EXCAVATOR MAINTANCE

CUSTOMER SUPPORT T O U G H W O R L D . T O U G H E Q U I P M E N T.
DEPARTMENT
C O N T E NT S
1. The Recommended oil

2. Main maintenance item and location

3. Maintenance Intervals

4. Maintenance point of every system

Attention

 Park the machine as follows before maintenance:

 1. Park the machine on flat ground.
 2. Lower the bucket onto ground.
 3. Set the engine speed to idling speed and run it for 3 minutes.
 4. Turn the start switch to OFF position and take off the key
 5. Push the pilot control lever to LOCK position.
 6. Attach a “DO NOT OPERATE” tag to right hand control lever
if the machine is not operated.
 1. The Recommended oil
Kinds of Circumstance
quantity Oil brand/Specification
oil plants temperature
-20 ～ 40℃ （ -4 ～
2# MSO2 lithium based grease★
104°F ）
According -20 ～ 40℃ （ -4 ～
lubricate Mobile EP2
to require 104°F ）
-20 ～ 40℃ （ -4 ～
Shell EP2 or RO2
104°F ）
Mobile 1# （ 5W-40 ）（ API CG-4 ） -20 ～ 20℃ （ -4 ～ 68°F ）
Mobile 1300 （ 15W-40 ）（ API CG- -10 ～ 40℃ （ 14 ～
4） 104°F ）
Engine oil 25L
Shell 10W-30 （ API CG-4 ） -20 ～ 35℃ （ -4 ～ 95°F ）
-10 ～ 40℃ （ 14 ～
Shell 15W-40 （ API CG-4 ）★
104°F ）
ASTM D975 NO.1 ★ -20 ～ 0℃ （ -4 ～ 32°F ）
Fuel 412L -10 ～ 40℃ （ 14 ～
ASTM D975 NO.2
104°F ）
SHELL antifreeze(100 ％ primary) and -30 ～ 40℃ （ -22 ～
Coolant 30 water 42:58 104°F ）

According SAE85W-140 （ API GL4 ） -Swing reduction -20 ～ 40℃ （ -4 ～

Gear oil "
Note: ★to" require
used by SAE85W-90
the manufacturer after the machine104°F
is newly produced 4
（ API GL4 ） -Travel reduction ）
Table of contents

1. The Recommended oil

2. Main maintenance item and locatoin

3. Maintenance Intervals

4. Maintenance point of every system

 2. Main maintenance item and location

Open the right door 、 may be check and maintenance on the

ground
Fuel prefilter Engine oil filter

Fuel fine-filter

Check hydraulic oil

Oil-water separator level ： daily check
(with Upgrade pump
of fuel ）
Pilot filter

Oil-water
separator filter

（ The view of after

open the right door ）
The water drain
balve of fuel
tank: everyday
or every 8 hour 6
2
. Main maintenance item and location

Open the back-left door 、 may be check and maintenance

on the ground

The sight glass

Ignition switch ( The view of after open
the back-left door )

7
2. Main maintenance item and location

Open the front-left door 、 may be check and

maintenance on the ground

Maintenance air filter ：

Inside filter, outside filter
Clean every 50 hours,replace every
500 hours

Outside filter of
air-condition

（ The view of after

open the front-left
door ）
8
2. Main maintenance item and location

Oil drain valve Great capacity

of engine oil engine oil pan
922D adopt 25L great
Oil drain valve of
capacity engine oil
engine oil →Driver can
pan （ 225C ：
keep clealily when let
18L ） →
engine oil out

9
2. Main maintenance item and location

Add lubrication to
track tension device

10
Table of contents

1. The Recommended oil

2. Main maintenance item and location

3. Maintenance Intervals

4. Maintenance point of every system

Table of contents
3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

3.1 Every 8 hours or every day service

 3.1.1 Check the oil level of the engine

 3.1.2 Check coolant level
 3.1.3 Check hydraulic oil level
 3.1.4 Drain water and trash from the fuel tank
 3.1.5 Clean the fuel pre-filter, fuel filter and trash
 3.1.6 Check the refrigerant for leakage.

