the longest posi-
tion, loosen and pull out the cover slowly.
4.4 Pull out the piston rod with the cover LG922E930E07531
together, place it on the sleeper.

7-216
7. Remove the parts such as piston, etc. extend the iron needle to the bottom of seal ring,
Remove components according to the and run through the primary sealing element,
sequence: Nuts→ Pistons → Cushion Collars → then overturn and pry the whole sealing element
Covers. to take it out.
8. Remove the cushion collars of telescope side. 10.2 Remove the buffer ring: first remove the
8.1 Remove the piston nut. backup ring (black), and the following removal is
8.2 Without damaging piston rod and cushion same as the removal of primary seal.
collar, knock the elastic rand with plastic ham-
mer or other tools to remove it. 11. Remove the dust ring and circlip.
8.3 Slide the cushion collar to the piston rod 11.1 When removing the dust ring, put the screw
screw, and then the baffle rings (2 slices) fall off. driver against the opening of the dust ring circlip,
8.4 Remove the cushion collar. There is a gap knock the bottom of circlip, and then pry the cir-
on the cushion collar, then remove the cushion clip to take it out.
collar by using the gap. 11.2 Continue to knock the screw driver until it
9. Removal of piston seal. running through the whole dust ring, then over-
9.1 The guide rings and wiper rings shall be turn and pry the entire dust ring to remove it.
removed simply by hands. 12. Remove the slide bushing.
9.2 Make the screw driver up-right with the seal 12.1 Find the juncture of the slide bushing.
ring and knock it with hammer, then cut off and 12.2 Support the upper end of the slide bushing
remove it. opening with screw driver, and then knock on
9.3 Take out the O-ring with iron needle. the screw driver with the hammer until it pass
through the whole slide bushing.
12.3 Remove the entire slide bushing with screw
driver.
Thread
13. Remove the lifting eye dust ring and the
bushing.
Piston rod 13.1 Remove the dust ring from the lifting eye
hole. Same as the removal of the cover dust
ring, remove it with screw driver or other tools.
Buffering Baffle ring 13.2 Remove the bushing with the back block,
Snap ring ring with Cushion collar (two-piece)
one notch as shown in figure.
10. Remove the cover seal.

10.1 Remove the primary seal: Put iron needle
against the upper edge of the seal ring and
7-217
Backrest
block
Press
Piston rod
Mounting clamp Dust ring
Shaft
bushing
Shaft
bushing
Installation 2. Assembling the cover units.
1. Install the lifting eye dust ring and bushing. 2.1 Press the slide bushing with the sectional
fixture.
1.1 Press it into the piston rod axle hole with the
sectional fixture. 2.2 Install the steel snap ring into the slide bush-
ing snap ring slot.
1.2 Install dust ring with the back block.
Recheck the slide bushing for the scratch.
 Don’t scratch the slide bushing during

the assembly.
Press
2.3 Take out the O-ring backup ring from the
heating box and assemble it, Press the backup
Mounting clamp ring with iron needle, and rotate it for one revolu-
tion around the ring recess to transform it. Place
Shaft
bushing
the relevant O-ring into the groove, install it with
iron needle and rotate it for one revolution to
ensure that the assembly is complete without
turn-up.
2.4 Overturn the cover by 180°.
7-218
2.5 Install the buffer ring into its groove. 2.9 Precautions about the installation of cover
sealing elements.
 Pay attention to the direction. Install the
small backup ring into the buffer ring,
and keep the circular side of the small
Dust ring and snap ring
backup at the inner side.
2.6 Install the primary seal ring into the seal ring Main sealing ring
groove. Buffering ring and snap ring
 Pay attention to the direction of the pri- Slide bushing

mary seal ring, and install the backup O-ring (white)
ring firstly if there’s primary seal backup
O-ring (Black)
ring,
2.7 Apply adhesive to the outside area of the
dust ring, place it on the dust ring groove, and
then place the guide sleeve under the pressure
head and press it.
2.8 Erase redundant adhesive around the dust
ring with wiping paper, and then install the
backup ring into its groove.
Clamp
Cover
Slide bushing
7-219
1. Forget to assemble or not

2. Whether the mounting
position is correct
3. Are there parts installed in
wrong direction?
Main sealing ring Buffering ring and

