CDM6215/CDM6225 SERVICE MANUAL

FOREWORD

The manual is used for help maintenance personnel to realize machine and improve
maintenance quality via introducing performance, and correct method relating to
maintenance and fault diagnosis. Please comprehend content contained in the Manual
so that to achieve satisfied effect in maintenance of each time.

Please read carefully and fully comprehend the Manual before your maintenance.

For details relating to engine, please refer to operating instruction of engine.

Illustrations contained in the Manual are used for describing visually and expressly,
while not representing all signification of the text.

The Manual is first issued version, it is hoped that the readers will kindly point out our
errors.

Copyrights reserved, unauthorized duplication and publish are a violation of applicable

laws.

LONKING EXCAVATOR STRATEGIC BUSINESS UNIT

November,, 2010
November
 CONTENTS

Chapter I Introduction..........................................................................................................1

Chapter Ⅱ Safety...............................................................................................................15

Chapter Ⅲ Summary......................................................................................................... 51

Chapter Ⅳ Structure, Function & Maintenance Standard................................................. 67

Chapter Ⅴ Test & Adjustment.........................................................................................177

Chapter Ⅵ Fault Diagnosis..............................................................................................217

Chapter Ⅶ Disassembly & Assembly..............................................................................269

Chapter Ⅷ Appendix....................................................................................................... 439

 Introduction

Chapter Ⅰ Introduction

1
 Introduction

2
 Introduction

CONTENTS

Chapter Ⅰ Introduction......................................................................................................... 1
Introduction
Summary.....................................................................................................................................................5

Structure of Manual....................................................................................................................................5

Maintenance of Engine...............................................................................................................................6

Lifting Instruction.......................................................................................................................................7

Connecting and Disconnecting of Pipe Connector.................................................................................... 8

Technical Specification of Oil Materials....................................................................................................9

Low-temperature Application Description...............................................................................................10

Standard Fastening Torque....................................................................................................................... 12

Wire Label................................................................................................................................................ 13

Unit........................................................................................................................................................... 14

3
 Introduction

4

Summary
� The manual is used for help maintenance
personnel to realize machine and improve
maintenance quality via introducing performance,
and correct method relating to maintenance and
fault diagnosis. Please comprehend content
contained in the Manual so that to achieve
satisfied effect in maintenance of each time.
� Please contact Lonking agent for uptodate
information whenever you doubt the machine or
the Manual.
Structure of Manual
This Service Manual mainly contains technical
information relating to maintenance performed in
maintenance shop. For convenience or
comprehension, we divide the Manual into following
chapters and divide each chapter into various sections
according to parts and elements.
� Structure and Function
The chapter clarifies structure and function of
parts and elements. It shall make user realize
structure of machine, and provide reference for
fault diagnosis.
In addition, the chapter also include hydraulic oil
pipe diagram, circuit diagram and maintenance
standard.
� Test and Adjustment
The chapter clarifies inspection necessary to
performed before/after your repairing
adjustment performed during repairing and
inspecting process.
Fault diagnosis diagram relating to “Fault” and
“Reason” is also included in the Section.
Introduction
� For any problem or suggestion, as well as
mistake in the Manual, please contact the
Company (duplicated documentation is effective)
by using “Revision sheet of fitment manual”.
Please excuse if there are changes relating to
technical specification contained in the Manual will
not be informed at once. Please use technical
specification described in manual of uptodate
version.
your
� Disassembly and Assembly
The chapter clarifies sequence necessary to
disassembly, installation, and assembly of parts
and elements, and precautions for these
operations.
� Maintenance Standard
The chapter provides evaluation standard for
inspection performed after disassembled parts
and elements.
Content in the chapter shall be expatiated in
and chapter “Structure and function”.
� Appendix
The chapter mainly provide hydraulic oilway
figure and circuit diagram.
In addition, the chapter also provides technical
specification of operating device and optional
element.
5
 Introduction

Maintenance of Engine
Correct maintenance is significant to normal operation
of engine and machine. Please perform maintenance
according to requirement described in the Manual
strictly.

� No personnel without approval of Lonking shall

participate in following work: repair, maintain,
sale, lease or handle any disassembled, modified
element relating to discharge, or engine and
machine of system.

� No modification relating to system of machine

and engine, such as air exhaust system, fuel
system, electric system, inlet system or cooling
system etc. Shall be executed without approval of
LONKING.

6
 Introduction

Lif ting Instruction

Lifting
Lifting

� Please perform following inspection if fails to

hoist parts and elements successfully by using
hoisting machine:

1) Inspect if all fastening bolt of parts and elements

are disassembled in full.

2) Inspect if parts and elements that obstructing

disassembly of the parts is existent.

Rope

1) Please select proper rope according to weight of

hoisting parts, refer to following sheet:

Rope

(standard “Z” or “S” rope without galvanization or

distortion)
Diameter Allowable load
mm kN t
10 9.8 1.0
11.5 13.7 1.4
12.5 15.7 1.6
3) Do not hoist weight with one rope. It is
14 21.6 2.2
recommended to hoist with two or above rope
16 27.5 2.8 after enwound them onto weight equably.
18 35.3 3.6
Hoisting weight with single rope may cause
20 43.1 4.4
dangerous accident if rope sliding from enwound
22.4 54.9 5.6
position under impact of rotation during hoisting
30 98.1 10.0
process.
40 176.5 18.0
50 274.6 28.0 4) Do not hoist weight if suspension angle between
60 392.2 40.0 rope and hook is too big. Force bore by each rope
shall be increased along with increment of
suspension angle while hoisting weight via two or
Allowable load value is rough estimated as 1/6
above ropes. Following sheet describes along
or 1/7 of breaking strength of used rope.
with change of angle, allowable load kN {kg} of
2) Hang rope at middle position of hook. each rope while hoisting weight via two or above
Rope may slide from hook and cause serious ropes. Allowable vertical hoisting load of each
accident during hoisting process if part from edge rope is 9.8 kN {1000 kg}.
of hook too close. Strength at middle position of
hook is maximal.

7
 Introduction

Total hoisting weight is 19.6 kN {2000 kg} it two

ropes are vertical, and hoisting weight changes to
9.8 kN {1000 kg} if suspension angle between
two ropes is 120°. In addition, these two ropes
shall bear super weight of 39.2 kN {4000 kg}
while hoisting load of 19.6 kN {2000 kg} in
angle of 150°.
Lifting Weight (kN (kg))

Lifting Angle (degree)

Connecting & Disconnecting of Pipe

Connector

� Please release residual pressure in hydraulic oil

tank before performing following operation. For
details, please refer to “Test and Adjustment”.
� Some hydraulic oil may flows out while
disassembling hose, although released residual
pressure in hydraulic oil tank, please prepare a oil
vessel.

8
 Introduction

Technical Specification of Oil

Materials
Replacement and filling period of oil materials, please
refer to technical maintenance schema.
Filling volume and oil designation of various positions
are shown as below:

CDM6215/CDM6225
Filling
Oiling Position Capability Designation
Volume
Swing Reduction Box 3.14L 3.14L SAE#140 (GL-4) gear oil
Traveling Reduction Box 2×5L SAE#140 (GL-4) gear oil
Hydraulic Oil Tank 280L 188L N46 or N68 wear resistant hydraulic oil
Engine Oil 18L 16L Class CH supercharged Diesel Engine Oil
Lubricating Points As Required 2# extreme pressure lithium lubricating grease
Lubricating Grease of Gear Ring 15kg 2# extreme pressure lithium lubricating grease
Fuel Tank 380L 340L 0# or10# diesel (summer) -10# diesel (winter)
Cooling System 20L 20L Lonking long life coolant
Coolant Tank 3L 1.5L Lonking long life coolant
Refrigerant of Air Condition 1000g 900±50g R134a

IMPORTANT
Application of improper coolant of cooling
system may corrupt engine, engine radiator, air
condition radiator and cause damage of parts and
elements of engine, radiator and air condition, or
leakage of coolant.

It is recommended to sample element operating under

heavy load condition or high temperature condition
once in every 250 hours. For obtaining better data
relating to fault information that cannot be provided by
sampling of 500 hours, can provide more information
during drain period with 250 hours sample period and
as well as improving fault detecting probability.

9
 Introduction

Low-temperature Application
Description
Important Safety Item

Major accident occurs during operation, maintenance Information, technical specification and diagram
and servicing of machine is caused in violation of contained in the Fitment manual is compiled according
safety rules and preventive measure. It is possible to existing information. These listed technical
avoid accident if realized various potential dangers. specification, measure value, adjusting value, diagram
Please warn working personnel on potential danger, and other item may be modified momentarily and
and provide working personnel with training so that make impact to servicing of machine. Therefore,
they can familiarize necessary technology and operate please obtain complete information before performing
tools correctly. operation. Please contact Lonking agent for uptodate
Incorrect operation, maintenance and servicing of information.
machine may cause bodily injures.
Content described in the segment applies to machine
Please perform these operation only after read files
of low temperature configuration.
relating to operation, maintenance and servicing of
machine carefully and comprehend them.
Warning provided by the Manual and nameplate of
machine that manufactured by Lonking cannot contain
all dangers. Please guarantee your and others’ safety if
your tools, operating program, working method or
operating technology are not recommended by the
Company. In addition, please ensure that your
operating method, maintenance or servicing program
should not damage machine or cause insecurity.

Description Relating to Starting & Running of

Machine under Low Temperature Condition

Designed value of starting temperature of low-
temperature configuration machine shall not be lower
than -40℃.
Please park machine out of work indoors as much as
possible and do well in freeze protection of the oil,
liquid and display if ambient temperature is lower than
-40℃.
Do not start engine directly if ambient temperature is
lower than -20℃. Monitoring shall display “no
starting, heating of engine oil is necessary” and “no
starting, heating of hydraulic oil is necessary”. Please
start engine after heated oil temperature to -20℃
above.
Engine oil heater locates on drain pan of engine oil
tank and hydraulic oil heater locates on bottom of
hydraulic oil tank, both heaters adopt external AC
240V power supply.
Machine shall start automatic inlet preheating during
ignition if ambient temperature is lower than 0℃.
During this process, engine shall not ignite until
finished preheating.
Do not operate immediately after started machine if
hydraulic oil temperature is lower than 0℃. For
protecting hydraulic system and running hydraulic
system normally, please run machine in idling until
temperature of hydraulic oil achieved 0℃. For
ensuring safety, please switch hydraulic safety lock at
lock position to LOCK while running machine in
idling.

10
 Introduction

Technical Specification of Oil Used for Machine

Operating Under Low Temperature Condition

Oiling Position Designation

Swing Reduction Box Lonking lower temperature gear oil
Traveling Reduction Box Lonking lower temperature gear oil
Hydraulic Oil Tank Lonking lower temperature hydraulic oil
Engine Oil Lonking lower temperature diesel gear oil
Lubricating Points Lonking lower temperature lubricating grease
Lubricating Grease of Gear Ring Lonking lower temperature lubricating grease
Fuel Tank Low temperature diesel (meet ambient temperature)
Cooling System Longking low temperature long lift coolant
Coolant Cylinder Longking low temperature long lift coolant
Air Condition Refrigerant R134a

IMPORTANT
� Please use raw liquor of coolant only. Diluents
coolant shall not meet antifreezing temperature.

� Application of improper coolant of cooling

system may corrupt engine, engine radiator, air
condition radiator and cause damage of parts and
elements of engine, radiator and air condition, or
leakage of coolant.

11
 Introduction

Standard Fastening Torque

Standard Fastening Torque Sheet (for application
of torque spanner)
Please fasten standard bolt and nut with torque
described in following sheet, except required
specially.

Bolt diameter Opening width of spanner

mm mm Nm
6 10 13.2±1.4
8 13 31±3
10 17 66±7
12 19 113±10
14 22 177±19
16 24 279±30
18 27 382±39
20 30 549±59
22 32 745±83
24 36 927±103
27 41 1320±140
30 46 1720±190
33 50 2210±240
36 55 2750±290
39 60 3290±340

Bolt diameter Opening width of spanner

mm mm Nm
6 10 9~12
8 13 22~30
10 17 45~59
12 19 78~104
14 22 124~165
16 24 193~257
18 27 264~354
20 30 376~502
22 32 512~683
24 36 651~868
27 41 952~1269
30 46 1293~1723
33 50 1759~2345
36 55 2259~3012
39 60 2923~3898

12
 Introduction

Wire Label
Please mark diameter of wire with different color and
symbol of wire diagram. Following wire label sheet
shall make for understanding “circuit diagram”.

AVSS Current
It is thinner than AVS insulator and applies to light
weight and thin line application.

External
Conductor Insulation Appearance Allowable Standard
Wire Label Diameter of
Composition Thickness Dimension Current Length
Conductor

0.3f 19/0.16 0.8 0.3 1.4 8 1500

0.3 7/0.26 0.8 0.3 1.4 8 1500

0.5f 19/0.19 1.0 0.3 1.6 10 1000

0.5 7/0.32 1.0 0.3 1.6 11 1000

0.75f 19/0.23 1.2 0.3 1.8 14 1000

0.85 19/0.24 1.2 0.3 1.8 14 1000

1.25f 37/0.21 1.5 0.3 2.1 19 800

1.25 19/0.29 1.5 0.3 2.1 19 800

2 37/0.26 1.9 0.4 2.6 26 500

13
 Introduction

Unit
Measure unit in the Manual adopt international unit
(SI).
Gravity conversion unit is marked in ( ).

For example: N (kg)

Nm (kgm)

MPa (kg/cm2)

kPa (mmH2O)

kPa (mmHg)

kW/rpm (HP/rpm)

g/kWh (g/HPh)

14
 Safety

Chapter Ⅱ Safety

Please read and realize precautions described by the Manual and safety
label of machine, and observe these precautions strictly while operating
or repairing machine.

15
 Safety

16
 Safety

CONTENTS

Chapter Ⅱ Safety
Safety........................................................................................................................ 15
Safety Instructions...........................................................................................................................................19

Learn about Safety Information...................................................................................................................... 21

Comprehend Signal Terms.............................................................................................................................. 21

Abide by Safety Instruction.............................................................................................................................22

Compressed Air and Compressed Water........................................................................................................ 22

Preparation for Emergency Condition.............................................................................................................23

Wear Protective Clothing.................................................................................................................................23

Noise Prevention............................................................................................................................................. 24

Inspection of Machine..................................................................................................................................... 24

General Precautions for Cabin........................................................................................................................ 25

Safety Equipment............................................................................................................................................ 25

Keep Machine Clean....................................................................................................................................... 26

Use Handrail and Ladder.................................................................................................................................26

Adjustment of Operator's Seat.........................................................................................................................27

Fasten Seat Belt............................................................................................................................................... 27

Ensure Perfect Sight........................................................................................................................................28

Move and Operate Machine Safely................................................................................................................. 28

Operate on Operator's Seat Only..................................................................................................................... 29

Engine Starting with Jump Start Cable........................................................................................................... 29

The Passenger Shall Leave Machine............................................................................................................... 30

Regulate Signal for Simultaneous Working of Several Machines..................................................................30

Confirm Travel Direction of Driven Machine................................................................................................ 30

Drive Machine Safely...................................................................................................................................... 31

Avoid Bodily Injury Caused in Tumbling Accident of Machine.....................................................................32

Avoid Bodily Injury Caused in Back Running or Swing Accident of Machine..............................................33

Avoid Roll-over............................................................................................................................................... 34

Evade Electric Wire.........................................................................................................................................35

Lifting Objects.................................................................................................................................................35

17
 Safety

Prevent from Splashing Scrap......................................................................................................................... 36

Park the Machine Safely.................................................................................................................................. 36

Handle Liquid Safely-Avoid Fire.................................................................................................................... 37

Transport Machine Safely................................................................................................................................38

Implement Safety Maintenance.......................................................................................................................39

No Operation Tag............................................................................................................................................ 40

Support Machine Correctly............................................................................................................................. 40

Keep Distance from Rotatable Parts................................................................................................................41

Prevent from Splashing of Parts......................................................................................................................41

Store Accessories of Machine Safely.............................................................................................................. 41

Use Tools Properly.......................................................................................................................................... 42

Avoid Burn.......................................................................................................................................................42

Replace Rubber Hose Regularly......................................................................................................................43

Evade High Pressure Liquid............................................................................................................................ 43

Prevent Fire......................................................................................................................................................44

Evacuation in Fire............................................................................................................................................45

Beware of Exhausted Smoke...........................................................................................................................46

Precautions for Welding and Polishing Operation.......................................................................................... 46

Avoid Heating Around Pressure Liquid Pipe...................................................................................................47

Prevent Flammable Liquid Pipeline from Heating..........................................................................................47

Remove Painting before Welding or Heating Operation.................................................................................47

Prevent Explosion of Battery...........................................................................................................................48

Maintain Air Condition System Safely........................................................................................................... 48

Handle Chemical Goods Safely.......................................................................................................................49

Handle Waste Safely........................................................................................................................................49

Prevention of Asbestos Dust............................................................................................................................50

Before Delivery of Machine to User............................................................................................................... 50

18
 Safety

Safety Instructions
� Important safety instructions � General precautions

Misoperation is dangerous. Please read the

IMPORTANT
Maintenance Manual carefully before your operation.
� Correct maintenance and overhauling are
significant to safe operation of machine. 1) Please read all precautions marked on fixed label
Maintenance and overhauling technology plate of machine before lubricating or repairing.
described in the Manual or recommended by 2) Please wear safety shoes and safety helmet during
Lonking are safe and effective. your operation. Do not wear loose clothing or
� For avoid injuring worker, the Manual uses clothing without button.
symbol of as safety caution mark. Please � Please wear safety glass while knocking
consider security and adopt necessary measure elements with hammer.
according to actual condition if danger or
� Please wear safety glass while polishing
potential danger occurs.
elements with grinding wheel.