13
3.1.1 Check the oil level of the engine

OK

 Attention: In order to avoid scalds , do not

inspect when engine oil is high temperature.
3.1.2 Check coolant level

 Attention: After the engine coolant temperature drops

down to 50 ℃ , slowly screw out the water radiator cap to
release pressure in order to avoid scalded by high
temperature vapor or splashing coolant.
 3.1.3 Check hydraulic oil level

Park the machine as follow before check:

OK
3.1.4 Drain water and trash from the fuel tank
3 . 1 . 5 C l e a n t h e f u e l p r e f i l t e r, f u e l f i l t e r a n d t r a s h
3.1.6 Check the refrigerant for leakage

Under normal working

condition, refrigerant
can be viewed through
the sight glass. An even
and stable refrigerant
flow indicates that the
refrigerant capacity is
normal. If bubbles are
found in the refrigerant,
then replenish
refrigerant because that
indicates a refrigerant
leakage in the system.
Table of contents
3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

 3.2 Every 50 hours or every week service

 3.2.1 Lubricate the boom pin

 3.2.2 Lubricate the bottom pin of boom
cylinder
 3.2.3 Lubricate the arm, bucket and linkage
pin
 3.2.4 Check and adjust the track
 3.2.5 Clean the air filter

21
3.2.1 Lubricate the boom pin

Boom pin
3.2.2 Lubricate the bottom pin of boom cylinder

The bottom pin of

boom cylinder
3.2.3 Lubricate the arm, bucket and linkage pin

Lubricate
point
3.2.4 Check and adjust the track

 (1) As the figure shows, swing the upper structure for 90°
and lower the bucket to the ground before raising the track.
Keep the angle of boom and arm within 90° to 110°, and
keep the bucket bottom contacted the ground.
 3.2.4 Check and adjust the track

 2) Measure the distance from the bottom of track frame and

the back of track shoe.
CLG922D ： 275 to 350 mm ；
CLG925D ： 275 to 350 mm ；
CLG936D ： 370 to 400 mm ；

Measure the
distance
3.2.4 Check and adjust the track

 (3) To tension the track, firstly turn

the grease fitting to the convenient
position, and then connect the
grease gun. Add grease till the
tension within the recommended
limit.

 (4) To loosen the track, turn the valve

counter clockwise and slowly. When
valve is loosened for 1 to 1.5 circles,
the grease will flow out from grease
outlet. If the grease does not flow out
smoothly, lift the track above ground,
slowly rotate the track.
3.2.5 Clean the air filter

A lot of dust Pat with

your hands

Caution: If the air has the

dust, will creates the
cylinder wear

Blowing from the

inside out with
compressed air
Table of contents

3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

3.3 Every 100 hours or two week service

 3.3.1 Lubricate the boom and arm pivot pin.

 3.3.2 Lubricate the pin of arm cylinder
 3.3.3 Lubricate the bottom pin of bucket cylinder
 3.3.4 Lubricate the piston pin of boom cylinder
 3.3.5 Check and adjust belt tension of fan
 3.3.6 Check and adjust belt tension of compressor

30
3.3.1 Lubricate the boom and arm pivot pin

Lubricate point
3.3.2 Lubricate the pin of arm cylinder

The piston pin The bottom pin

3.3.3 Lubricate the bottom pin of bucket
cylinder

The piston The bottom

pin pin
3.3.4 Lubricate the piston pin of boom
cylinder

 The piston pin

of boom
cylinder
3.3.5 Check and adjust belt tension of fan

 Slack fan belt could cause

inappropriate battery charging,
engine heating and quick and
abnormal wear. But over
tightened fan belt also will cause
bearing and belt damaged.
 9.5-12.7mm (the maximum
deformation by hand )
3.3.6 Check and adjust belt tension of compressor

 Slack fan belt could cause air

condition refrigeration capacity
fall

 5-10mm (the maximum

deformation by hand )
 Table of contents
3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

3.4 250Hours or monthly

 3.4.1 Check the swing reduction gear oil

 3.4.2 Check the travel reduction gear oil
 3.4.3 Check the tightening torque of bolts and
nuts
 3.4.4 Replace the engine oil
 3.4.5 Replace the engine oil filter
 3.4.6 Replace the primary fuel filter
 3.4.7 Replace the fuel filter
 3.4.8 Clean the air-condition filter

38
3.4.1 Check the swing reduction gear oil
 Take out dipstick, the oil level should reach the position
between L and H. If the oil level is below L, then open oil fill
cap to replenish gear oil.