Do not confuse snap ring
with the snap ring Slide bushing
Firstly, install the No damage on
buffering ring the internal
Then, install surface
the snap ring
(note the
direction)
Dust ring Snap ring

O-ring and backup ring
Install it to the Install it in the
bottom groove. Piston rod Snap
may be scratched if ring
it slides out from the

开损伤
groove.
O-ring Fail
Qualified O-ring Fail
Snap ring
protrudes sinks
upward downward
 The chamfering side faces outward and

3. Install the piston sealing elements.
the two gaps of the backup ring are not
3.1 Install the black lining ring into the seal ring on the same direction.
groove of the piston with iron needle (prevent
3.6 Both guide rings and wiper rings have open-
the sealing elements from being scratched).
ings, open the openings in minimum limit, and
3.2 Put the guide jig onto the piston.
then install it from the axial direction.
3.3 Take out the primary seal ring from the heat-
ing box and install it to the interior guide jig, and
then place the exterior pressure sleeve.
3.4 Press the external sleeve by the compres-
sor. Press the seal ring into the groove, then
remove the sleeve and guide jig.
3.5 Install snap ring of the seal ring for hole
7-220
4.3 For the piston rod with the front cushion col-
Please compress Backrest block Please compress
lar, install the facing parts of the cushion collar
using a compressor using a compressor
according to the following figure.
Jig
Correcting clamp
Flat wire Cushion Piston
direction collar
Jig
Piston
Seal ring Seal

ring
Snap ring
Front buffer
4. Install the piston rod as.
4.1 Fix the piston rod side.
4.2 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 following figure to install the
guide sleeve and piston rod.
LG922E930E07539
7-221
4.4 For the piston rod with back buffer, install 5.3 When the piston rod entering into the cylin-
relevant parts according to the following orders. der body, protect the wiper ring and guide ring
• 4.4.1 Install the jaggy direction of the buffer from falling off.
ring into the ring recess towards the thread
side. 6. Tighten the cover
• 4.4.2 Install the facing parts of the cushion Tighten it according to the required tightening
collar according to the following figure. torque on the assembling drawing.
• 4.4.3 Put the baffle ring (2 slices) into the 6.1 The thread type: tighten it with the hook
slip groove. spanner.
• 4.4.4 Press the cushion collar towards the
baffle ring sufficiently, and then install the
rand. Knock it into the slip groove with
hammer without damaging the piston rod Punch
Riveting
and cushion collar.
Setscrew
Steel ball
Thread
Piston rod
Buffering ring Buffer bearing Baffle ring

7. Install the tubing.
Clip
with notch bushing (two-piece) 7.1 Confirm whether the O-ring is installed into
the groove correctly.
7.2 Insert the oil tube into the connector and
tighten the nut.
4.5 Fasten the piston nut. 7.3 According to the requirements of assembling
4.6 Install the setscrew and steel ball on nut. drawing, adjust the position of the oil tube and
• After fastening piston nut, put in steel ball tighten the clamp.
and tighten setscrew. Rivet two parts of the 7.4 Tighten the fastening nut.
periphery with the cushion head.
5. Install the piston rod into the cylinder body.
5.1 Fix the cylinder body vertically or horizon-
tally.
5.2 The vertical situation: install piston rod into
the cylinder body according to its dead-weight.
7-222
8. Test run
8.1 Conduct full-stroke movement more than six
times slowly after the machine body is installed
to keep the hydraulic cylinder full of oil.
8.2 If the oil cylinder is filled with exhaust vents,
try to pressurize the exhaust vent side (return
side) to release the air.
8.3 Apply the grease or engine oil to the bushing
at both ends of the lifting eye.
Note the
O-ring
7-223
CLG920D/922D 7.7 A/C system
June 10, 2015 7.7.1 Removal and installation of A/C compressor as
7.7 A/C system 1. Remove four captive bolts (1) of diesel engine
fan protection shield. Move shield-lh of the fan
7.7.1 Removal and installation (2).
of A/C compressor as
Removal 2

Before the removal of the air compressor
assembly, recycle the refrigerant in the A/C sys-
1
tem by using the refrigerant filling device, and
ensure that there is no pressure in the A/C sys-
tem, and then remove it. During the recycle of
the refrigerant, please wear the goggles cor-
rectly to prevent personal injury.
LG922E930E07544
 During the removal and the installation,