3) Welding operation is performable by experienced

� Preparation
1) Please stop the machine onto horizontal, rigid
ground and underlay wheel or crawler with
packing block to prevent it from moving before
oiling or repairing.
2) Please fall dozer, ridge buster, bucket or other
operating device onto ground before operation.
Please adopt safety pin or packing block to
prevent operating element from dropping if fails
to fall it. In addition, please lock all control rod
and hang warning board onto them.
3) Please support machine with packing block, jack
or skid bed before assembling or disassembling
the machine.
welder that achieved training. Please use welding
glove, veil, wear skirt, hat, proper clothing during
welding operation.
4) Please come to consistent operation procedure
before operation and inform cooperator before
any operation while operating under cooperation
of one or several personnel. Please hang label that
marked with “Repairing” on control desk of
operation room.
5) Please keep tools in good condition and use them
correctly.
6) Please store tools and disassembled element at
appointed position of repairing shop. Keep
cleanness of operating zone. Smoke at appointed
zone, except operating period.

4) Please clear clay and oil dirt from pedal or step.

Please get in/get down machine by using
balustrade, ladder or gangplank. Do not jump
upon or jump down machine directly. Please
ensure safety via using skid bed if application of
balustrade, ladder or gangplank is impossible.

19
 Safety

� Operating precautions

1) Please loosen filler cap, drainage plug or
hydraulic measure slowly to prevent from
spurting of oil while disassembling them.
Please release pressure in pipeline completely
before disconnecting, disassembling element of
oil/water/gas pipeline
2) Mind high temperature of oil and water in
pipeline after stalled engine.
Please perform operation with oil/water pipeline
after cooled oil and water in them.
3) Disassemble lead of accumulator before your
operation. Please start disassembly of lead from
cathode (-) terminal.
4) Please use hoisting machine or crane while
hoisting heavy element.
Please ensure that no rope, chain or hook is
damaged.
Please use hoisting equipment that be provided
with enough hoisting force.
Install hoisting equipment at correct position.
Please operate slowly to prevent hoisting element
impacting with other element while using one
hoisting machine or crane. Do not repair hoisting
element.
with a small amount of gasoline if necessary.
9) Please assemble all parts back to original position.
Please replace damaged parts and elements with
new one.
It is necessary to ensure that no hose and electric
wire contact with other parts and element and
cause damage while starting machine, after
installed them.
10) Do not distort high-pressure hose while installing
it. Damaged hose is dangerous, please install it
carefully. Please inspect if connecting element is
installed correctly.
11) Please adopt regulated fasten torque while
assembling/installing parts and elements. Please
inspect if protecting element (for example:
protecting cover), high-vibration/high-speed
element are installed correctly.
12) Do not insert finger or hand into these two holes
while aligning them.
13) Please inspect if measure tools is installed
correctly before measuring hydraulic pressure.
14) Do not stand on both terminal of crawler while
disassembling/assembling crawler of crawler
machine, because abrupt relief of crawler.

5) Please remain two bolts on opposite side while

disassembling cover bearing inner pressure or
spring pressure. Please loosen bolts or
disassemble them after released pressure slowly.

6) Disassemble carefully without damaging electric

wire. Damaged wire may cause electric fire.

7) Please prevent fuel or oil spurting from pipeline

while disassembling pipeline. Please wipe off fuel
or oil dropped onto ground immediately to
prevent from slipping, or fire.

8) In general, it is impermissible clean parts and

elements with gasoline. Please clean electric parts

20
 Safety

Learn about Safety Information

� This is the sign to note safety.

� When you see this sign, you shall be aware

of the danger of staff injury.

� Please abide by the proposed cautions and

safe operation method.

Comprehend Signal Terms

� On the safety label of machine, the terms
indicating the extent or degree of injury such as
DANGER (danger), WARNING (warning) or
CAUTION (caution) will be used with the sign of
noting safety together.

� "DANGER" indicates the condition of direct

danger. If this condition happens, death or
severe injury will be caused.

� "WARNING" indicates the condition of

hidden danger. If this condition happens,
casualty will be caused.

� "CAUTION" indicates the condition of

potential hazard. If this condition happens,
minor or moderate injury will be caused.

� "DANGER" or "WARNING" safety label is

set near specific hazard position. Refer to
"Caution" safety label for general safety
measures.

� After the safety alarm sign is used on the

machine, some safety labels won't use the
terms stipulated above.

� "CAUTION" also has the meaning of noting

safety information in this Manual.

� In order to separate machine protection from staff

safety, this Manual adopts the term "Important",
if some dangerous state occurs, machine will be
damaged.

� "Note" indicates adding some explanation to

certain part in relevant information.

21
 Safety

Abide by Safety Instruction

� Please read and abide by all safety labels on the
machine as well as the contents related with
safety in this Manual.

� When necessary, the safety label shall be installed,

maintained and replaced.

� If the safety label or Operation Manual is

damaged or lost, you shall ask your
consignor to prepare a substitute, in the same
way, you shall prepare a backup (used to
describe machine model and serial number
preparation).

� Learn how to operate and control machine

correctly and safely.

� The machine can be only operated by the trained,

qualified and named staff.

� Keep your machine in good condition.

� If the machine is refitted without approval,

it'll probably damage its function or reduce
safety and influence machine service life.

� The safety instruction in the chapter "Safety" aims

at describing basic safety procedure of machine.
However, these relevant safety instructions won't
probably involve every hazardous condition you
will encounter. If you have problem, before the
machine operation and maintenance is started,
you shall ask for instruction from your foreman
or named dealer.

Compressed Air and Compressed

Water � The maximum pressure of air used for cleaning
must be below 0.2MPa.
� The scrap or hot water will splatter due to
compressed air or compressed water which will
� The maximum pressure of water used for cleaning
cause personal injury.
must be below 0.25MPa.
� When the compressed air or compressed water is
used for cleaning, the protective clothing,
protective shoes, goggles or face shield shall be
worn.

22
 Safety

Preparation for Emergency Condition

� Preparation shall be made for fire or accident.

� The first aid box and fire extinguisher shall

be prepared at accessible place.

� Read and comprehend the instruction on the

fire extinguisher thoroughly, and the fire
extinguisher shall be used correctly.

� In order to ensure the fire extinguisher can

work at the required time, the fire
extinguisher shall be check and maintained
in accordance with the technical
specification of fire extinguisher Operation
Manual and proper interval.

� The rules for emergency shall be made to

handle fire and accident.

� The emergency telephone number of doctor,

ambulance, hospital and Fire Company shall
be prepared beside your telephone.

Wear Protective Clothing

� Wear proper clothes and safety articles.
You will probably need the following:
Hard helmet
� The operator shall be concentrated on machine
operation. Don’t listen to the radio or the music
with earphone when operating.

Safety shoes

Safety glasses, goggles and face shield

Safety gloves

Hearing protective equipment

Anti-radiation clothes

Rain-proof article

Gauze mask or filtering face mask

Correct equipment must be worn, and wear proper

working clothes. Don’t have the mind of fluke.

� Avoid wearing loose clothes, jewelry or other

things which will hook joystick or other
components of machine.

23
 Safety

Noise Prevention
� The hearing will be damaged or lost in the
environment of big noise for long time.

� Wear proper hearing protective article such

as ear muff or earplug to prevent harmful or
uncomfortable big noise.

Inspection of Machine
� Before the machine is started every day or per
shift, go around the machine to check the machine
thoroughly to prevent personal injury.

� When going around the machine to check it,

the check contents must include the whole
gist in the chapter of "Check before startup".

24
 Safety

General Precautions for Cab in

abin
� Before entering the cab, the dirt or engine oil on
the sole of working shoes shall be removed
thoroughly. For any control device such as foot
pedal, if the worker's shoes are pasted with dirt or
engine oil, when he/she operate the foot pedal, the
foot will slide off the foot pedal to cause personal
accident.

� Don't put the part or tool around the operator's

seat. They shall be stored at specified position.

� Don't put bottle in the cab. Don’t paste any

transparent ornament on the window because it
can focus sunlight to cause fire.

� When operating the machine, the driver can't

listen to the radio, can't enjoy music with
earphone or using mobile telephone in the cab.

� Keep the machine away from flammable or

explosive substance.

� The ashtray shall be covered when it's used so as

to extinguish match or cigarette end.

� Don't leave cigarette end in the cab. When

temperature in the cab rises, the cigarette end will
probably cause explosion.

Safety Equipment
� Ensure all the shields and covers are in position. If
the shield and cover is damaged, repair it
immediately.

� Learn about the use method of safety device and

use it correctly.

� Don't disassemble any safety device and keep

them in good condition.

25
 Safety

Keep Machine Clean

� If water enters electric system, the system will be
probably out-of-work or fail. Don’t flush the
electric system with water or steam (sensor,
connector).

� If the machine is checked and maintained if there

is mud or oily soil, the staff will probably slip and
fall or the dirt will probably enter eyes. Keep
machine clean all the time.

Use Handrail and Ladder

� Falling is one the major reasons to cause injury.

� When you get on and off the machine, face

the machine and use the ladder and handrail
together.

� Don't use any joystick as handrail.

� Don't jump on and off the machine. Don’t get

on of off the moving machine.

� When getting on and off the machine, note

the platform, ladder and handrail are slippery.

26
 Safety

Adjustment of Operator's Seat

� If the seat isn't regulated well, the operator's body
or hands will feel fatigue to cause operating
failure.

� The operator shall regulate the seat when

operating different machine.

� When the operator's back is against the seat

back, the foot pedal shall be stepped down
thoroughly and all the joysticks can be
operated correctly.

� If not, the seat shall be moved forward or

backward, and then check it again.

Fasten Seat Belt

� If machine rolls over, the operator will be
probably injured and/or thrown out of cab.
Furthermore, the operator will be probably
pressed by the roll-over machine to cause severe
injury or death.

� Before machine is operated, check the belt,

snap ring and component of safety belt
thoroughly. If any one is damaged or worn,
the safety belt or other component shall be
replaced before machine is operated.

� When machine is working, the operator shall

fasten the safety belt all the time, to reduce
the injury opportunity due to accident as
possible.

� Our company suggests the safety belt be

replaced every 3 years.

27
 Safety

Ensure Perfect Sight

� In order to operate or travel machine safely, check
whether there is worker or obstacle in surrounding
area of the machine, and then check the working
place. The following procedure shall be abided by.

� When working in dark place, switch the

working lamp and head lamp of machine on,
when necessary, set auxiliary lighting in the
working place.

� If sight is poor due to fog, snow, rain or dust,

operation shall be stopped.

Move and Operate Machine Safely

� The staff nearby will be knocked down.

� Pay special attention to not knocking down

the staff nearby. Before the machine is
moved, turned or operated, the position of
staff nearby shall be confirmed.

� The travel alarm and horn shall be under

working condition (if these devices are
available). When the machine is moved, the
staff nearby shall be warned.

� When the machine travels, swings or

operates in narrow area, it shall be instructed
by signal man. Before the machine is started,
the hand signal shall be coordinated.

28
 Safety

Operate on Operator's Seat Only

perator's
� Improper engine start procedure will probably
cause out-of-control of machine and then cause
severe injury or death.

� The driver can only start the engine sitting on

the seat.

� The engine can't be started standing on the

track or ground.

� The engine can't be started via the short-

circuit of starter terminal.

� Before the engine is started, all the joysticks

are set for neutral position.

Engine Starting with Jump Start

Starting
Cable
� The battery gas will be explosive to cause severe
injury.

� If the engine must be started via jump start

cable, the related instruction in the chapter of
"Product Operation" must be abided by.

� The operator must sit on the seat so that the

machine can be controlled when the engine is
started. The start via jump start cable is
performed by two persons.

� The frozen battery can't be used.

� If the correct jump starting procedure isn't

abided by, it'll cause battery explosion or
out-of-control of machine.

29
 Safety

The Passenger Shall Leave Machine

� The passenger on the machine will be injured
such as being impacted by object and thrown out
of the machine.

� Only the operator is allowed to be on the

machine. The passenger shall leave machine.

� If passenger disturbs operator's sight, the

machine will be operated unsafely.

Regulate Signal for Simultaneous

Working of Several Machines
� For the work including several machines, the
signals known by all participants shall be
specified. Meanwhile, a signal man shall be
appointed to coordinate working place. All the
staves must obey the command of signal man.

Confirm Travel Direction of Driven

Machine
� The wrong operation of travel pedals/travel levers
will cause severe injury or death.

� Before the machine is driven, ensure the

position of undercarriage corresponding to
operator. If the travel motor is in the front of
cab, when travel pedals/travel levers are
operated forward, the machine will move
backward.

30
 Safety

Drive Machine Safely

� Before the machine is moved, confirm the
direction of pushing travel pedals/travel levers.

� Ensure the machine passes by all barriers.

� Avoid crossing barrier. The soil, rock

fragment and/or broken material will be
probably scattered around the machine. No
one is allowed to stand around the machine
when machine moves.

� The machine will skid or roll over on the slope,

and severe injury or death will be probably caused.

� When the machine travels on the slope

forward or backward, the bucket shall face
the travel direction and about 200～300mm
(A) above ground.

� If the machine skids or is unstable, lower the

bucket on the ground and stop machine.

� If the machine crosses slope or turns on the

slope, it'll probably skid or roll over. If the
Wrong
machine has to make a turn, the direction can
be changed after it's moved on the level
ground to ensure safe operation.

31
 Safety

Avoid Bodily Injury Caused in

Tumbling Accident of Machine
� If the staff attempts to get on or block the moving
machine, severe injury or death will be caused.

In order to avoid roll-over:

� Select one level ground suitable for machine

parking.

� Don't park the machine on the slope.

� Lower the bucket and/or other working tool

on the ground.

� Turn the auto-idle/acceleration selector and

H/P mode switch to OFF position.

� Run the engine idle for 5 minutes with low-

speed and no load to cool the engine.

� Stop the engine to take out the key from the

key switch.

� Pull the hydraulic lockout control to "Lock"

position.

� Wedge the two tracks and lower the bucket

on the ground. If the machine has to stop on
the slope, the bucket tooth shall be inserted
into the soil.

� Position the machine to prevent roll-over.

� When the machine is parked, a rational

distance shall be provided with other
machine.

32
 Safety

Avoid Bodily Injury Caused in Back

Running or Swing Accident of
Machine
� When the machine reverses or the superstructure
slew platform swings, if there is staff near the
machine, he/she will be impacted or squeezed to
cause severe injury or even death. To avoid
accident due to machine reverse or swing:

� You shall look around before reverse or

machine swing. All the staves nearby shall
leave.

� Keep the travel alarm at working state (if this

device is available). Note the nearby staves
entering the working area. Before the
machine is moved, the staves nearby shall be
warned with horn or other signal.

� When the sight is blocked at reverse, signal

man shall be arranged. Note the signal from
the signal man. When the working condition
needs signal man, the hand signal shall
conform to local provision.

� The machine can be only operated when the

signal man and machine operator fully
comprehend the signals.

� Learn about the meanings of all flags, signals

and signs used during the work, and confirm
who can give signal.

� Keep the window, mirror and lamp clean and

in good condition.

� The dust, rain and fog will reduce the

visibility. The machine shall reduce speed
and use lighting due to visibility reduction.

� Read and comprehend all the instructions in

Operation & Maintenance Manual.

33
 Safety

Avoid Roll-over
Don't attempt to jump off the inclined vehicle, it'll
cause severe injury or life danger. The speed of vehicle
roll-over is faster than your jumping speed. Fasten the
seat belt.

� When the machine is operated on the slope, the

danger of roll-over will happen frequently to
cause severe injury or even death.

To avoid roll-over:

� Pay special attention to the following before

operating machine on the slope.

� Level the working area of machine.

� Lower the bucket on the ground and

approach the machine.

� Reduce working speed to prevent roll-over

or skidding.