OK

Refill oil
Oil dipstick Port for lubricating oil
3.4.2 Check the travel reduction gear oil
 (1) Move the machine slowly until oil level plug is located to
level mark
 (2) Unscrew air exhaust plug slowly to release pressure after
the gear oil cools down completely
 (3) Unscrew plug to check oil level. The oil should be below
the oil level mark
Oil level mark

Oil drain plug

Refill oil
3.4.3 Check the tightening torque of bolts and
nuts
 1.If there is any looseness, tighten to the specified torque

 2.Replace the bolts and nuts with new one of same quality
or higher quality

 3. Use torque wrench to check and tighten bolts and nuts

 4.Ensure the threads are clean when mounting or

replacing

 5.Apply lubricant to bolts and nuts to maintain their

frictional coefficients
3.4.4 Replace the engine oil

The oil drain valve Drain Oil Refill Oil

Attention: In order to avoid scalds , do not replace when

engine oil is high temperature.
3.4.5 Replace the engine oil filter

Engine oil filter

3.4.6 Replace the primary fuel filter

The primary fuel filter

3.4.7 Replace the fuel filter

The fuel filter

3.4.8 Clean the air-condition filter

The fresh
air filter
Table of contents
3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

3.5 500Hours, or 3 months

 3.5.1 Lubricate the swing bearing

 3.5.2 Lubricate the swing gear
 3.5.3 Clean the surface of radiator group
 3.5.4 Replace the air filter
 3.5.5 Clean the surface of the condenser

48
 3.5.1 Lubricate the swing bearing

 Check the lubricant on the gear, lubricant must properly flow

on the surface of gears. If need, refill about 0.5 kg lubricant.

The swing
bearing

NOTICE: Do not fill too much grease.

 3.5.2 Lubricate the swing gear
 Remove cover near the swivel joint at the bottom of the swing
gear compartment. Refilling capacity for the grease is about 4
kg.

Lubricate the Cover

Cover
swing gear
3.5.3 Clean the surface of radiator group

Use pressure air to clean radiator or oil cooler

 If the surface of
radiator group is very
dirty, the water and
oil temperature will
overheat.
NO PRESSURE
WASHERS
ALLOWED!!
Clean
3.5.4 Replace the air filter

External filter Internal filter

3.5.5 Clean the surface of the condenser

 If the surface of the

condenser is very
dirty, Air conditioning
cooling effect will be
affected

Clean
Table of contents

3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

 3.6 Every 1000 hours or six months service

 3.6.1 Replace the fuel lift pump filter.

 3.6.2 Replace the swing reduction gear oil.(500 hours
replace for the first time )
 3.6.3 Replace the travel reduction gear oil.(500 hours
replace for the first time )
 3.6.4 Replace the pilot oil filter.
 3.6.5 Replace the hydraulic oil return filter.
 3.6.6 Lubricate the bearing of swing reduction gear.

55
3.6.1 Replace the fuel lift pump filter

The fuel lift pump filter

3.6.2 Replace the swing reduction gear oil

Drain Oil plug Port for

lubricating oil

Attention: 500 hours replace for the first time

3.6.3 Replace the travel reduction gear oil

Oil drain plug Drain oil Refill oil

Attention: 500 hours replace for the first time

3.6.4 Replace the pilot oil filter

pilot oil filter Replace the pilot Cleaning housing

oil filter internal
3.6.5 Replace the hydraulic oil return filter

 (1) Slowly loosen the breather cap counterclockwise to release

pressure, then open the cap carefully
 (2) Secure cover with hand to overcome the spring force when
removing the last two bolts. Open the cover.
 (3) Remove spring and return filter.
 (4) Replace with a new return filter.
 (5) Install spring, cover and o-ring.
3.6.6 Lubricate the bearing of swing reduction
gear