2. Unscrew locking bolt (3) of A/C belt tension
it is prohibited to use cottony gloves, in pulley
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 sys-
tem.
LG922E930E07545
7-224
7.7.1 Removal and installation of A/C compressor as June 10, 2015
3. Unscrew tension bolt (4) of A/C belt tension 6. Separately remove captive bolt (7) of A/C
pulley to removable position of A/C belt. refrigerating tube on the side of A/C compres-
4. Move tension pulley along guide groove of sor, and move refrigerating tubes (8) and (9)
compressor bracket and take down A/C belt (5). out.
7
4
5
8
LG922E930E07546 LG922E930E07548
5. Disconnect base machine harness connector 7. Remove four captive bolts (10) of A/C com-
(6) mutually inserting with compressor clutch pressor with spanner, and take down A/C com-
connector pressor (11).
8. Weight of compressor as: 6Kg.
11
10
LG922E930E07547
LG922E930E07549
7-225
June 10, 2015 7.7.1 Removal and installation of A/C compressor as
Installation
• Adjust the pre-tightening force of the A/C
compressor belt to 441±88.2N.
• M6 bolt torque of connector: 10±2Nm.
• Upon the assembly of the A/C compressor,
it needs to use the refrigerant filling equip-
ment to vacuumize the A/C system and fill
it with refrigerant, and the filling quantity of
the refrigerant is 950±50g.
7-226
7.7.2 Removal and installation of A/C evaporator as June 10, 2015
7.7.2 Removal and installation of A/C evaporator as

Removal

Before the removal of the A/C evaporator as, recycle the refrigerant in the A/C system by using the
refrigerant auto filling and recovery installation, 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 pre-
vent 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.
Figure Steps
1. Remove six captive bolts (1) of bottom
plate on lower part of floor plate, and
take down bottom plate (2).
LG922E930E07550
7-227
June 10, 2015 7.7.2 Removal and installation of A/C evaporator as
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
7 6
LG922E930E07552
7-228
7.7.2 Removal and installation of A/C evaporator as June 10, 2015
4. Remove fixed clamp (8) of A/C water

pipe.
5. Pull water pipes (9) and (10) out.
8
10
LG922E930E07553
6. Remove fridge (12) and storage grid

(13) on upper part of A/C hood in the
cab.
12
13
LG922E930E07555
7-229
7. Remove the two screws (13) on the

coverplate at the back of the cab.
Remove the coverplate (14).
14
13
LG375A02003
8. Remove four captive bolts (15) and

three fastening screws (16) of A/C
hood cover and take down the cover
15 17
(17) & (18).
18
16
LG922D07026
7-230
9. Remove three captive bolts (19) of

cover, and take down the cover (20).
10.Remove the fixing screws (21) on the
mounting bracket of return air strainer.
Remove the mounting bracket (22) of
return air strainer.
20
19 22
21
LG922D07027
11.Remove setscrew (23) of new air duct

that butt joint with new vent o
evaporator as to extract new air duct
23 (24).
24
LG922D07028
7-231
12.Remove the hoop (25) of the rear air

duct upon the evaporator assembly.
Remove the the rear air duct (26) &
25 (27).
27
26
LG922D07029
13.Remove four air ducts (23)(24)(25) on

the side of evaporator as.
23
24 25
LG922E930E07560
14.Remove two captive bolts (26) of air

duct guard plate on front lower part of
evaporator as, and take down air duct
guard plate (27).
27
26
LG922E930E07561
7-232
15.Push feet blow air duct (27) forward,

and separate from feet blow air duct of
evaporator as.
27
LG922E930E07562
16.Remove the connectors (28) and (29)

connected with A/C harness and
28 located on rear part of evaporator as.
29
LG922E930E07563
17.Remove seven captive bolts (30) of

evaporator as.
18.Move A/C evaporator as (31) from the
floor.
31
30
LG922E930E07564
7-233
Installation
• The torque requirements of the A/C cooling pipe connectors on the side of the evaporator as: M6,
10±2Nm.
• After the installation of the A/C evaporator as, it needs to use the refrigerant filling equipment to vacu-
umize the A/C system and fill it with refrigerant, and the refrigerant filling quantity is 950±50g.
• Pay attention to the orientation when installing air filter outside the air conditioner, suede side of evap-
orator should face inward.
7-234
CLG920D/922D 7.8 Cab
June 10, 2015 7.8.1 Removal and installation of cab
7.8 Cab
7.8.1 Removal and installation of cab
Removal