� Avoid changing direction when traveling the

slope.

� If the machine has to cross on the slope, the

slope can't exceed 15°.

� When the swing is performed with load, the

swing speed can be reduced as required.

� Handle the machine with care on the freezing

ground.

� The ground will be softened due to

temperature increase so that the machine will
travels unstably.

34
 Safety

Evade Electric Wire

� If the machine or working device can't be kept a
safe distance with the wire, severe injury or even
death will be caused.

� When the machine is operated near wire, any

part or load of machine can't be moved to the
range of 3m plus double length of wire
insulator to the wire.

� Check and abide by relevant local rules.

� If the land is wet, it'll enlarge the area for

electric shock of staves, so the staves nearby
and coworkers shall leave site.

Lifting Objects
Lifting
� If the lifted article is lowered, the staff nearby will
be impacted or pressed by the lowered article, to
cause severe injury or even death.

� When lifting is performed by this machine,

local rules must be abided by.

� Don't use the damaged iron chain or scraped

steel cable, lifting tool or cable.

� Before lifting is performed, the position of

superstructure slew platform shall be
confirmed, and make the travel motor at the
back.

� The load shall be moved slowly with care.

Sudden movement is forbidden.

� All the staves shall leave load.

� The load can't pass over the staff.

� Anyone can't approach the load until it has

been in position on the bearing block or
lowered on the ground safely and reliably.

� The chain or lifting tool can't be assembled

on the bucket tooth. The bucket tooth will be
probably disconnected to cause load falling.

35
 Safety

Prevent from Splashing Scrap

� If the scrap hits eyes or any part of body, severe
injury will be probably caused.

� Prevent the injury due to metal block or

scrap; wear goggles or safety glasses.

� Before any article is knocked, the staff

nearby shall leave working area.

Park the Machine Safely

� In order to avoid accident:

� Park the machine on the solid and even

ground.

� Lower the bucket on the ground.

� Turn the auto-idle/acceleration selector and

H/P mode switch to OFF position.

� Run the engine idle for 5 minutes with low

speed and no load.

� Turn the key switch to OFF to shut down the

engine.

� Take out the key from the switch.

� Drag the hydraulic lockout control to LOCK

position.

� Close the window, skylight and cab door.

� Lock all the accessible doors and engine

compartment.

36
 Safety

Handle Liquid Safely - Avoid Fire

� Handle fuel with care because it's highly
inflammable material. If the fuel catches fire, it'll
cause explosion and/or fire so as to cause severe
injury or death.

� When smoking or approaching naked fire or

sparkle, don't fill oil. (Smoking or fire is
forbidden when filling oil to the machine)

� The engine shall be shut down before filling

oil to the machine.

� The fuel shall be filled outdoors.

� All the fuel, most of lubricating grease and some

coolant are inflammable.

� Store the inflammable fluid at the place

without fire risk.

� Don't burn or punch the pressure container.

� Don't store the oily wiping cloth, it'll

probably catch fire or cause spontaneous fire.

� The oil filler cap of fuel and engine oil shall

be tightened.

37
 Safety

Transport Machine Safely

Safely
� When the machine is loaded and unloaded from optimal stability of machine.
one truck or trailer, the danger of roll-over will
11) Connect the chain or steel cable on the machine
exist.
frame reliably.
� When this machine is transported on public
road, local rules shall be abided by.

� When this machine is transported, proper

truck or trailer shall be provided. When this
machine is loaded and unloaded, note the
following items:

1) Select the solid and even ground.

2) The loading platform or gangway shall be used.

3) When the machine is loaded and unloaded, signal

man shall be arranged.

4) When the machine is loaded and unloaded, set the

auto-idle/acceleration selector and H/P mode
switch for OFF position, to avoid increasing
speed accidentally due to unconsciously operating
certain one joystick.

5) The low-speed mode of travel mode switch shall

be selected. When high-speed is selected, the
travel speed will be increased automatically.

6) When the machine travels on the gangway

forward or backward, turning will be forbidden
because it's very dangerous. If turning is required,
the machine must return to the ground or truck
body, regulate travel direction and then travel
again.

7) When the machine travels on the gangway

forward or backward, only the travel control can
be operated, other joysticks can't be operated.

8) There is a projection at the joint of gangway top

and truck body. Cross this place with care.

9) When the slew platform of superstructure swings,

the injury due to machine roll-over shall be
prevented.

10) Keep the arm at the retractile position, rotate the

slew platform of superstructure slowly to keep

38
 Safety

Implement Safety Maintenance � Don't work under the machine lifted by boom.

In order to avoid accident: � Some parts shall be checked regularly, repair or

� Learn about maintenance procedure before work
is started.
� The working area shall be kept clean and dry.
� Don't spray water or steam in the cab.
� The machine can't be lubricated and maintained
when it's moved.
� The hand, foot and clothes shall be kept away
from power-driven parts.
� Before machine maintenance is started, the
following shall be performed:
1) Park the machine on the even ground.
2) Lower the bucket on the ground.
3) Set auto-idle/acceleration selector for OFF
position.
4) Run the engine idle for 5 minutes with low
speed and no load.
replace them as required. Please refer to related
contents of the chapter "Maintenance" in this
Manual.
� All the parts shall be kept in good condition and
installed correctly.
� If the component is damaged, repair it timely. The
worn or damaged part shall be replaced. Remove
the accumulative grease, engine oil or dirt.
� When the parts are cleaned, the uninflammable
clean oil shall be used all the time. The part or
surface can't be cleaned with the highly
inflammable oil such as fuel or petrol.
� Before the electric system is regulated or the
machine is welded, the battery grounding cable (-)
shall be disconnected.
� The working place shall be provided with
sufficient lighting unless the place is very safe.

5) Turn the key switch to OFF position to shut

down the engine.

6) Operate each joystick for several times to

release the pressure in the hydraulic system.

7) Take out the key from the switch.

8) Hang the "No operation" plate on the

joystick.

9) Pull the hydraulic lockout control to "Lock"

position.

10) Cool the engine.

� If certain one maintenance procedure has to be

performed when the engine is running, the
machine shall be watched.

� If the machine has to be lifted, the angle between

boom and arm shall be kept within 90° ～ 110°.
For all the machine components which must be
lifted for maintenance, they must be supported
reliably.

39
 Safety

� When working inside the machine or below the

machine, safe portable lamp shall be used.

� Check whether the bulb has been covered by wire

cover. The hot filament in the broken bulb by
accident will ignite the overfilled fuel or engine
oil.

� The working area shall be displayed thoroughly.

When working inside of machine or below the
machine, the service lamp shall be used.

� The working lamp shall be used to protect guard.

Prevent the overfilled engine oil, oil anti-freezing
agent or window detergent catching fire due to
broken bulb.

No Operation Tag
� Severe injury will be caused due to accidental Danger
operation of machine.

� Before you service the equipment or before

you repair the equipment, attach a warning
NO OPERATION
tag of "No operation" to the start switch or to
the controls.

SIGNED BY
DATE

Support Machine Correctly

� Never work on the unsafe and unreliable machine.

� Before you get on the machine, the

accessories must be lowered on the ground.

� If you have to work on the lifted machine or

accessory, the machine or accessory must be
supported reliably. The machine can't be
supported on the slag brick, hollow tile or the
bearer which will be broken due to
continuous load. Never work on the machine
only supported by one jack.

40
 Safety

Keep Distance from Rotatable Parts

� Severe injury will be caused due to being
entangled by rotating component.

� In order to avoid accident, prevent the hand,

foot, clothes, jewelry and hair being
entangled when working around the rotating
component.

Prevent from Splashing of Parts

� The lubricating grease in the track regulator is
under high pressure.

If the following cautions are not abided by, the

severe injury, blindness or even death will be
probably caused.

� Don't attempt to disassemble grease fitting or

valve assembly.

� Because the part will be probably ejected,

keep the body and face away from the valve.

� The travel reduction device is under pressure.

� Because the part will be probably ejected,

keep the body and face away from the air
drain plug to prevent being injured. The gear
oil is hot.

� After the gear oil is cooled, unscrew the air

drain plug to release pressure.

Store Accessories of Machine Safely

� The stored machine accessories such as bucket,
hydraulic hammer and dozer will probably fall to
cause severe personal injury or even death.

� These accessories and devices shall be stored

safely to prevent falling. Keep children and
staves nearby away from the storage area.

41
 Safety

Use Tools Properly

� The tools shall be suitable for the work.

� Danger will be probably caused by using

improper tools, parts and working procedure.

� When some part is fastened or unfastened,

the tool with correct size shall be used to
prevent injury due to slip of wrench.

� Only the part recommended by our company

is used.

Avoid Burn
Hot injected fluid:

� After the machine is operated, the engine coolant

will be hot and has pressure. The pipe of engine,
heat radiator and heater contains hot water or
steam. If the skin contacts the overfilled hot water
or steam, severe burn will be caused.

� In order to prevent being injured by the

ejected hot water, before the engine is cooled,
don't remove the top cover of heat radiator.
When the cover is opened, rotate cover
slowly until it stops. After pressure is
released thoroughly, remove the top cover.

� The hydraulic oil tank contains pressure.

Similarly, the top cover can be only removed
after pressure is released thoroughly.

Hot liquid and surface:

� The engine oil, gear oil and hydraulic oil will

become hot when working. The engine, hose,
pipeline and other parts will also become hot.

� Any maintenance or check can be started

after the oil and component is cooled.

42
 Safety

Replace Rubber Hose Regularly

� The rubber hose containing inflammable fluid will
be probably broken caused by pressure due to
aging, fatigue and scrape. The quality
deterioration degree of rubber hose due to aging,
fatigue and scrape is hard to be judged relying on
simple check.

� Replace the rubber hose regularly.

� If the rubber hose isn't replaced regularly, it'll

probably cause fire eject liquid on the skin, or the
accessory at the front end falls on the staff nearby,
so as to cause severe burn, gangrene, severe
injury or even death.

Avoid High Pressure Liquid

� The ejected diesel fuel or hydraulic oil due to
pressure will penetrate skin or eyes, to cause
severe injury, blindness or death.

� In order to avoid this danger, the pressure

can be released before the hydraulic pipeline
or other pipeline is disconnected.

� All the joints shall be tightened before

pressure is increased.

� Use one piece of sheet paper to find leakage,

the hands and body shall be prevented being
injured by compressed liquid. Wear face
mask or goggles to protect eyes.

� If accident happens, see the doctor who is

familiar with the injury of this kind. After
any liquid enters skin, it shall be removed via
surgical operation within several hours, else
mortification will be caused.

43
 Safety

Prevent Fire
Check oil leakage:

� The leakage of fuel, hydraulic oil and lubricating � Before the machine is operated every day, the
grease will probably cause fire. function of key switch shall be checked:

� Check whether there is oil leakage due to lost 1) Start the engine and run it under low speed or
or loosened clip, knotted hose, friction of idle speed.
pipeline or hose, damage of oil cooler,
2) Turn the key switch to OFF position to
loosening of oil cooler flange bolt.
confirm the engine can be stopped.
� Fasten, repair or replace any lost, loosened
� If any abnormal condition is found, it must be
or damaged clip, tube, hose, oil cooler and
repaired before machine operation.
oil cooler flange bolt.

� Don't bend or knock the pressure duct.

� Don't assemble the bent or damaged pipeline,

tube or hose.

Check short circuit:

� Short circuit can cause fire.

� Check and fasten all the electric connection.

� Before work is started, check whether there

is loosened, knotted, hardened or cracked
cable and wire.

� Before work is started, check whether

terminal cover is lost or damaged.

� If the cable or wire is loosened or knotted,

don't start machine.

Remove inflammable material:

� The spilled fuel and lubrication oil as well as

refuse, lubricating grease, scrap, accumulated
coal slack and other inflammable matter will
probably cause fire.

� In order to prevent fire, the machine shall be

checked and cleaned every day, and the
spilled or accumulated inflammable matter
shall be removed immediately.

Check the key switch:

� Once fire happens, if the engine can't be stopped,

fire will become bigger to influence fire extinction.

44
 Safety

Check the emergency braking switch of engine:

� If fire happens and the sealed air in the hydraulic
oil tank can't be released, fire-extinguishing will
be influenced and fire will become bigger.

� Check the emergency braking switch

function of engine every other 250h.

1) Start and run the engine under low idle speed.

2) Turn the emergency braking switch of

engine to the "Emergency stop" position.

3) Ensure all the engines have been stopped and

the sealed air of hydraulic oil tank is released
(hiss sound can be heard).

� If any abnormal condition is found, repair it

before machine operation.

Check heat shield:

� The damage and loss of heat shield will probably

cause fire.

� For the damaged or lost heat shield, it shall

be repair or replaced before machine
operation.

Evacuation in Fire
� If fire happens, the machine can be left according
to the following methods:

� If time permits, turn the key switch to OFF

position to stop machine.

� If time permits, fire extinguisher can be used.

� Leave machine.

� In case of emergency, if the door or front window

of cab can't be opened, break the back and front
window with break hammer and then escape.
Refer to the chapter of escape method at
emergency.

45
 Safety

Beware of Exhausted Smoke

� Prevent choke. The fume discharge by the engine
will cause disease or death.

� If the machine has to be operated in the

building, ventilation must be sufficient. Or
remove the fume with extended exhaust pipe,
or open the window to introduce sufficient
ambient air to the working area.

Precautions for Welding and Polishing

Operation
� Welding can generate smoke and/or sparkle.

� When welding is performed, the place with

fine ventilation and preparation shall be
ensured. Before welding is performed, the
inflammable substance shall be stored in a
safe place.

� Welding can be only performed by

professional worker. The non-professional
worker can't perform welding.

� Perform polishing on the machine will cause fire.

Before polishing is performed, the inflammable
substance shall be stored in a safe place.

� After welding and polishing is completed, check

whether abnormal condition such as smoke exists
in the surrounding environment of welding area.

46
 Safety

Avoid Heating Around Pressure

Liquid Pipe
� The heating near the pressure pipe will probably
generate inflammable vaporific substance which
will severely burn yourself and staves nearby.

� Don't perform electric welding, brazing or

use welding saw near the pressure liquid pipe
or other inflammable material to prevent the
object being heated.

� When the heat exceeds critical combustion

zone, the pressure liquid pipe will be cut off
at any moment. Before electric welding and
brazing is performed, the temporary fire-
proof isolating device can be set to protect
hose or other materials.

Prevent Flammable Liquid Pipeline

from Heating
� Don't perform welding or flame cutting to the pipe
containing inflammable fluid.

� Before welding or flame cutting is started, these

pipes shall be thoroughly cleaned with non-
flammable solvent.

Remove Painting before Welding or 2）If solvent or paint remover is used to remove paint,
Heating Operation the paint remover shall be removed with soap and
� When the electric welding and brazing is water before welding. Move the container
performed or welding saw is used, the paint will containing solvent or paint remover and other
generate hazardous gas due to heating. Disease inflammable materials out of the working site.
will be caused by inhaling these gases. Before welding or heating is started, at least 15
minutes shall be spent on gas ventilation.
� Prevent generating poisonous gas or dust.

� All the works shall be done outdoors or in the

place with fine ventilation. The paint or
solvent shall be handled properly.

� The paint shall be removed before welding or

heating:

4) If the paint is polished by emery paper or grinding

wheel, prevent inhaling dust. Accordingly, wear
qualified gauze mask.

47
 Safety

Prevent Explosion of Battery

� The battery gas can be explosive.

� Keep the sparkle, lighted match and naked

fire away from battery top.

� The metal can't be placed at the electrodes of

both sides when battery is charged. The
voltmeter or gravimeter is used.

� Don't charge the frozen battery, or it'll

probably cause explosion. The battery
temperature shall be increased to 16℃
(60℉).

� When the battery electrolyte is lower than

standard, don't use the battery or charge it
continually. This battery will probably cause
explosion.

� The electric spark will be generated by

unscrewing terminal. All the terminals shall
be tightened.

� The battery electrolyte is poisonous. If the battery

is exploded, the battery electrolyte will be
probably splashed into the eyes to cause blindness.

� When the specific gravity of electrolyte is

checked, wear the goggles.

Maintain Air Condition System Sa fely

Safely
� If the refrigerant is splashed on the skin, it'll cause
partial frostbite.

� When the air-conditioning system is

maintained, refer to the correct use method
of refrigerant container.

� The reclaiming and re-circulating system

shall be used to prevent refrigerant being
discharged into the air.

� Prevent the refrigerant vapor contacting skin.

48
 Safety

Handle Chemical Goods Safely

� The exposed hazardous chemicals will cause
severe injury. The chemicals with potential hazard
used on the machine include lubricant, coolant,
paint and binder.

� The Material Safety Data Sheet (MSDS)

includes detailed introduction to chemicals:
hazard to body and health, safety measures
and emergency reaction technology.