Lubricate point
Table of contents

3. Maintenance Intervals

3.1 Every 8 hours or every day service

3.2 Every 50 hours or every week service

3.3 Every 100 hours or two week service

3.4 Every 250 hours or every month service

3.5 Every 500 hours or three months service

3.6 Every 1000 hours or six months service

3.7 Every 2000 hours or every year service

3.7 Every 2000 hours or every year service

3.7.1 Replace the hydraulic oil.

3.7.2 Replace the suction oil filter of hydraulic oil tank
3.7.3 Replace the coolant and clean the internal surface
of radiator

63
 3.7.1 Replace the hydraulic oil
 （ 1 ） Swing the revolving frame to 90 °to park the machine on a flat
ground.
 （ 2 ） Retract the arm cylinder and extend the bucket cylinder
completely to lock the machine.
 （ 3 ） Lower the bucket onto ground. 。
 （ 4 ） Shut down the engine and take out the key.
 （ 5 ） Push the pilot shutoff lever to LOCK position.
 （ 6 ） Clean the top of hydraulic tank to prevent dust coming into the
hydraulic oil system.
 （ 7 ） Slowly loosen the breather cap counterclockwise to release
pressure, then open the cap carefully..
 （ 8 ） Open the hydraulic tank cover.
 3.7.1 Replace the hydraulic oil
 （ 9 ） Remove suction filter and rod group.
 （ 10 ） Clean the oil outlet of hydraulic tank and unscrew oil drain plug
to drain oil. Collect the oil with container.
 （ 11 ） Clean the internal surface of suction filter and hydraulic oil
tank.Take out the screen to wash. If it needs to replace with a new filter,
install the new filter onto the rod.
 （ 12 ） Install suction filter and rod group. Ensure the filter is fixed to
correct position.
 （ 13 ） Wash the hydraulic oil tank with clean hydraulic oil. Wipe it with
clean and dry towel. Install and tighten the oil drain plug.
 （ 14 ） Install the hydraulic oil cover. Ensure the suction filter and rod
are fixed to correct position.
 （ 15 ） Refill hydraulic oil to the position between low and high mark.
 3.7.1 Replace the hydraulic oil

 （ 16 ） Unscrew the air exhaust plug from the top of the pump. Fill oil to
 the pump through the plug mouth and then install the air
 exhaust plug.
 （ 17 ） Start the engine and run it at idle speed. Put a “DO NOT
 OPERATE” tag to the pilot shutoff lever. Make sure the pilot
 shutoff lever is at LOCK position.
 （ 18 ） Loosen the breather cap to release the air until the oil flows out
 of the mouth. Tighten the cap.
 （ 19 ） Run the engine at a speed of 1200 rpm. Operate the control
 lever slowly for about 15 minutes to exhaust the air in the system.
 （ 20 ） Retract the arm cylinder and extend the bucket cylinder
 completely to lock the machine.
 （ 21 ） Lower the bucket onto ground.
 3.7.1 Replace the hydraulic oil

 （ 22 ） Shut down the engine and take out the key.

 （ 23 ） Push the pilot shutoff lever to the LOCK position.
 （ 24 ） Check sight glass of the hydraulic oil tank. Refill hydraulic oil if
 necessary.
3.7.2 Replace the suction oil filter of hydraulic
oil tank
3.7.3 Replace the coolant and clean the internal
surface of radiator
 （ 1 ） Slowly screw out the water radiator filler cap to release
pressure after the coolant temperature is below 50 ℃ .
 （ 2 ） Open the water release valve at the bottom of the radiator,
drain out the coolant of the engine and collect with a container.
 （ 3 ） After draining out coolant of the engine, close the water
release valve at the bottom of the water radiator.
 （ 4 ） Check all water lines and clamps of cooling system for
damage, replace if necessary. Check water radiator for leakage,
damage and piled-up trashes, clean and repair if necessary.