Before the removal of the cab, move the machine to the level ground to guarantee there is no heavy
sway while lifting the cab, and avoid the personal injury.
 Please be careful about the operation, and during the lift, the water pipes and harness shall not
drag other components.
Figure Steps
1. Open the left backdoor of the bonnet(1). Turn off
the cathode switch(2). Open the left frontdoor
(3)of the bonnet. Remove the battery cover (4).
Remove the cathode cable (5) from the battery.
3 4 5 2 1
LG922D07030
2. Remove the coverplate (6) at the back of the cab.
6
6
LG922D07031
7-235
3. Remove the hoops (11) for fixing the cooler (7),

sundries box (8) and for connecting the air duct
(9) & (10).
7
8
11
11
9
10
LG922D07032
4. 1. Remove the fridge (7), sundries box (8), upper

cover (12) and lower cover (13) and cover (14)
behind the cab and move them out;
7
8
12
14
13
LG922D07033
7-236
5. Remove the 5 of air ducts (9) (10) (16) (17) (18)

connecting to the A/C evaporator (15);
9
10
16
17
18 15
LG922D07034
6. Disconnect the connector (19) on right rear

upright of the cab;
7. Disconnect a row of connectors (20) at the rear of
the cab;
8. Disconnect two connectors connected with
19 20
21 23 controller (21);
9. Disconnect two connectors (22) connected with
fuse box;
22 10.Disconnect the nine-pin plug (23)
11.Disconnect the connector (24) connecting frame
harness and A/C harness and located on right
side of A/C evaporator (15)
12.Remove the four fixing clamps (25), pull out its
wire harness and place on the floor;
24 25 15
LG922D07035
7-237
13.Disconnect the two relays (26) (27) of the A/C

evaporator (15);
15
26
27
LG922D07036
14.Remove the step (28);

15.Move floor mat out (29);
29
28
LG922D07037
7-238
16.Remove the 10 bolts (30) connecting the cab and

floor plate and located on cab bottom frame.
30
30
30 30
LG922D07038
17.Disconnect water pipe (31) on washing end of

wiper washer reservoir in the rear of the cab from
washer reservoir (32);
18.Remove the clamp (33) from fixed water pipe
(31);
19.Tidy water pipe (31) and fix on outer wall of the
33 cab, located at water pipe outlet on right rear side
of the cabin outside the cabin.
32
31
LG922D07039
20.Install the M16 eyebolt to the lug (35) on the top

of the cab, and use the 4 M16 sling bolts (34) to
hook two eyebolts on the diagonal corners and
36 remove the cab from the machine.
34 21.Start lifting equipment, and slowly lift the cabin.
35
 The cab weight is 350kg, so please
select applicable sling.
 Please be careful about the operation,

and during the lift, the water pipes and
harness shall not drag other compo-
nents.
LG922D07040
7-239
Installation
 The mounting bolt of the cab is M12-10.9 and its tightening torque is 120±10 Nm;
 All need applying of thread locker (code is ANL8).
 Clean the thread hole before applying tread locker.

7-240
June 10, 2015 7.8.2 Removal and installation of floor plate as
7.8.2 Removal and installation of floor plate as

Removal
 When removing the hose, mark on the hose and connectors to facilitate the matching when
assembling:
 Seal the removed connectors or covers or plugs on hoses to prevent water, dust, etc.;
 Clean the area around the assembling ports.
Corresponding figure Operation procedure

1. Remove the cab. For specific operations, refer to
7.8.1 Removal and Installation of Cab
2. Remove the plate (1) and plate (2) on lower part
of the cab.
1 2
LG922D07041
3. Disconnect the two connectors (5) & (6)

connecting with the floor frame wire harness (3)
and the frame wire harness (4). Separate the
frame wire harness (4) from the floor frame(7);
6
4
7
LG922D07042
7-241