� Before any work is started, MSDS shall be

referred to for the harmful chemicals.
Accordingly, you can confirm which is
dangerous and how to do this work safely.
Then use the recommended equipment
according to the procedure.

Handle Waste Safely

� If the refuse is disposed improperly, it'll threaten
the ecological environment. The potential
hazardous wastes generated by LONKING
equipment include oil, fuel, coolant, brake fluid,
filter and battery and so on.

� When liquid is discharged, use the leak proof

container. Don't use food or beverage
container, it'll cause someone to drink by
mistake.

� Don't pour the waste liquid on the ground,

into the sewer or any water source.

� If the air-conditioner refrigerant is leaked

into the air, the atmosphere of the Earth will
be damaged. The government can requires
one air-conditioner service center with
license to reclaim and recycle air-conditioner
refrigerant.

� Acquire the correct method of recycling or

waste disposal from local environmental
protection center or recycling center.

49
 Safety

Prevention of Asbestos Dust

� If the asbestos dust in the air is inhaled, lung
cancer will be caused. When doing dismantlement
work is performed or the industrial waste
materials are disposed on the working place, the
danger of inhaling asbestos will exist. The
following rules shall be abided by:

� When cleaning is performed, spray dust to

reduce dust, don't clean with compressed air.

� If the air probably contains asbestos dust, the

machine must be operated in front of the
asbestos dust and all the staves shall wear
qualified gauze mask.

� During the operation process, other people

can't approach.

� The rules, provisions and environment

standards of working place shall be abided
by.

Before Delivery of Machine to User

� After maintenance or repair is completed, the
following shall be confirmed:

� The machine function shall be normal

especially safety system.

� The worn or damaged part has been repaired

or replaced.

50
 Summary

Chapter Ⅲ Summary

51
 Summary

52
 Summary

CONTENTS

Chapter Ⅲ Summary................................................................................................................. 51
Summary
Overall Dimension...........................................................................................................................................55

Operating Range.............................................................................................................................................. 57

Technical Specification....................................................................................................................................59

Weight List.......................................................................................................................................................62

Capability of Oil and Coolant..........................................................................................................................64

Fuel and Engine Oil......................................................................................................................................... 65

Memo:..............................................................................................................................................................66

53
 Summary

Overall Dimension
CDM6215
CDM6215

54
 Summary

a Overall Length 9440 (mm)

b Overall Height 3200 (mm)
c Tumblers Distance 3265 (mm)
d Radius, Swing Center to Rear End 2750 (mm)
e Counterweight Ground Clearance 1009 (mm)
f Track Gauge 2200 (mm)
g Overall Width 2809 (mm)
h Width of Upper Structure 2740 (mm)
i Track Shoe Width (Standard) 600 (mm)
j Min. Ground Clearance 478 (mm)

55
 Summary

CDM6225
CDM6225

a Overall Length 9440 (mm)

b Overall Height 3200 (mm)
c Tumblers Distance 3462 (mm)
d Radius, Swing Center to Rear End 2750 (mm)
e Counterweight Ground Clearance 1009 (mm)
f Track Gauge 2200 (mm)
g Overall Width 2809 (mm)
h Width of Upper Structure 2740 (mm)
i Track Shoe Width (Standard) 600 (mm)
j Min. Ground Clearance 478 (mm)

56
 Summary

Operating Range
CDM6215
CDM6215

A Max. Digging Radius 9900 (mm)

B Max. Digging Depth 6630 (mm)
C Max. Digging Height 9250 (mm)
D Max. Dumping Height 6620 (mm)
E Max. Digging Radius on the Ground 9750 (mm)

57
 Summary

CDM6225

A Max. Digging Radius 9900 (mm)

B Max. Digging Depth 6630 (mm)
C Max. Digging Height 9250 (mm)
D Max. Dumping Height 6620 (mm)
E Max. Digging Radius on the Ground 9750 (mm)

58
 Summary

Technical Specification

Model CDM6215 CDM6255

Bucket Capability m3 1 1.1

Operating Weight kg 21220 21800

Max. Digging Depth mm 6630 6630

Max. Digging Radius mm 9900 9900

Operation
Max. Digging Radius on The Ground mm 9750 9750
Range
Max. Digging Height mm 9250 9250

Max. Dumping Height mm 6620 6620

Performance

Digging Force of Bucket kN 128 128

Max.Digging Force of Arm kN 99 99

Rotation Speed rpm 11.6 11.6

Travel Speed Km/h 3.33/5.54 3.33/5.54

Gradeability Degree 35 35

Pressure to The Ground kPa 51 51

Standard Track Shoe Width mm 600 600

Overall Length (for Transportation) mm 9440 9440

Full Width mm 2809 2809

Dimension

Track Shoe Width mm 600 600

Overall Height (for Transportation) mm 3200 3200

Min. Ground Clearance mm 478 478

Radius, Swing Center to Rear End mm 2750 2750

59
 Summary

Machine model CDM6215 CDM6225

Model B5.9
Six-stroke, water-cooling, inline, upright,
Type direct injection turbocharger and
intercooler
Cylinder Quantity-Diameter × Course mm 6－102×120
Piston Displacement L(cc) 5.9
Rated Power kW/rpm (HP/rpm) 112/1950 (150/1950)
Engine
Performance

Max. Torque Nm/rpm (lb-ft/rpm) 614/1500 (453/1500)

Max. Idle Speed rpm 2180
Min. Idle Speed rpm 700
Min. Fuel Consumption g/kWh (lb/HPh) 208 (0.342)
Start Motor 24V, 4.5kW
Generator 24V, 70A
Battery 12V, 120Ah×2
Carrier Roller (per side) 2
Track Roller (per side) 7 8
Chassis

Assembling triple Assembling triple

grouser track shoe grouser track shoe
Track Shoe
(45 joints on each (47 joints on each
side) side)
Type × Quantity Variable Plunger
Main Pump Flow L/min 208×2
Hydraulic Equipment

Setting Pressure MPa (kg/cm2) 31.5

Type × Quantity 6-slide valve+1 slide valve
Main Valve
Control Method hydraulic
Plunger Type (with brake valve and stop
Travel Motor
Hydraulic brake): ×2
Motor Plunger Type (with safety valve and
Swing Motor
closed type brake): ×1

60
 Summary

Boom Boom
Type Arm Bucket
(left) (right)

Internal Diameter of
Hydraulic Equipment

Hydraulic mm 120 120 140 120

Cylinder
Cylinder
Diameter of Piston Rod mm 85 85 100 85
Course mm 1260 1260 1430 1030
Max. Course mm 3020 3020 3420 2640
Min. Course mm 1760 1760 1990 1610
Hydraulic Oil Tank Sealing Case
Hydraulic Oil Filter Oil Returning Side of Oil Tank
Hydraulic Oil Cooler Air-cooled

61
 Summary

Weight List

The sheet is used for reference of elements and

transportation.
Unit: kg

Model CDM6215 CDM6225

Engine Assembly (not include water and engine oil) 805 805
� Engine 432 432
� Dumper 12 12
� Main Pump 157 157
Radiator Assembly 103 103
Hydraulic Oil Tank and Oil Filter Assembly (not include hydraulic oil) 200 200
Fuel Tank (not include fuel) 170 170
Platform Assembly 1880 1945
Cabin 270 270
Operator's Seat 36 36
Counter Weight 4023 4023
Swing Reductor 209 209
Travel Motor 208×2 208×2
Center Swing Joint 38 38
Track Base Assembly
� Swing Circle 348 348
� Front Idler 130×2 130×2
� Carrier Roller 33×4 33×4
� Track Roller 38×14 38×16

62
 Summary

CDM6215 CDM6225
Track Shoe Assembly
� Standard Triple Grouser Track Shoe (600 mm) 1320×2 1320×2
� Wider Triple Grouser Track Shoe (600 mm) -- --
� Rubber Track used for road (rubber mat) -- --
Boom Assembly 2280 2280
Arm Assembly 1038 1038
Bucket Assembly (0.8m3) 860 860
Bucket Assembly (0.9m3) 830 830
Bucket Assembly (1.0m3) 862 874
Rock Bucket (0.8m3) 796 796
Rock Bucket (1.0m3) 925 925
Boom Cylinder Assembly 168×2 168×2
Arm Cylinder Assembly 278 278
Bucket Cylinder Assembly 158 158

63
 Summary

Capability of Oil and Coolant

Select According to Ambient Temperature Capability (L)
Sort of
Vessel Regulated Filling
Liquid -30 -20 -10 0 10 20 30 40℃
Volume Volume

SAE 30

SAE 10W 18 18
Drain Pan
SAE 10W-30

SAE 15W-40
Engine
Damper Box Oil 1 --
Swing Reductor
3.14 3.14
Box
Travel Reductor
SAE 30 -- 2×5
Box
Front Idler (per) 0.19~0.21 0.19~0.21
Track Roller (per) 0.22~0.25 0.22~0.25
Carrier Roller(per) 0.11~0.12 0.11~0.12

SAE 10W
280 188
Hydraulic
Hydraulic System SAE 10W-30
Oil
SAE 15W-40

GB252 superior
–10# diesel

GB252 superior –35# diesel

GB252 superior –10#

Fuel Tank Diesel 380 --
diesel

GB252 superior –20# diesel

GB252 superior
–0# diesel

Cooling System Coolant Fill Lonking Pure Coolant 20 --

For ensuring quality of oil product, please

purchase Lonking pure oil from appointed
agent of Lonking.

64
 Summary

Fuel and Engine Oil

� Shown as above sheet, please select fuel and oil

according to ambient temperature.

� Regulated oil volume denotes total oil volume

that including oil in pipeline. Refilling volume
denotes filling volume for normal inspection,
maintenance and oil replacement.

� While starting engine under ambient temperature

of 0 ℃ below, please adopt SAE 10W or SAE
10W-30 engine oil although temperature raises to
10℃ by day.

65
 Summary

Memo
Memo：：

66
 Structure, Function & Maintenance Standard

Chapter Ⅳ
Structure, Function &
Maintenance Standard

67
 Structure, Function & Maintenance Standard

68
 Structure, Function & Maintenance Standard

CONTENTS
Chapter Ⅳ tandard.................................................... 67
Structure, Function & Maintenance Standard
Engine..............................................................................................................................................................71
Radiator........................................................................................................................................................... 73
Power Drive System........................................................................................................................................74
Swing System..................................................................................................................................................75
Swing Circle....................................................................................................................................................76
Track Frame.................................................................................................................................................... 78
Front Idler........................................................................................................................................................79
Track Roller.....................................................................................................................................................81
Carrier Roller...................................................................................................................................................83
Track Shoe.......................................................................................................................................................85
Machine Profile............................................................................................................................................... 86
Hydraulic Oil Tank..........................................................................................................................................87
Main Pump...................................................................................................................................................... 89
Main Valve...................................................................................................................................................... 91
Swing Motor..................................................................................................................................................112
Travel Motor................................................................................................................................................. 114
Central Swing Connector.............................................................................................................................. 116
Control System..............................................................................................................................................118
Pilot Valve.....................................................................................................................................................120
Foot Pedal Valve........................................................................................................................................... 126
Pilot Valve Block.......................................................................................................................................... 130
Accumulator.................................................................................................................................................. 131
Hydraulic Cylinder........................................................................................................................................132
Work Equipment........................................................................................................................................... 137
Air Condition System....................................................................................................................................143
Radio Use...................................................................................................................................................... 152
Engine Control.............................................................................................................................................. 154
MCSS Electric Control System.....................................................................................................................161
Sensor............................................................................................................................................................ 174
Memo:........................................................................................................................................................... 176
69
 Structure, Function & Maintenance Standard

70
 Structure, Function & Maintenance Standard

Engine

1. Diesel Engine 9. Radiator

2. Stainless Steel Inlet Pipe of Intercooler 10. Air Filter
3. Water Outlet Hose of Engine 11. Suction Pipe
4. Fan 12. Stainless Steel Outlet Pipe of Intercooler
5. Left Front Bracket 13. Intake Hose
6. Water Intake Hose of Engine 14. Limit Plate
7. Front Shock Pad of Engine 15. Rear Shock Pad of Engine
8. Water Separator 16. Right Rear Bracket

71
 Structure, Function & Maintenance Standard

17. Muffler � Technical Specification

18. Engine Oil Filter � Rated Power/Engine Speed: 112kW/1950 rpm
19. Elastic Coupling
� Max. Torque/Engine Speed: 610N·m/1500 rpm
20. Fuel Filter
21. Left/Right Bracket
22. Auxiliary Radiator

72
 Structure, Function & Maintenance Standard

Radiator

1. Sealing Plate
2. Sealing Washer
3. Intercooler � Technical Specification

4. Oil Radiator � Water Radiator Power: 70.5 kW

5. Water Radiator � Intercooler Power: 28.5 kW
6. Brace Rod Components � Oil Radiator Power: 55 kW
7. Radiator
8. Protecting Wire Net

73
 Structure, Function & Maintenance Standard

Power Drive System

1. Front Idler 7. Main Pump

2. Central Swing Connector 8. Travel Speed Solenoid Valve
3. Main Valve 9. Swing Brake Solenoid Valve
4. Final Drive 10. Swing System
5. Travel Motor 11. Swing Motor
6. Engine 12. Swing Circle

74
 Structure, Function & Maintenance Standard

Swing System

1. Swing Pinion
2. Spacer
3. Case
4. 2# Planetary Gear
5. 2# Sun Gear
6. Gear Ring
7. 1# Sun Gear
8. Swing Motor
9. Oil Gauge
10. 1# Planetary Gear
11. 1# Planetary Bracket
12. 2# Planetary Bracket
13. Drain Plug

75
 Structure, Function & Maintenance Standard

Swing Circle

Outer Circle
Inner Circle

1. Inner Swing Circle � Technical Specification

2. Steel Ball � Module Number: 12
3. Outer Swing Circle � Gear Number: 91
� Pressure Angle: 20°
� Lubricating Grease Quantity: 15 Kg

S.N. Item Standard Measure

Axial clearance of bearing (being assembled Standard clearance Limit clearance

4 Replace
on chassis) 0.02~0.25 0.5

76
 Structure, Function & Maintenance Standard

Swing Motor

Swing System

Outer Circle

Inner Circle

77
 Structure, Function & Maintenance Standard

Track Frame

1. Front Idler 6. Track Shoe

2. Track Frame 7. Centre Guard
3. Carrier Roller 8. Spring
4. Final Drive 9. Front Guard
5. Track Roller

� Technical Specification
� Track Roller Quantity: CDM6215: 7
CDM6225: 8
� Standard Track

Item Model CDM6215 CDM6225

Width of Track Shoe 600mm 600mm

Quantity of Track Shoe (one side) 45 Joints 47 Joints

78
 Structure, Function & Maintenance Standard

Front Idler

4 3 5

1
2

Unit: mm

S.N. Item Standard Measure

Standard Dimension Repair Limit

1 External Diameter of Flange
Ф560 --

2 External Diameter of Slide Way Ф520 508

Rebuild or Replace
3 Width of Flange Ф85 --

4 Total Width Ф164 --

5 Width of Slide Way Ф39.5 33.5

79
 Structure, Function & Maintenance Standard

1. Pin
2. Bracket
3. Seal Ring
4. O-Ring
5. Bush
6. Body
7. Plug
8. Pin Shaft

80
 Structure, Function & Maintenance Standard

Track Roller

1
2

4 5 6

Unit: mm

S.N. Item Standard Measure

Standard Dimension Repair Limit

1 External Diameter of Flange
Ф139 --

2 External Diameter of Slide Way Ф160 148

3 Total Width Ф360 -- Rebuild or Replace

4 Internal Width Ф79 --

5 Width of Slide Way Ф47 53

6 Width of Flange Ф29.5 --

81
 Structure, Function & Maintenance Standard

1. Pin
2. Shaft cover
3. Seal ring
4. O-ring
5. Bush
6. Roller
7. Pin shaft
8. Shaft cover
9. Plug

82
 Structure, Function & Maintenance Standard

Carrier Roller

3 4

2
1

Unit: mm

S.N. Item Standard Measure

Standard Dimension Repair Limit

1 External Diameter of Flange
Ф169 --

2 External Diameter of Slide Way Ф142 100 Rebuild or Replace

3 Width of Slide Way Ф40 --

4 Width of Flange Ф16 --

83
 Structure, Function & Maintenance Standard

1. Fixing Cover
2. Seal Ring
3. O-Ring
4. Bearing
5. Pin Shaft
6. Roller
7. Stop Plate
8. Locking Plate
9. End Cover

84
 Structure, Function & Maintenance Standard

Track Shoe 6 5 4

6 5 4

2 7

2 7
1
1

3
3

Unit: mm

S.N. Item Standard Measure

Standard
Repair Limit
1 Pitch of Rail Chain Dimension

Ф190 Ф193
Overturn or Replace
Standard Running

2 External Diameter of Bush Dimension Normal Load Compacting Load

Ф58.72 -- Ф63.32

Standard
Repair Limit
3 Height of Rail Chain Dimension Repair or Replace

Ф106 Ф97

4 Ф155.6
Clearance of Clawer Board
5 Ф119.6 Replace
Bolts
6 Ф69

7 Internal Width of Rail Chain Ф82.6 Repair or Replace

85
 Structure, Function & Maintenance Standard

Machine Profile

S.N. Name S.N. Name S.N. Name

1 Counterweight 13 Boom 25 Idler Cushion

2 Engine 14 Arm 26 Carrier Roller
3 Radiator 15 Bucket Cylinder 27 Base

4 Hood 16 Rocker Rod 28 Travel Motor

5 Main Valve 17 Bucket 29 Diesel Tank

6 Air Filter 18 Boom Cylinder 30 Hydraulic Oil Tank

7 Swing Motor 19 Joystick Control 31 Platform

8 Air Condition 20 Foot Pedal Control 32 Main Pump

9 Cabin 21 Track 33 Pilot Valve

10 Seat 22 Swing Circle 34 Oil Filter

11 Swing Connector 23 Front Idler 35 Muffler

12 Arm Cylinder 24 Track Roller

86
 Structure, Function & Maintenance Standard

Hydraulic Oil Tank

1. Air Filter
2. Oil Gauge � Technical Specification
3. Oil Temperature Sensor � Water Radiator Power: 70.5 kW
4. Oil Filter Element � Intercooler Power: 28.5 kW
5. Oil Outlet Pipe � Oil Radiator Power: 55 kW
6. Oil Return Filter
7. Oil Return Pollution Alarm
8. Oil Tank Body
9. Magnetic Block
10. Ball Valve