Drain the Coolant Fill Coolant

3.7.3 Replacing the coolant inside the
radiator and cleaning
 （ 5 ） Replenish cleanser which is mixed with water and sodium
carbonate into the cooling system of the engine.The level should reach
normal level of the engine and keep stable within 10 minutes.
 （ 6 ） Keep the water radiator filler cap open, start the engine, when
the
 coolant temperature is over 80 ℃ , run the engine for 5 minutes again.
 （ 7 ） Stop the engine, drain out cleanser.
 （ 8 ） Replenish clean water into cooling system of the engine till it
reaches normal level and is kept stasble within 10 minutes. keep the
water radiator filler cap open, start the engine, when the coolant
temperature is over 80 ℃ , run the engine for 5 minutes again.

Drain the Coolant Fill Coolant

3.7.3 REPLACING THE COOLANT INSIDE
T H E R A D I AT O R A N D C L E A N I N G

 （ 9 ） Stop the engine, drain out water in the cooling system. If the
drained water is still dirty, clean the system again till the drained water
gets clean.
 （ 10 ） Close all drain valve, then replenish new coolant

Drain the Coolant Fill Coolant

Table of contents

1. The Recommended oil

2. Main maintenance item and locatoin

3. Maintenance Intervals

4. Maintenance point of every system

 4.1 Diesel engine system
Interval(hours)
Quanti
Component 8 50 100 250 500 1000 2000
ty

Check 1
1 ． Engine oil
Replace 25L ★★★
2 ． The engine oil filter Replace 1 ★★★
3 ． Drain any water and trash from the fuel １
tank.
Drain 1
4 ． Fuel pre-filter.
Replace 1 ★★★
5 ． Replace fuel filter 2 ★★★

6 ． The external components of Clean 1

air filter Replace 1
7 ． The internal components of Replace 1
air filter
8 ． Check coolant level 1
9 ． Check and adjust belt tension of fan 1

10 ． Replace the coolant 30L

Clean the internal surface of radiator Every 2000 Hours or Every Year Service

11 ． Clean the surface of radiator group 1 ※1

★★★ The first service time ※ Shorten the time of maintenance 73
4.1 Diesel engine system

 Check coolant level—everyday or 8 hours

When the engine is cooling, the water in radiator must be full.

 Check and adjust fan tension (from B series diesel engine operation and
maintenance mannual)
 Key point: loose fan drive belt may cause lack of battery charging,
engine heating and abnormal and rapid wear of belt. While the belt is
too tight, may cause the damage of bearing and drive belt

74
4.1 Diesel engine system

 Antirust :
 When change coolant water, add about 0.58L （ 0.15
gallon ） antirust, while using antifreeze, antirust is not
available any more.
 Antifreeze:
 If the temperature is forecast down to below 0 ℃ (32
degrees Fahrenheit), please add a mixture of antifreeze and
softened water into the coolant system. If antifreeze you
have bought including ratio instruction, please follow the
instructions and make the mixtures according to the local
minimum temperature. The following table lists the
proportion of SHELL stock temperature for ratio of
antifreeze and mixture for the reference.
75
4.1 Diesel engine system

Antifreeze ratio table:

the proportion of SHELL antifreeze and water

The ratio of The ratio of Condensing point

antifreeze water
30% 70% -15℃
34% 66% -20℃
39% 61% -25℃
41.8% 58.2% -30℃
45% 55% -35℃

76
4.1 Diesel engine system

 Clean the outer part of radiator---per 500 hours

 1 ． Open side entrance and engine hood .
 2 ． Use the compressed air or water to clean or
wash the radiator and oil coolant .

77
4.2 Swing and travel reduction

Components Quantit Intervals(Hours)

y 8 50 100 250 500 1000 2000

1 ． Swing Oil level —

Reductions check
replace 3.4L ★★
★
2 ． Travel Oil level —
Reductions check
replace 5.5L×2 ★★
★

★★★ The first service time

78
 THANK YOU
T O U G H W O R L D . T O U G H E Q U I P M E N T.