4. Disconnect two A/C water pipes (8) and
refrigerating tubes (9) located on lower part of A/
C evaporator assembly.
LG922D07043
5. Disconnect 13 pilot lines connectors (10) located

on the rear part of the cab;
10
10
LG922D07044
7-242
7.8 Cab CLG920D/922D
7.8.2 Removal and installation of floor plate as June 10, 2015

6. Disconnect the 6 pilot tubes (12), located at the
bottom of the floor frame and connected to
walking pilot valve (11);
11 12 7. Disconnect pilot clamp (13), clamp (14) and
clamp (15) at the bottom of floor;
13 8. Arrange all the 6 pilot tubes (11) and pull them to
the rear part of the cab to ensure there is no
pulling phenomenon during the process of lifting
cab.
9. Arrange 13 pilot hydraulic lines (10) and ensure
there is no pulling phenomenon with other parts
during lifting process.
LG922D07045
10.Remove the 4 of M16 mounting bolts (16)

connected to the floor frame (7) and the absorber
(17).
15 10
14
LG922D07046
7-243
16 16
17
16 16
LG922D07047
11.Install the 4 of M12 eyebolts (18) to the lifting

holes at 4 corners on the floor frame.
12.Hook the eyebolts (18) with 4 hooks of the sling
(19).
19 13.Start lifting device, and slowly hang from floor
plate.
18  The bearing capacity of the sling shall
not be less than 300 KG.
 Please be careful about the operation,

7
and the pilot pipes shall not drag other
components during the hang process, .
LG922D07048
Installation
• Tightening torque of mounting screw of cab shock absorber is 305±25N.m, and apply thread locker
(ANL8) on the thread to prevent the looseness of nut.
Part of copyrights is reserved by Cummins Co.,Ltd.
Any reproduction shall be used for specific purpose
with permission of Cummins.
It is forbidden to use and/or reproduce the document
without permission of Cummins.

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201506001

Applicable type and model: CLG920D/922D Cummins QSB7

Safety ........................................................... 1-1

1.1 Safety precautions ......................................................................................... 1-4

Article 65 of California Suggestions

1.1 Safety precautions Do not wear loose clothes, jewelries or long

When operating and maintaining the

Goggles, safety glasses or mask can protect

If you work under loud noise, please wear

• Learn about the gesture singles and the

use inflammable materials as detergents, Compressed air

• Report all necessary repair work in a timely

High-pressure solution Even if the pressured liquid is leaked from a

Safe disposal of waste liquid Precautions for accumulator

Asbestos Prevention of extruding or

• Make sure there's no foreign matter in the

• If the repair procedure must be performed Coolant

• When checking the coolant level, the

• At working temperature, the hydraulic oil

Protection for fire and explo- cleaned completely.

• Clean and tight all the electrode connec-

Diethyl ether Piping, pipe and hose

Fire extinguisher and first aid Prevention of injury by thunder

Inspect and maintain the fire extinguisher

Cab protector Measures in emergency

be away from hazardous zone. Please add TOP

2 1. Escape hammer 2. Fire extinguisher (optional)

Precautions for accessories

Precautions for operating

Precautions for operating

gency. Selection of rope

Note: allowable load value is 1/6 of breaking

2.1 How to read the Manual .....................................................................2-3

2.1 How to read the Manual

2.2 Marking of Revised Version

2.3 General Torque Specifications

Tightening torque of 24° cone O-ring sealed connector

Hose inner Tightening torque

Tightening torque of flange-type sealed connector bolt

Bolt Tightening torque

Tightening torque of thread angle type sealed connector

Joint tightening torque

2.4 Unit conversion table

Parameters Metric unit British unit Multiple

2.5 Cable Identification Methods

Indicates heat-resistant, lower-voltage wire for automobiles, red, with

Color abbreviation codes

Color Abbreviation Color Abbreviation

Remark: the code composed of two colors indicates double-color wire

Circuit type and color abbreviation code

Circuit type Color abbreviation codes

2.6 Coating materials

Name Specifications Main features and purposes

2.7 Weight table

Components Weight (kg)

2.8 Usage specifications for oils

Oil change interval

Technical specification of oil (QSB7 engine)

3 Structural Function and

3.1 Power system ................................................................................................. 3-3

3.1 Power system 3.1.2 Water radiator, hydraulic

1. Left rear engine support

1. Intercooler hydraulic oil radiator