87
 Structure, Function & Maintenance Standard

Oil Filling & Air-vent Filter

Oil Suction Filter

Oil Return Filter

Oil Return Pollution Alarm

Oil Gauge

Oil Temperature Sensor

Oil Outlet Pipe

Ball Valve

88
 Structure, Function & Maintenance Standard

Main Pump

Min. flow adjusting bolt

89
 Structure, Function & Maintenance Standard

� Technical Specification

� A1, A2: Delivery Port

� B1: Suction Port

� Dr: Drain Port

� Pi1, Pi2: Pilot Port

� A3: Delivery Port of Gear Pump

� B3: Suction Port of Gear Pump

� Max. Displacement: 106.5×2 cm3

� Rated Speed: 1950 min-1

� Pressure: 34.3 MPa

� Max. Flow: 208×2 L/min

� Max. Output Horsepower: 104 kW

� Max. Output Torque: 511 N·m

90
 Structure, Function & Maintenance Standard

Main Valve
Outside View Drawing

91
 Structure, Function & Maintenance Standard

92
 Structure, Function & Maintenance Standard

93
 Structure, Function & Maintenance Standard

Interface List

Dimension Fastening Torque Symbol Interface Description

G-1 (ISO 228/1) 200~250 (Nm) R1 Swing and oiling interface

G-3/4 (ISO 228/1) 150~180 (Nm) Ck1, Ck2 Bucket confluence interface
XAtr Right traveling pilot interface
XBtr Right traveling pilot interface
(XAo) (Backup pilot interface)
(XBo) (Backup pilot interface)
XAk Bucket back pilot interface
XBk Bucket spread pilot interface
XAb1 Boom lift pilot interface
XBb1 Boom drop pilot interface
XAa2 Arm back confluence pilot interface
XBa2 Arm spread confluence pilot interface
G-3/8 (ISO 228/1) 69~78 (Nm) XAtL
Left traveling pilot interface
XBtL
XAs
Slewing pilot interface
XBs
XAa1 Arm back pilot interface
XBa1 Arm spread pilot interface
XAb2
Boom lift confluence pilot interface
(Psp)
(Slewing priority pilot interface)
(XAas)
XBp1 Bucket confluence pilot interface
Dr5 Oil leakage interface
Pilot interface used for lifting pressure of main
Pz
overflow valve
Py Traveling signal interface
Px Signal used for operation besides traveling
PG
Pilot pressure resource interface
PH
Dr1
G-1/4 (ISO 228/1) 34~38 (Nm)
Dr2
Leakage interface
Dr3
Dr4
FL Negative control signal interface (side of P1)
FR Negative control signal interface (side of P2)
PaL
Fastening valve pilot interface
PbL

94
 Structure, Function & Maintenance Standard

Dimension Fastening Torque Symbol Interface Description

Atr Right traveling motor interface

Btr Right traveling motor interface

(Ao)
Backup interface
(Bo)

Ak1 Interface on side of piston head of bucket cylinder

Bk1 Interface on side of piston rod of Bucket cylinder

Ab1 Interface on side of piston head of boom cylinder

Bb1 Interface on side of piston rod of boom cylinder

M10 (ISO 724) 49~65 (Nm)
AtL
Left traveling motor interface
BtL

As
Slewing motor interface
Bs

Aa1 Interface on side of piston head of arm cylinder

Ba1 Interface on side of piston rod of arm cylinder

P1 Pump interface (side of P1)

P2 Pump interface (side of P2)

M12 (ISO 724) 83~110 (Nm) R2 Oil return interface

� Technical Specification

� Standard Flow: 250 (L/Min)

� Maximal Pressure: 34.3 (Mpa)

� Operating Oil Temperature: -20℃~90℃

� Maximal Oil Leakage Pressure: 0.3 (Mpa)

95
 Structure, Function & Maintenance Standard

Function

� Action

� Neutral

96
 Structure, Function & Maintenance Standard

97
 Structure, Function & Maintenance Standard

� Operating oil output from main pump P1 flows

into pump interface (P1) of valve body A (101)
and be introduced into neutral bypath (21) and
parallel channel (22). Operating oil output from
main pump P2 flows into pump interface (P2) of
valve body B (102) and be introduced into neutral
bypath (18) and parallel channel (6).

� Operating oil output from main pump P1 return to

operating oil tank via neutral bypath (21),
negative control orifice (NR1), oil tank channel
(13), from oil tank interface (R2) return operating
oil tank. from oil tank interface (R20) return
operating oil tank.

� While switch valve core via controlling rod of

pilot control valve, operating oil output from
main pump P2 supplies operating oil after be
introduced into neutral bypath (18). On the other
hand, operating oil output from main pump P1
supplies left traveling valve core (310) after be
introduced into neutral bypath (21). In addition,
slewing valve core (305), valve core (307) of
boom 2, valve core (302) of arm 1 are supplied by
parallel channel (22).

98
 Structure, Function & Maintenance Standard

� Negative Control Action

a. General Action

Negative control signal consisted by neutral bypath

(18, 21) acts and control output flow of pump under
following condition.

1) No operation is performed under neutral state

(negative control action a)

2) Control rod of pilot valve slightly (negative

control action b)

Operating oil output from main pump P1 (28) is

introduced into oil tank channel (13) via neutral
bypath (21), channel (3), negative control orifice (9).
Operating oil shall rise pressure of channel (3) while
passing negative control orifice. The pressure shall
become negative control pressure signal FL and be
introduced into adjustor of pump P1 via negative
control channel (4). System shall control adjustor of
pump and reduce output flow of pump P1 (28)
according to this.

99
 Structure, Function & Maintenance Standard

a. General Action (continuous)

Negative control overflow valve (611) consists of cone

valve (15), spring (16) and valve body (101). In case
that pressure of channel (3) rises and achieves setting
pressure of spring (16) under effect of operating oil
flowing into neutral bypath, operating oil of channel (3)
shall open cone valve (15) and flow out to oil tank
channel (13).

In case that control rod of pilot control valve is neutral,

operating oil output from pump P1 (28) flows to
operating oil tank via middle bypath (21), negative
control orifice (9), oil tank channel (13). At this time,
resistance passing negative control orifice (9) and
pressure FL of channel (3) become maximal pressure
(FL1), and angle of pump P1 (28) becomes minimal
one, and reduce output flow of pump P1 (28) to
minimal volume. (Qmin)

100
 Structure, Function & Maintenance Standard

b. Negative Control (micro operation)

During lifting operation of boom, pilot pressure oil of

XAb1 interface enters into boom valve core (303) and
moves to lift slightly, as a result, channel (19) opens
slightly and neutral bypath (18) closes slightly, to
divide liquid flow of operating oil into two parts. One
part flows to negative control orifice (7) via neutral
bypath (18) and the other part flows Ab1 interface via
parallel channel (6) and channel (19). Flow through
negative control orifice (7) and neutral bypath (18)
reduces slightly and depresses pressure FR of channel
(10) slightly. Output flow of pump P2 (27) shall be
increased while depressing FR. Boom valve core (303)
shall close neutral bypath (180) completely and shut
down operating oil flowing to neutral bypath if operate
rod of pilot valve ulteriorly. And then, pressure of
channel (10) changes to 0 and output flow of pump P2
becomes maximal. (Qmax)

It is possible to realize correct action of execution

mechanism by controlling output flow of pump via
operating rod of pilot valve slightly.

It is same for pump P1 (28), controlled via negative

control orifice (7).

101
 Structure, Function & Maintenance Standard

� Spool Operation - Boom

a. Operation of Boom Raise

Operating oil output from main pump P2 flows to

spool (303) of boom 1 via interface P2 and parallel
In addition, oil overflowing from piston rod of boom
loop (6). Operating oil output from main pump P1
cylinder flowing into interface Bb1 and via spool (303)
flows to spool (307) of boom 2 via interface P1 and
of boom 1, oil tank channel (13), from oil tank
parallel loop (22).
interface (R2) return operating oil tank.
During operation of boom raise, pilot pressure oil of
Operating oil output from main pump P2 interflows
pilot control valve flows into XAb1 interface and
with operating oil output from main pump P1 at
spool (303) of boom 1 gets over pretightening force of
internal side of valve body and supply piston head of
spring (371), (372) and move spool leftwards.
boom cylinder. Confluence of operating oil shall
Operating oil output from main pump P2 flows to
improve lift speed of boom, but spool (303) of boom 1
parallel channel (6) and pushes single-way valve LCb1
acts and oil output from main pump P2 supplies
(511) and be introduced into spool (303) of boom 1.
cylinder only while controlling rod of pilot valve
And then, flows out from interface Ab1 via fastening
slightly.
valve HV (516) and flows into piston head of boom
cylinder. At the same time, pilot pressure oil flows into
XAb2, spool (307) of boom 2 and single-way valve
CCb (511). Operating oil interflowing at channel (8)
flows into piston head of boom cylinder via interface
Ab1.

102
 Structure, Function & Maintenance Standard

b. Operation of Boom Lower

During operation of boom lower, pilot pressure oil

flows into XBb1 interface and PbL interface, spool
(303) of boom 1 gets over pretightening force of
spring (371) and (372) to move spool rightwards.

Operating oil output from main pump P2 flows into

parallel channel (6), pushes single - way valve LCb1
(511) and from interface Bb1 flows into piston rod of
boom cylinder.

On the other hand, oil at side of piston head of boom

cylinder flows into interface Ab1 and return to
operating oil tank via valve core (303) of boom 1, oil
tank channel (4) and oil tank interface R2. System
shall slow down action of boom cylinder via limiting
flow at channel (45).

103
 Structure, Function & Maintenance Standard

� Spool Operation - Arm

a. Operation of Arm Out

During operation of arm out, pilot pressure oil flows

into XBa1 and XBa2, spool (302) of arm 1 gets over
pretightening force of spring (371), (372) and move
leftwards, spool (306) of arm 2 gets over pretightening
force of spring (373), (375) and move leftwards.
Operating oil output from main pump P1 flows to
parallel channel (22), pushes single-way valve LCa1
(511), and flows to side of piston rod of arm cylinder
via fastening valve (516) and interface Ba1.

At the same time, operating oil output from main pump

P2 is introduced into parallel channel (22) and neutral
bypath (21) and flows to spool (306) of arm 2 via
boom priority valve (104). And then, interflows with
Ba1 interface vi internal channel of spool (306) of arm
2 and flows to side of piston bar of arm cylinder.

On the other hand, oil at side of piston head of arm

cylinder flows into interface Aa1 and return to
operating oil tank via spool (302) of arm 1, oil tank
channel (13) and oil tank interface R2.

104

b. Operation of Arm In
Small load
During operation of arm in, pilot pressure oil flows
into XAa1 and XAa2 interface, spool (302) of arm 1
gets over pretightening force of spring (371), (372)
and moves rightwards, spool (306) of arm 2 gets over
pretightening force of spring (373), (375) and moves
rightwards.
Operating oil output from main pump P1 flows to
parallel channel loop (22), pushes single-way valve
LCa1 (511)of channel and be introduced into spool
(302) of arm 1 via U-channel. And then, flows out
from interface Aa1 via external side of spool and flows
to side of piston head of arm cylinder.
At the same time, operating oil output from main pump
P2 flows to parallel channel (22), flows into spool
(306) of arm 2 via boom priority valve (104). And then,
interflow with Aa1 interface at internal channel of
spool (306) of arm 2 and flow to side of piston head of
arm cylinder.
105
Structure, Function & Maintenance Standard
On the other hand, oil output from side of piston rod of
arm cylinder return operating oil of rising pressure to
Ba1 interface via self-weight of arm. Operating oil
back to Ba1 interface flows into internal side of valve
core (302) of arm 1 via hole on external side of it, push
hole of single-way sleeve spool under condition of
small load, flows into U-channel oppositely and
interflows at Aa1 interface, the process is called as
regeneration of arm.
Plunger (d) and additional spool (e) moves rightwards
if pressure at side of piston head of arm cylinder rises,
at the same time, pressure at downflow of single-way
sleeve valve (f) closes the valve to cut off regeneration
of arm. Operating oil at side of piston rod of arm
cylinder flows into internal side of spool via Ba1
interface and external hold (a) of arm spool, flows out
from external hole (b) of spool and return to operating
oil tank via oil tank interface R2.
 Structure, Function & Maintenance Standard

Chamber pressure of piston head of arm cylinder rises

106
 Structure, Function & Maintenance Standard

� Spool Operation - Arm

a. Operation of Bucket Out

During operation of bucket out, pilot pressure oil flows

into XBk interface and bucket spool (304) gets over
pretightening force of spring (371), (372) and moves
leftwards.

Operating oil output from main pump P2 flows to

parallel channel loop (6), pushes single-way valve Ck2
(513) and be introduced into bucket spool (304) via U-
channel. And then, flows out from interface Bk1 via
external side of spool and flows into side of piston rod
of bucket cylinder.

On the other hand, oil output from side of piston head

of bucket cylinder flows into Ak1 interface and via
external side of spool, oil tank channel (13) and oil
tank interface (R2) return to operating oil tank.

5 1 3
371 372

1 3 304 6 4

107
 Structure, Function & Maintenance Standard

b. Operation of Bucket In

During operation of bucket in, pilot pressure oil flows

into XAk interface and bucket spool (304) gets over
pretightening force of spring (371), (372) and moves
leftwards.

Operating oil output from main pump P2 flows to

parallel channel loop (6), pushes single-way valve Ck2
(513) and be introduced into bucket spool (304) via U-
channel. And then, flows out from interface Ak1 via
external side of spool and flows into side of piston rod
of bucket cylinder

On the other hand, oil output from side of piston head

of bucket cylinder flows into Bk1 interface and return
to operating oil tank via external side of spool, oil tank
channel (4) and oil tank interface R2.

5 1 3
371 372

1 3 304 6 4

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 Structure, Function & Maintenance Standard

� Swing

During operation of right/left swing, operating oil

output from main pump P1 is introduced into swing
motor.

Pilot pressure oil flows into XAs interface, swing

spool (305) gets over resistance of spring (371), (372)
and moves leftwards. Operating oil output from main
pump flows to parallel channel loop (22), pushes
single-way valve LCs (517) and be introduced into
swing spool (305) via U-channel. And then, flows out
from interface As via external side of spool and return
via interface Bs, after rotated motor. Oil output from
motor returns to operating oil tank via external side of
swing spool (305), oil tank channel (13) and oil tank
interface R2.

Swing operation of opposite direction is same as it

above mentioned.

1 3 305 517 2 2 4 371 372

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 Structure, Function & Maintenance Standard

� Travel

During operation of travel, operating oil output from

main pump P1 is supplied to left travel motor and
operating oil output from main pump P2 is supplied to
right travel motor. Pilot pressure oil flows into XatL
and Xatr, as a result, right travel spool (310) gets over
pretightening force of spring (328), (329) and moves
leftwards.

Operating oil output from main pump flows to parallel

channel loop, pushes single-way valve and be
introduced into left travel spool (310) via U-channel.
On the other hand, operating oil output from main
pump is introduced into right travel spool (301). Oil
output from travel motor flows into BtL and BtL
interface, and return to operating oil tank via oil tank
interface R2.

Travel operation of opposite direction is same as it

above mentioned.

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 Structure, Function & Maintenance Standard

� Main Relief Valve

511
Operating oil output from main pump P1 and P2 flows 11 511
into control valve via interface P1 and P2 and be 611
introduced into main overflow valve MR (601) via
single-way valve CMR1 (511) and CMR2 (511). Main
overflow valve shall act if pressure of channel (11)
achieves setting pressure of main overflow valve MR
(601).

� Action of Main Relief Valve

Pilot valve core (24) presses onto valve seat of pilot 25 31

39 24 34 38 11
valve and oil in channel (11) fails to flow into oil tank
channel (14) if pressure of channel (11) is lower than
setting pressure of main overflow valve MR (601).
Pilot valve core (24) gets over pretightening force of
spring (39) and opens if pressure of channel (11)
achieve setting pressure. After opened pilot spool (24), 14
oil of indoor (33) flows to oil tank channel (14) via 33 32 35 30
channel (32), and oil of channel (11) flows into
channel (30) via orifice (31) synchronously. Opening
of pilot spool (24) shall depress pressure of indoor (35),
as a result, main spool (38) gets over pretightening
force of spring (34) and moves leftwards, and oil in
channel (11) flows into oil tank channel (14). Pressure
in channel (14) shall keep as setting pressure of main
overflow valve (601). User could adjust setting
pressure via adjusting screw (25).

111
 Structure, Function & Maintenance Standard

Swing Motor

GN
A, B

DB

DP SH
AN PG

A, B: Main Oil Port

M: Compensation Port
PA, PB: Pressure Measure Port
DB: Oil Drain Port
PG: Brake Release Port
SH: Brake Pilot Port
L: Level Measure Port
IP: Oil Inlet of Gear Oil
DP: Oil Outlet of Gear Oil
AN: Exhaust Port of Lubricating Oil
GN: Filler of Lubricating Oil

112
 Structure, Function & Maintenance Standard

A B

PA
PB

IP M

D L
B

DP, AN
SH

Technical Specification
� Pressure Angle: 20°
� Quantity of Gear: 13
� Module: 12

Capability (cm3) 129.2

Hydraulic Max. pressure (MPa) 25.5

motor Flow (L/min) 208

Output torque (25.5MPa) (N·m) 525

Reduction ratio 20.01

Reductor
Output torque (25.5MPa) (N·m) 10500

113
 Structure, Function & Maintenance Standard

Travel Motor

Fastening torque: 252±39.2 N·m

Fastening torque: 252±39.2 N·m (25.7±4.0 kgf·m）
(25.7±4.0 kgf·m)

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 Structure, Function & Maintenance Standard

Hydraulic Circuit

Technical Specification

Using Condition
Reduction Ratio 56
Reduction Gear Output Torque N·m (kgf/m) 34303/19232
Output Speed rpm. (3498/1961)
27.9/47.6
Operating Pressure MPa 34.3 (350)
Hydraulic Motor Rotation Speed rpm. 1563/2666
Flow L/min 208
System Pressure MPa (kgf/cm2) 34.3 (350)

Swing Direction (Along

Oil Inlet Oil Outlet
Direction Of X)
Clockwise
Anticlockwise

115
 Structure, Function & Maintenance Standard

Central Swing Connector

Central

Oil drain

B
D
A D A

C
C

A E
D

Technical Specification

Oil Port A, B, C, D E
Item
Rated Pressure (Kg/Cm2) 325 30
Rated Flow (L/Min) 315
Maximal Slewing Speed (Rpm) 10
Slewing Torque (Kg·m) MAX23

116
 Structure, Function & Maintenance Standard

B A

E
D C
F

Dr Dr
Ps Ps
Upper Upper

Lower Lower

Travel
左行走马达 Motor L.H. Travel
右行走马达Motor R.H.

117
 Structure, Function & Maintenance Standard

Control System

R.H.

(R3)
(R1)
(R4)
(R2)

(Travel 3)
(Travel 4)
(Travel 1)
(Travel 2)
L.H.
(L2)
(L4)
(L3)
(L1)

1. Joystick Control R.H.

2. Foot-Pedals
3. Foot Pedal Valve
4. Joystick Control L.H.

118
 Structure, Function & Maintenance Standard

� Joystick Controls (standard mode)

� There is marked with sign on machine to

display standard control mode of control rod
and pedal.

� Avoid contacting crawler with boom cylinder

during digging process.

� Please put traveling motor on back side of

machine during digging process to reduce load
of sprocket and chain belt to minimal level,
improve safety and hoisting capacity to
maximal level.

� Control rod shall return to neutral position

automatically after be released and function of
machine shall stop.

(1) Swing Right (5) Boom Lower

(2) Swing Left (6) Boom Raise
(3) Arm Out (7) Bucket In
(4) Arm In (8) Bucket Out

119
 Structure, Function & Maintenance Standard

Pilot Valve

Sectional View

120
 Structure, Function & Maintenance Standard

Section B - B

Technical Specification
� Primary side pressure: maximal pressure 6.9 MPa
(70 kgf/cm2)
� Secondary side pressure: maximal control
pressure 0~4.4 MPa (0~44.8 kgf/cm2)
� Rated flow: 10 L/min
� Operating angle: ±12.4°

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 Structure, Function & Maintenance Standard

Operating Principle

① Pilot Valve ② Pilot Pump ③ Main Pump ④ Main Valve

⑤ Hydraulic Motor ⑥ Hydraulic Cylinder ⑦ Shuttle Valve

Hydraulic Circuit Diagram

� Pressure Relief Valve
� Neutral state

Sliding valve (301) is prop up to upper position
(position shown in assembling section) under
action of spring (335), spring seat (311), and
washer 1 (215). Reversing output interface of
sliding valve is connected with interface T, so that
pressure of output interface 1, 2 are same as it of
interface T.
� Operating section of pilot valve in inclining from
neutral state
Push rod (214) on side of interface 1 shall be
depressed while rotating cam (420) shown in
assembling section clockwise, and sliding valve
moves downwards under action of washer 1,
spring seat, secondary pressure setting spring
(324), washer 2 (217), washer 3 (313), to connect
interface P with interface 1, so that oil output from
pilot pump flows into interface 1 and generate
pressure.
In case that rising pressure of interface 1 reaches to
elastic force of secondary pressure setting spring set
via inclining operating section, hydraulic pressure bore
on sliding valve is balanced with elastic force of spring
and make interface 1 output invariant pressure.
Sliding valve on side of interface 2 maintains neutral
state and oil output from main valve is exhausted via
interface T.
In addition, push rod of some specification may press
in sliding valve enforcedly from top side of sliding
valve while operating section approaching to maximal
angle, to connect interface P with output interface and
form similar pressure state

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 Structure, Function & Maintenance Standard

� Buffer Section of Operating Section

� Neutral state
Push rod is propped up to topside under action of
buffer spring (336, 337) and plunger (224), shown
as assembling section diameter.
� Operating section begins inclining from neutral
state {refer to buffer operating principle diameter
(1)}
Push rod on side of interface 1 shall be pressed
and plunger shall move downwards while rotate
cam clockwise.
At this time, oil in buffer plunger chamber is
discharged via orifice of plunger and provides
buffering power via pressure generated in the
process.
On the other hand, push rod on side of interface 2
moves upwards under action of buffer spring and
plunger.
At this time, oil in buffer plunger chamber flows
out from oil chamber under action of steel balls
(225) (active as steel-ball single-way valve, three
positions). And oil besides plunger chamber is
discharged from channel on upper terminal of
valve body connecting with interface T.
� Operating section inclines to opposite direction
from maximal inclining angle (refer to operating
principle (2))
Cam shall rotate anticlockwise while rotating
clockwise to maximal angle, during this process,
push rod on side of interface 2 shall be pressed
and plunger shall move downwards.
At this time, oil in buffer plunger chamber flows
out from oil chamber under action of steel balls
(225) (active as steel-ball single-way valve, three
positions). And oil besides plunger chamber is
discharged from channel on upper terminal of
valve body connecting with interface T.
Above all, the valve operate in buffering power
structure regardless running from maximal
inclining position to neutral position, or running
from neutral position of maximal inclining
position.
� Shuffle Valve
� Neutral state
Pressure of secondary pressure interface is same
as it of oil tank interface, pressure of output
interface of shuffle valve is same as it of oil tank
interface.
� Operating section of pilot valve begins inclining
from neutral state.
The interface is closed while pressure of
secondary pressure interface rising and steel ball
is pushed to secondary pressure interface of
certain side. At this time, pressure of output
interface of shuffle valve is same as it of the
secondary pressure interface selected by high
pressure, namely, the higher secondary pressure is
selected and output from output interface of
shuffle valve.

Same as content abovementioned, buffer plunger

chamber is discharged via orifice of plunger and
provides buffering power via pressure generated
in the process.

On the other hand, push rod on side of interface 1

moves upwards under action of resetting spring
(335) and plunger.

123
 Structure, Function & Maintenance Standard

Push rod

Damping hole

Plunger piston

Plunger compartment

Operating from neutral

position to direction,
oil in right (left) plunger
compartment is
exhausted via damping
hole. Pressure generated
while passing damping
hole is buffer force.

124
 Structure, Function & Maintenance Standard

Max. course

Oil on the outside of

plunger piston is
exhausted via channel
between upper end
section of valve body
and T-adapter

Oil in plunger
compartment is
exhausted via damping
hole. Pressure generated
while passing damping
hole is buffer force.

Operating control rod

from state to
opposite → state,
plunger piston on left
side shall bring into
play as buffer plunger
piston

125
 Structure, Function & Maintenance Standard

Foot Pedal Valve

Oil outlet

Oil inlet

Torque: 29.4±2.0 N·m

(300±20 kgf·cm)

126
 Structure, Function & Maintenance Standard

Torque: 29.4±2.0 N·m

Torque: 33.3±3.4 N·m (300±20 kgf·cm)
(340±35 kgf·cm)

Hydraulic Schematic Diagram

Technical Specification
� Max. Primary Pressure: 6.9 MPa (70kgf/cm2)
� Flow: 10 L/min

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 Structure, Function & Maintenance Standard

Operating Principle

� Neutral state

Oil chamber A and B of main valve and oil

controller P1 and P2 of PPC valve are connected
with discharging chamber D via micro-adjusting
hole f in valve rod (1).

� During micro adjusting process (neutral → micro

adjustment)

Spring seat (9) is pushed, valve rod (1) is pushed

by metering spring (2) and moves downwards
while circular disc (5) begins pushing plunger (4)

At this time, micro-adjusting hole f is

disconnected from discharging chamber D. With
the same breath, it connects with pressure
chamber PP of pump, and pilot pressure oil of
main pump flows to oil chamber A via controlling
hole f and oil chamber P1. Valve rod (1) is pushed
back to micro-adjusting hole f and disconnected
from pressure chamber PP of pump while oil
pressure of oil chamber P1 rising. With the same
breath, hole f connects with discharging chamber
D and discharges pressure in chamber P1. Via this
method, valve rod (1) moves upwards and
downwards to balance acting force of metering
spring (2) and pressure in chamber P1. Position
relation between valve rod (1) and valve body (10)
shall not modify until spring seat (9) pressed valve
rod (1) (hole f locates at one point between
discharging hole D and pressure chamber PP of
pump). As a result, metering spring (2) is
compressed according to moving volume of
control rod and pressure of P1 port rises according
to course of control rod. Above all, valve rod of
main valve shall move to certain position at where
pressure of chamber A (same as pressure of P1
port) is balanced with spring power of sliding
valve resetting spring of main valve.

128
 Structure, Function & Maintenance Standard

� Micro control (returning of control rod)

Acting force of center spring (3) and pressure of

chamber P1 push valve rod (1) upwards during
returning process of circular disc (5).

In this way, micro-adjusting hole f connects with

discharging chamber D and discharge pressure oil
in chamber P1. Metering spring (2) pushes valve
rod (1) upwards and disconnects hole f from
discharging chamber D. With the same breath, it
connects with pressure chamber PP of pump and
supplies pressure oil to chamber P1 until pressure
resumed to pressure corresponding to position of
control rod.

Oil in discharging chamber D flows in via control

hole f of valve of inoperative side and fully charge
chamber B via chamber P2.

� Full course

Circular disc (5) pushes piston (4) downwards and

spring seat (9) pushes valve rod (1) downwards.
Hole f disconnects from discharging chamber D
and connects to pressure chamber PP of pump. As
a result, pilot pressure oil of main pump flows to
chamber A via micro-adjusting hole f and oil
chamber P1 and pushes sliding rod of main valve.
Oil in chamber B discharges from P2 to chamber
D via micro-adjusting hole f.

129
 Structure, Function & Maintenance Standard

Pilot Valve Block

Plug Screw

Travel Speed Valve

Instant Forcing Valve

Hydraulic Safety Valve

Pilot Bypass Valve

Breaker Valve (used for low-
temperature model)

Technical Specification
� Pre-charging Pressure of Accumulator: 15bar
� Range of Operating Voltage: DC24v±15%
� Filtration Precision: 10u
� Permissible Operating Temperature: -20～120℃

130
 Structure, Function & Maintenance Standard

Accumulator

1. Air Plug
2. Shell Body
3. Hoisting Valve
4. Seat
5. Peltry
6. Oil Outlet

131
 Structure, Function & Maintenance Standard

Hydraulic Cylinder
� Boom Cylinder (L.H.)

Torque: 353～372N·m
(36～38kgf·m)

Torque: 54.0～58.9N·m
(5.5～6.0kgf·m)

1. Pin Bush 10. Rod Components

2. Pin 11. Cylinder Components
3. Pipe Components 12. Piston
4. Dust-Guard Ring 13. Dust Ring
5. U-WASHER 14. Wear Ring
6. Shock-Absorbing Seal Ring 15. Piston Seal
7. Bush 16. Piston Nut
8. Retainer Ring 17. Adjusting Screw
9. Front End Cover 18. Oil Nozzle

132
 Structure, Function & Maintenance Standard

� Boom Cylinder (R.H.)

Torque: 353～372N·m
(36～38kgf·m)

Torque: 54.0～58.9N·m
(5.5～6.0kgf·m)

1. Pin Bush 10. Rod Components

2. Pin 11. Cylinder Components
3. Pipe Components 12. Piston
4. Dust-Guard Ring 13. Dust Ring
5. U-WASHER 14. Wear Ring
6. Shock-Absorbing Seal Ring 15. Piston Seal
7. Bush 16. Piston Nut
8. Retainer Ring 17. Adjusting Screw
9. Front End Cover 18. Oil Nozzle

133
 Structure, Function & Maintenance Standard

� Arm Cylinder

Torque: 72.5～84.3N·m
Torque: 54.0～58.9N·m
(7.4～8.6kgf·m)
(5.5～6.0kgf·m)

1. Pin Bush 13. Retainer Ring

2. Pin 14. Cover
3. Spring Washer 15. Rod Components
4. Hexagon Bolt 16. Cylinder Components
5. O-Ring 17. Dust Ring
6. Pipe Components 18. Wear Ring
7. Oil Nozzle 19. Piston Seal
8. Retainer Ring 20. Locating Ring
9. Dust-Guard Ring 21. Plug
10. U-WASHER 22. Bracket
11. Shock-Absorbing Ring 23. Spring
12. Bush 24. Check Valve

134
 Structure, Function & Maintenance Standard

� Bucket Cylinder

Torque: 981±98N·m
(100±10kgf·m)

Torque: 54.0～58.9N·m
(5.5～6.0kgf·m)

1. Pin 12. Bush

2. Pin Bush 13. Retainer Ring
3. Hexagonr Bolt 14. Front End Cover
4. Spring Washer 15. Rod Components
5. O-Ring 16. Cylinder Components
6. Pipe Components 17. Piston
7. Flange Of Oil Port 18. Dust Ring
8. Retainer Ring 19. Wear Ring
9. Dust-Guard Ring 20. Piston Seal
10. U-WASHER 21. Oil Nozzle
11. Shock-Absorbing Ring

135
 Structure, Function & Maintenance Standard

Technical Specification

Cylinder
Boom (L.H.) Boom (R.H.) Arm Bucket
Item

Internal diameter Ф120 Ф120 Ф140 Ф120

External diameter Ф140 Ф140 Ф165 Ф140
Piston rod diameter Ф85 Ф85 Ф100 Ф85
Course 1260 1260 1430 1030
Max. course 3020 3020 3420 2640
Min. course 1760 1760 1990 1610

136
 Structure, Function & Maintenance Standard

Work Equipment

C B

F
A
E

137
 Structure, Function & Maintenance Standard

Unit: mm
S.N. Item Standard Measure

Standard Tolerance
Clearance among Standard
Dimension Shaft Hole
1 connecting pin and bush
of swing frame & boom -0.125 +0.255
90 0.345-0.430
-0.175 +0.220
Clearance among bush and
-0.125 +0.035
2 connecting pin of boom & 90 0.125-0.210
-0.175 +0
arm
Clearance among
-0.110
3 connecting pin & bush of 70 +0.230 +0.200 0.310-0.420
-0.190
arm & link
Clearance among Replace
-0.100 +0.046
4 connecting pin and bush 80 0.100-0.220
-0.174 +0
of arm & bucket
Clearance among
-0.100 +0.046
5 connecting pin and bush 80 0.100-0.220
-0.174 +0
of link & bucket
Clearance among
-0.110
6 connecting pin and bush 80 +0.245 +0.210 0.320-0.435
-0.190
of links

138
 Structure, Function & Maintenance Standard

Dimension of Arm

139
 Structure, Function & Maintenance Standard

Unit: mm
Model

CDM6215/CDM6225

S.N.
+0.046 −0.125
1 Φ80 0 −0.175

+1
2 Φ121 + 0.5
+0.255
3 Φ90 + 0.220
+0.245 −0.125
4 Φ80 + 0.210 −0.175

+0.230 −0.110
5 Φ70 + 0.200 −0.190

+0.245 −0.110
6 Φ80 + 0.210 −0.190

+0.245
7 Φ80 + 0.210

8 385.9

9 270.6

10 759.7

11 2920

12 446.7

13 2499

14 1590.3

140
 Structure, Function & Maintenance Standard

Dimension of Bucket

A-A

141
 Structure, Function & Maintenance Standard

Unit: mm

Model
CDM6215/CDM6225
S.N.

1 478.6

2 486±0.2

3 1452

4 159.5

5 80.8
+1
6 312 + 0.5
+0.046 −0.1
7 Φ80 + 0 −0.174

+0.5
8 322 + 0
+0.046 −0.1
9 Φ80 + 0 −0.174

10 45º

11 80º

12 R56.5

13 R56.5

142
 Structure, Function & Maintenance Standard

Air Condition System

Circuit Diagram of Air Condition

Right front panel of cab

1. Insolation Sensor
2. Control Panel
3. Air Condition Unit Components

143
 Structure, Function & Maintenance Standard

External air sensor

4. Air Condition Harness

144
 Structure, Function & Maintenance Standard

5. Hot Water Pipe of Air Condition 11. V Belt

6. Water Valve 12. Compressor Assembly
7. Liquid Hose (with pressure switch) 13. Air Suction Hose
8. Liquid Storage Assembly 14. Exhaust Hose
9. Liquid Hose 15. Adjustable Fitting
10. Condenser Assembly

145
 Structure, Function & Maintenance Standard

Application of Air Condition

Control Panel of Air Condition

Function Description of Key

Key Name Description

The key is used for switching between On/Off modes.

On/Off button Background light of control panel is turned on and control panel is operable
after turn On the switch.

Control panel sends manual control command of air condition system to

controller and keeps running compressor.

Air condition Note: it is needless to press the button during application of air condition
switch system.

It is possible to achieve cooling requirement via simple temperature setting

under automatic temperature control mode.

Depress (press lower key) or raise (press upper key) displayed value of
Temperature presetting temperature while pressing temperature selection switch.
selection Displayed value shall depress or raise one analog quantity after pressed it for
one times.

Air output
Display analog quantity of air volume
selection

Air intake
selection Corresponding symbol of control panel shall light and open air valve of
circular air inlet while pressing the switch.
(circular air)

Air intake
selection Corresponding symbol of control panel shall light and open air valve of fresh
air inlet while pressing the switch.
(fresh air)

146
 Structure, Function & Maintenance Standard

Precautions

1) Please use air condition system after started 4) It is possible to display fault orderly by pressing
engine, and turn off power switch after stopped “<” “>” of temperature setting switch if more
engine. than one fault are detected.
2) Please run air condition for five minutes once in 5) Press internal/external cycle key synchronously
one week if disuse air conditioner in spring, after fault diagnosis to eliminate fault code.
autumn or winter, to prevent moving element of
6) Press OFF to resume normal display.
system form rust caused in nonuse of long period.
3) Please exhaust water in water tank or fill
antifreeze solution if ambient temperature is
lower than 0℃ during nonuse of long period to
prevent copper pipe of heater from frost crack,
because heating system is connected with water
tank.

Fault Diagnosis

1) Temperature setting and air volume of LCD crush

out and operation is stopped after pressed OFF
switch.
2) LCD displays self-diagnosis mode after pressed
“<” “>” of temperature setting switch
synchronously for three seconds,
3) Monitoring display and fault mode:

Displayed
Fault Mode
Content

E-- No fault

E11 Open circuit of air sensor

E12 Short circuit of air sensor

E18 Short circuit of solar sensor

Open circuit of water temperature

E15
sensor

Short circuit of water temperature

E16
sensor

E43 Abnormity of air valve of ventilator

E44 Abnormity of air mixing valve

147
 Structure, Function & Maintenance Standard

Operating Method of Air Condition

● Automatic Operation

1) Lights above temperature, air volume, automatic

switch, air condition switch shall light after set
automatic mode setting switch ⑤ as ON.

2) Adjust temperature switch to set comfortable

temperature. Air condition shall operate and
switch air volume, air outlet and internal/external
air automatically according to setting temperature
automatically.

Note Air outlet shall be in state of or

and limit air volume according to water
temperature of engine automatically.

Temperature Automatic mode setting

switch ⑤
setting switch ③

Air volume Setting temperature

display display

● Stop of Automatic Operation

Lights above temperature, air volume, automatic

switch, air condition switch shall crush out and
operation stop after pressed OFF switch as ①.

OFF switch ①

148
 Structure, Function & Maintenance Standard

● Manual Control Operation

1. Press fan adjusting switch ② to adjust air volume.

Confirm setting temperature and air volume via
LCD.

2. It is possible to judge if air condition switch ⑧ is

opened via light above switch.

3. Set proper temperature via adjusting temperature

setting switch ③.

4. Set required air outlet via adjusting outlet mode

switch ④.

5. Select required internal/external air mode via

selecting internal/external air switching button ⑥.

Outlet mode setting switch ④

Fan speed setting
Temperature setting switch ③
switch ②

Internal/external air mode Air condition

switch ⑥ switch ⑧

● Stop of Manual Operation

Press OFF switch ①

Light above temperature setting, air volume and air

condition switch of LCD crush out and operation stops.

OFF switch
①

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 Structure, Function & Maintenance Standard

� Bylevel Mode Operation

1. Press fan switch ② and adjust air volume.

Confirm setting temperature and air volume via
LCD.

2. Press outlet mode setting switch ④ and select

outlet mode.

3. Turn ON air condition switch ⑧ and confirm it

via light above switch.

4. Adjust fan speed setting switch ②, temperature

setting switch ③, internal/external air mode
switch ⑥ to proper position.

Bylevel mode denotes output cold wind at head

position and output hot wind at foot position.

Fan speed setting Outlet mode setting switch ④

switch ② Temperature setting switch ③

Internal/external air mode Air condition

switch ⑥ switch ⑧

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 Structure, Function & Maintenance Standard

� Defrosting Operation

1. Press fan switch ② and adjust air volume.

Confirm setting temperature and air volume via
LCD.

2. Adjust outlet mode switch ④ to make it switch

from to .

3. Select external air introduction state via

internal/external air switch ⑥.

4. Adjust temperature adjusting switch ③ and set

temperature as 32 degree (maximal greenhouse
volume)

Adjust shutter position of outlet to blow wind

onto glass.

Note It is possible to dehumidify after opened air

condition switch ⑧ in rainy season.

Outlet mode setting switch ④

Fan speed setting
Temperature setting switch ③
switch ②

Internal/external air mode Air condition

switch ⑥ switch ⑧

151
 Structure, Function & Maintenance Standard

Radio Use
Radio Control Panel

① Power control button

② Band selection button

③ Automatically search store/prestore station

audition button

④ Station preset button

⑤ LCD
⑥ Manual selection button
AS FM
• Frequency increases key ∧ PS AM

• Frequency decreases key ∧

CLK
⑦ Clock button
⑧ Volume control button
• Volume increases key ∧

• Volume decreases key ∧

Operation Method of Radio

� Power On / Off If the manual tuning ∧/∨ buttons are pressed

Press the "POWER" button to turn on the power
and then press it again to turn off the machine.
� Volume Control
Press the "∧" button, to gradually increase the
volume; press the "∨" button to gradually
decrease the volume.
� Band selection button
Press the FM / AM button to convert the radio
band, thus the brand will be cycled between the
FM1/FM2/FM3/AM1/AM2/FM1.
� Manual Tuning
Short-press the Manual Tuning ∧/∨ buttons and
then manually up/down to search the station
based on the step frequency.
� Automatic Tuning
over 0.5s, the searching station up/down will be
down automatically based on step frequency until
finding the required station. And then this station
is kept for audition.
� Store Stations
After man ually/automatically searching the
station, if any of station preset buttons of
M1~M6 is pressed over 2s, the currently playing
frequency will be stored at the appropriate
position. Each band can store 6 stations, thus
total of 30 stations can be stored.
� Auto Search Stored Station
If the AS / PS button is pressed over 1s, the
station will be searched from current frequency
upwards. The searched station will be
automatically stored at the preset position.

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 Structure, Function & Maintenance Standard

� Prestored Station Audition

If the AS / PS button is pressed less than 1s, all

prestored station will be played 5 s in turn. If this
button is pressed again during the playing process
of prestored station, the playing will be stopped
to return to the current station.

� Station Section

Short-press any of preset buttons M1~M6 less

than 2s, the corresponding prestored station will
be directly played.

� Clock Operation

Press the CLK key to enter the clock display

model and then press it again to return.

In the clock display model, long-pressing the

CLK key exceeds 1s until the clock display
flashes, the clock adjustment model will be
entered. Short-pressing the manual tuning ∧ key
once will add one hour and long-pressing it will
be continuously increased. Short-pressing the
manual tuning ∨ key once will add one minute
and long-pressing it will be continuously
increased.

The clock adjustment model will exit after 5s

without operation.

153
 Structure, Function & Maintenance Standard

Engine Control

Throttle Control Lever

1. Start Switch
2. Throttle Dial
3. Bettery

154
 Structure, Function & Maintenance Standard

Water temperature To preheating To generator

sensor device

To cut-off spool

To starter

To pump

To electric cabinet
harness
Flexible shaft
of throttle

4. Injection Pump
5. Throttle Executer

155
 Structure, Function & Maintenance Standard

To pump To
spe
ed
sen
sor
To Px, Py

to
e
cab lectr
ine ic
th
arn
ess
Generator

6. Starter

� Summary:

� It is possible to start and stop engine simply by

using start switch (1).

� Engine throttle control lever receives signal of

throttle dial (2) and send the signal to throttle
motor to control angle of throttle lever of ejection
pump (4) and speed of engine.

156
 Structure, Function & Maintenance Standard

� Start engine

� After turned on starting switch, starting switch (Power)

Throttle dial Engine
sends starting signal to starting motor, starting High
(Start motor) Start switch
High Low
motor rotates and starts engine. Low Governor
(Start signal)
Motor

At the same time, throttle motor inspect signal

output from fuel control panel and adjust rotate

Engine stop solenoid

Engine stop solenoid

(Driving signal)
Potentiometer
valve (pull out)
speed of engine to the speed set by throttle knob.

valve (hold)
� Engine shall not start if stop solenoid valve
(dump valve) of engine is not activated. (At the
Throttle control lever
same time, controller output starting signal of Throttle signal
t (ON signal from start switch)

starting motor and driving signal for three

seconds.)

Throttle
油门旋钮 dial
● Speed control of engine High
Engine
(Start motor)
Start switch
High Low

� Throttle knob transmits signal to throttle motor Low Governor

Motor
according to position of pointer. Throttle motor
calculate angle of speed adjustor motor according
Engine stop solenoid

Engine stop solenoid

(Driving signal)
to the signal, transmit signal to speed adjustor
Potentiometer
valve (pull out)

valve (hold)

motor and drive it to the angle.

In the process, potentiometer measures operating

angle of adjustor motor and feedback to throttle Throttle signal
油门拉杆
Throttle control lever

motor, to make it obey operation of adjustor t (ON signal from start switch)

motor.

Throttle dial Engine

油门旋钮 Start switch
● Stop engine Low (Start motor)
High Stop

Governor
� Throttle motor shall drive speed adjustor motor to Motor

make it adjust to low idling angle position after

detected that starting motor rotated to stopping
Engine stop solenoid

Engine stop solenoid

(Driving signal)
Potentiometer
valve (pull out)

position.
valve (hold)

Engine shall stop running if signal of engine stop

solenoid valve (holding) driven by control center
油门拉杆
signal directly turns OFF Throttle signal
Throttle control lever

t (ON signal from start switch)

� For maintaining power supply of system to

complete stop of engine, throttle motor shall drive
accumulator relay.

157
 Structure, Function & Maintenance Standard

otorr
Throttle Moto

Bracket

Spring

Connecting terminal

Connector

Wire sealing
Lead pipe

158
 Structure, Function & Maintenance Standard

Potentiometer

Bearing

Gear Components

Motor

159
 Structure, Function & Maintenance Standard

Plug A

Technical Specification
� Rated Voltage: DC28v
� Max. Course: 57 mm
� Allowable Load: 123 N

160
 Structure, Function & Maintenance Standard

MCSS Electric Control System

Installation of Flexible Throttle Shaft, Engine Gear
and Engine Start

Installation of AC2 Flexible Throttle Shaft

� It is possible to connect AC2 flexible throttle shaft

onto rocking beam of throttle only after installed
electric control system and electrified machine,

� Uncased length of AC2 flexible throttle shaft is

quite smaller and can not connect to rocking
beam of throttle before electrifying machine.

� After electrified machine, AC2 flexible throttle

shaft shall spread to initial position automatically
under control of main controller. Connect AC2
flexible throttle shaft to hole C of rocking beam Engine speed Min. Engine speed
of throttle, shown as following figure, and mark Gear
without load (rpm) with load (rpm)
position of hole C with a white line.
1 1000
� Engine shall calibrate rotate speed automatically
without manual intervention, refer to description 2 1140
in following text. 3 1260

4 1380
Engine Gear and Engine Speed 5 1500
� Engine is set with ten gears of 1-10. middle left 6 1620 1506
position of display shall display corresponding
7 1740 1618
gear while adjusting rotate speed knob. Display
shall indicate “Rotate speed knob exceeds range 8 1860 1730
value” if position of rotate speed knob exceeds
9 1980 1841
range of 1-10 gears. Rotate speed value of each
gear is shown as right sheet. 10 2120 1971

� Hereinto, gear 6-10 belong to operating gear, and

gear 1-5 is inoperative gear used for special
condition such as adjustment of assembling
position etc.

Engine Start

� Please switch hydraulic safety control rod to

“Lock” while starting engine.

161
 Structure, Function & Maintenance Standard

Element Installation

Installation of Hydraulic Pressure Sensor Hydraulic Filter Alarm Switch

� Direction of twin pump: the one closing to engine
is left pump (or front pump), the one apart from
engine is right pump (or rear pump), twin pump is
provide with five sensors:
Pressure sensor 400bar of left pump: assembled at
a1 port on side of hydraulic oil tank of left pump
Pressure sensor 400bar of right pump: assembled
at a2 port on side of hydraulic oil tank of right
pump
Servo pressure sensor 60bar: assembled at a4 port
besides servo valve.
� Alarm switch is connected with normally opening
contact and close during alarm period.
� Pilot filter alarm switch: model: VD5C.0, locates
on pilot valve, belongs to build-in device of pilot
valve block.
� Pump and motor oil filter alarm switch: model
VMF2F.0, assembled external oil filter besides
pump.
� Main oil filter alarm switch: model VR2C.0,
assembled on hydraulic oil tank.

Left negative flow feedback pressure sensor 60bar: Air Filter Alarm
assembled at Pi1 port of left pump adjustor.
� Normally opening switch, closed during alarm
Right negative flow feedback pressure sensor period. Equipped for air filter.
60bar: assembled at Pi2 port of right pump
adjustor. Oil Level Sensor
� Draw out stopper pin of case shell during
Hydraulic Demand Switch assembling process.

� These two pressure switch are assembled at Py

and Px port of main valve respectively. Px port Temperature Sensor
locates on top face of main valve and Py port � Fastening torque 24±4Nm.
locates on rear side face of main valve-closing to
engine. Py controls traveling and Px controls
slewing and assembling.

� Hydraulic output switch is a normally opening

switch, which shall close if hydraulic action
occurs.

Installation of Engine Speed Sensor

� Screw rotate speed sensor to bottom and roll back

it for 3/4 cycle about (slightly smaller than 3/4),
and then fasten it by using fastening nut with
torque of 36±5Nm

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 Structure, Function & Maintenance Standard

Connecting Requirement for Sensor and Alarm Switch

� Connection of hydraulic pressure sensor--4pin

type, pin 1 is power line, pin 2 is signal line, pin 3
is reserved, and pin 4 is grounding line.

� Connection of hydraulic pressure sensor--3pin

type, pin 1 is power line, pin 2 is signal line, pin 3
is reserved.

� Connection of hydraulic filter alarm switch--4pin

type, pin 1 is signal line, pin 3 is grounding line,
pin 2 and pin 4 are reserved.

� Adjust direction of junction seat in junction box

so that junction interface of junction box is
downcast or horizontal. For preventing from
water leakage, no rubber ring at junction interface
shall be missed.

� Do not rinse directly to junction interface.

Connection of Fuel Solenoid Valve and Coil Protector

� Fuel solenoid valve: resistance of pull coil

(PULL), holding coil (HOLD) and grounding line
(COM), PULL-COM are 1.2 OHM about, and
resistance of HOLD- COM is 52 OHM about.

� Lead wire of coil protector: white wire is PULL

wire (PULL), red wire is holding wire (HOLD),
black wire is grounding line (COM). Coil
protector controls electrifying time of pull coil of
fuel solenoid valve as 0.7-1.7s/times

Electric Control Wiper

� Provided with reset climbing function. Motor

operate in anticlockwise while running from
stopping position downwards.

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 Structure, Function & Maintenance Standard

System Fault Diagnosis

CAN Communication Fault

System shall display alarm information if circuit

between display and main controller is disconnected or
main controller fails of electrification after electrified.

Except system time, all parameters displayed on

display screen are N/A.

Throttle Gear Fault

� Fault:

Display parts of gears of 1-10 while not display

gear 1 and gear 10.

� Reason:

Wire connecting with throttle knob is open circuit

or NG contact, or throttle knob is loosened or
depart from original position.

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 Structure, Function & Maintenance Standard

Monitor

Display Interface

Shown as the right figure.

The left of upper part is fuel gauge, the right is water

thermometer.

The lower part is as follows:

The position at the top left corner where 1 is displayed

is the gear 1 - 10 of engine speed gear;

00059 is displayed in the middle of upper part,

indicating total time of engine running;

The tortoise icon at the top right corner indicates low-

speed running of current machine;

1210 is displayed in the right middle, indicating

current engine speed;

The current time is displayed at the bottom left corner.

When the safety mechanism is locked, "Locked" icon

below the travel status.

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 Structure, Function & Maintenance Standard

Key Function

As the right figure, the upper part is menu operation

key, and the lower part is the function operation key.

Instruction of menu operation key:

The key can be pressed to access the Settings

interface directly, reset the Contrast, Backlight,
Buzzer Volume, Key Clicks, Change Language,
Set Clock, Factory Setup, Restore Factory
Defaults, and view the vehicle information,
display, software & hardware version number
of controller in About menu.

Return.

Confirm.

The key can be pressed to access main menu as

the right Figure.

The options of Machine Status, Settings,

Maintenance Help, Maintenance Records and
Alarm History can be selected via the Up and
Down key, after it's selected, press key
to view detailed information.

Up.

Down.

Left.

Right.

Enter.

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 Structure, Function & Maintenance Standard

Instruction of Function Key

Alarm cancel key. Working mode selector switch.

High-and-low speed switch key, if current
condition is low-speed status, the screen will
display tortoise icon, meanwhile, press this
key and the right green lamp of tortoise will be
on; when this key is pressed, the green lamp
beside the rabbit icon at the left of this key will
on, and the screen will display rabbit icon
simultaneously, and high-speed status has
been switched.
This switch is used to set the operation and
operating force of working equipment. The
operation will be easier through selecting the
mode matching the operation type.
Please select the working mode via the keys on
the display panel in accordance with the
working condition and self-demand:
H mode: heavy-load mode

Windscreen wiper switch key. S mode: economic mode

Windscreen wiper switch/change-over key. L mode: light-load mode

Press the key once, the wiper will work under B mode: break mode
low-speed, and the green lamp at the left of
The fine regulation of above mode can be
key will be on simultaneously; press the key
performed via the throttle knob .
twice, the wiper will work under high-speed,
and the green lamp at the right of key will be
on; press the key three times, the wiper will
work continually, and the green lamps at both
sides of key will be on; press the key four
times, the wiper will stop work, and the green
lamps at both sides of key will be off
simultaneously.

Auto idle speed/manual idle speed mode

switch key, when lamp is on, it'll be auto idle
speed mode.

Manual idle speed enabled/disabled key,

when lamp is on, it'll be enabled mode, and
it'll be effective under manual idle speed
mode.

Working lamp switch change-over key. Press

the key once, the working lamp of platform
will be on, and the left green lamp will be on
simultaneously; press the key twice, the
working lamps of platform and boom will be
on simultaneously and the green lamps at both
sides will be on; press the key three times, the
working lamps of platform and boom will be
off simultaneously, and the green lamps at
both sides will be off.
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 Structure, Function & Maintenance Standard

Instruction of Change Language

Press key to to access the Settings interface

directly (as the right figure). The option of Change
Language(语言选择 ) can be selected via the Up and
Down key.

Press key to enter.

Settings interface in Chinese

The English Settings interface is as the right figure.

Press the key to Change the language to Chinese.

Settings interface in English

168
 Structure, Function & Maintenance Standard

System Parameter Inquiry

� After the Machine Status is selected in the main

menu, parameter inquiry can be started as the
right Figure.

169
 Structure, Function & Maintenance Standard

Maintenance Help

Select Maintenance Help in the main menu, the details

are as Figure below.

Input of Maintenance Records

Select Maintenance Records in the main menu, the

details are as Figure below.

Alarm Display and Alarm Record

� As shown in right figure, this window can be

entered after the alarm record is selected through

170
 Structure, Function & Maintenance Standard

main menu; and the real-time alarm record and

historical alarm record can be changed over
through pressing the confirm button.

� Alarm at three levels:

For third mode, the subtitles and a warning icon

are red, requiring that the machine should be shut
off for maintenance. The buzzer will open for
these alarms.

For second mode, the subtitles and a warning icon

are yellow, denoting that the working mode of
machine will need to be changed or the machine
needs the necessary maintenance.

For first mode, the subtitles and a warning icon

are orange, only reminding the staff to carry out
the necessary maintenance for machine.

� The code for each item is constituted from left to

right is: machine running hours, alarm date and
alarm time.

� Alarm will be displayed in chronological order,

with most recent alarm at the top. At least 50,000
alarm can be stored. If exceed this value
(depending on store content), the first on will be
deleted.

� Alarm display on the alarm area of main default

window: if there are multiple alarms, the most
emergency alarm will first be displayed. The
alarm information will automatically disappear
after the elimination of fault.

Throttle calibration

(This function is only be available for commissioning,

171
 Structure, Function & Maintenance Standard

maintenance and service personnel)

� After the machine state is selected through main

menu, the throttle actuator calibration can be
carried out after selection.

� This function can be used when the throttle

calibration is prompted on display.

� When carrying out the throttle calibration, display

the calibration prompt label. The system can
automatically calibrate the speeds of all gears of
engine, without manual operation. The calibration
prompt label can disappear after calibration.

172
 Structure, Function & Maintenance Standard

System Function, Parameters, Alarm and

Protection

Water Temperature Gauge

Low Oil Pressure Protection
� Blue area is for below -20℃; green area is for -
(When speed> 600rpm pm, the pressure is less than
20~ 102℃; yellow area for 102℃~105℃ and red
69kPa)
area for >105℃.
� When the oil pressure is lower than the standard
value, the oil pressure switch is turned off and the
Water Overheat Protection graphic alarm is given. The engine will be
reduced to low idle within 3 seconds. The user
� The overheat protection function will be activated
needs to stop the machine at appropriate time, to
if the water temperature exceeds 102℃. The
protect the engine.
engine can not be shut down but decelerated. The
special process is shown in right Figure:
Hydraulic oil temperature
Protection way as follows:
� The normal temperature is -20 ~ +85℃
Keep the original engine speed, and reduce the
hydraulic power in three steps. � High temperature is +85 ~ +90℃

The first two steps will continue to 3min. if the water � Over-high temperature is for> +90℃
temperature is reduced below 100 ~102℃, the
machine will be back to normal state.
Fuel oil

� If the fuel oil is too low, the system will give an

alarm.
In protection state, the machine's movement speed will
be reduced. Pay attention to safety.

Third step: If the water temperature rises above 105℃,

the engine will run at low idle speed. The user needs to
stop the machine at appropriate time, to protect the
machine for finding out the reason.

Auto / Manual idle function

� Auto-idle: If no hydraulic power demand with 3

seconds, the engine speed will be reduced to
100r/min or to 1300r/min within 5 seconds.

� Manual Idle: The speed will be reduced to

1300r/min.

173
 Structure, Function & Maintenance Standard

Sensor
� Oil Level Sensor

Bracket

Connector

Float Float
A Flange magnet

Section A-A

Technical Specification
Oil Level Sensor
� Draw out stopper pin of case shell during
assembling process.
� Voltage Range: 6-24V
� Operating Temperature: -25℃～+70℃

174
 Structure, Function & Maintenance Standard

� Speed Sensor

Connector
Nut

Technical Specification

Speed Sensor

� Electric Connection: Flat Connection

� Operating Temperature: -25℃～+140℃
� Storage Temperature: -40℃～+140℃
� Fastening Torque 36±5Nm

175
 Structure, Function & Maintenance Standard

Memo:

176
 Test & Adjustment

Chapter Ⅴ
Test & Adjustment

177
 Test & Adjustment

178
 Test & Adjustment

CONTENTS

Chapter Ⅴ Test & Adjustment 1777

djustment....................................................................................................17
Standard Value Sheet for Engine Parts............................................................................................................. 182

Standard Value Sheet for Chassis Parts............................................................................................................ 183

Inspection of Engine Oil Level.........................................................................................................................189

Measure of Engine Speed................................................................................................................................. 190

Test for Air Boost Pressure............................................................................................................................... 192

Measure of Smoke Color.................................................................................................................................. 193

Measure of Compressing Pressure................................................................................................................... 194

Measure of Leakage Pressure........................................................................................................................... 195

Detect Engine Oil Pressure...............................................................................................................................196

Adjust Engine Speed Sensor.............................................................................................................................197

Test and Adjust Tension of AC Generator Belt.................................................................................................198

Prevent Unexpected Accident of Engine Control System................................................................................199

Inspection and Adjustment of Track Tightness................................................................................................ 200

Inspect Clearance of Swing Circle................................................................................................................... 202

Measure of Sprocket Abrasion......................................................................................................................... 203

Measure Hydraulic Oil Pressure for Work Equipment, Swing System and Travel Hydraulic Loop...............204

Measure Output Pressure of Pilot Main Valve................................................................................................. 206

Adjustment of Work Equipment and Swing Pilot Valve.................................................................................. 207

Inspect Hydraulic Drift Position of Work Equipment...................................................................................... 208

Release Surplus Pressure in Hydraulic Loop................................................................................................... 210

Measure of Oil Leakage....................................................................................................................................211

Exhaust..............................................................................................................................................................214

Memo:...............................................................................................................................................................216

179
 Test & Adjustment

180
 Test & Adjustment

� Please mind following items while judging

according to standard value sheet of test,
adjustment, or fault diagnosis.

1. Standard value of new machine described in the

Sheet belongs to value of new machine delivered
from manufacturer, which is used as reference for
judging abrasion of machine, or reference value
for repairing.

2. Reference value for fault judgment described in

the Sheet belong to estimated value based on
various test result relating to delivered machine,
which is used as reference for judging fault
together with repairing condition and application
condition.

3. These standard parameter shall not be sued as

standard for treating counterclaim.

� Please park machine onto horizontal ground,

insert safety pin and prevent machine from
moving by using packing block during testing,
adjusting or fault diagnosis process.

� Please use promissory signal and avoid access of

extraneous personnel while operating jointly.

� Please cool water before inspecting water level of

radiator, to prevent from scald.

� Notice don’t caught by mind fan, fan belt or other

rotary elements.

181
 Test & Adjustment

Standard Value Sheet for Engine Parts

Model CDM6215/CDM6225

Engine 6C8.3

Item Measured Operating Condition Unite Standard Value

High idling speed 2100±50

Engine Speed rpm
Low idling speed 1000±50

(Coolant temperature: in operating range) 0.345

High idling speed

Engine Oil
Pressure MPa
SAE15W-40
Low idling speed 0.069

Engine Oil Full-speed range

℃ 110
Temperature (In oil case)

Tightness of Belt Flexibility while pressing with finger force

mm 10
(Air Compressor) of 98N{10kg (221b)}

182
 Test & Adjustment

Partss
Standard Value Sheet for Chassis Part

Model CDM6215/CDM6225

Sort Item Measured Operating Condition Unit Standard Value

� Water temperature of engine: in

operating range

� Hydraulic oil temperature: in operating

2 Pump Relief range 2030±50

� Engine runs in high idling speed

� Arm is in the condition of relief

� Water temperature of engine: in

operating range
Engine Speed

� Hydraulic oil temperature: in operating

2 Pump Relief + Touch range
rpm 2030±50
Power Intensification
� Engine rotates in high idling

� Arm overflow+ touch power

intensification switch is ON

� Engine rotates in high idling

Engine Speed In
� Automatic decelerator switch is ON
Automatic Decelerator 1350±50
Acting
� All control rods are in mid position
state

183
 Test & Adjustment

Model CDM6215/CDM6225

Sort Item Measured Operating Condition Unit Standard Value

� Hydraulic oil temperature: in operating range

� Engine runs in high idling speed

Unloading
� Operating mode: H mode 3.9±1.0
Pressure
� Output pressure of hydraulic pump while control
lever locating at neutral position

� Hydraulic oil temperature:

in operating range

Boom � Engine runs in high idling Raise 32±1.0

speed

� Operating mode: H mode

Hydraulic oil Pressure

MPa

(kg/cm2)
Arm

35±1.0

� Output pressure of hydraulic pump during

Bucket
unloading of all measured oil pipes

� Value in bracket: pressure of hydraulic oil while

single-click touch power intensification switch
Swing 25±1.0
is ON (for reference only)

Travel 35±1.0

184
 Test & Adjustment

CDM6215
Model
CDM6225

Standard
Sort Item Measured Operating Condition Unit
Value

Swing
brake � Hydraulic oil temperature: in operating range Degree 100
angle
� Engine runs in high idling speed

� Operating mode: H mode

� Overrun of swing roller disc while stopping it after rotated

for one cycle.
Swing

Swing
Hydraulic oil temperature: in operating range Second 25±2.0
time �

� Engine runs in high idling speed

� Operating mode: H mode

� After rotated for one cycle, measure time used for rotating
another five cycles

185
 Test & Adjustment

CDM6215
Model
CDM6225

Sort Item Measured Operating Condition Unit Standard Value

Low 22±2.0s

� Hydraulic oil temperature: in operating

Travel Speed range Second

� Engine runs in high idling speed

� Operating mode: H mode

High 14±2.0s
� Flat ground

� After traveled for 10m, measure time

required for traveling another 20m.

Travel

� Hydraulic oil temperature: in operating range

� Engine runs in high idling speed

� Operating mode: H mode

Travel
mm 500
Disalignment � Travel speed: low

� Hard ground

� After traveled for 10m, measure departure occurs

after traveled for another 20m (X)

186
 Test & Adjustment

CDM6215
Model
CDM6225

Sort Item Measured Operating Condition Unit Standard Value

Boom
Cylinder
(cylinder 10mm/15min
retraction
volume)

� Hydraulic oil temperature: in operating range

Hydraulic Slippage of Work Equipment

� Flat and horizontal road surface

Arm � Measure pose of work equipment is shown as

Work Equipment

cylinder above figure.

(cylinder 30mm/15min
spread � Engine stops mm
volume)
� Control lever of work equipment locates at neutral
position

� After set in initial stage, measure once in every

five minutes and judge it according to dropping
volume occurred in 15 minutes

Bucket
Cylinder
(cylinder 100mm/15min
retraction
volume)

187
 Test & Adjustment

CDM6215
Model
CDM6225

Sort Item Measured Operating Condition Unit Standard Value

� Hydraulic oil temperature: in operating

range

� Engine runs in high idling speed

� Operating mode: H mode

Multiple Operation Performance

� Travel speed: low

Departure for � Firm ground
controlling
traveling and � After ran for 10m, measure departure (X) mm 500
work equipment after ran it for another 20m
synchronously

188
 Test & Adjustment

Inspection of Engine Oil Level

Do not fill too much lubricating oil into crank case, to

avoid damaging engine.

Engine oil shall not return to crank case

completely if machine is declining, or stopping
time of engine is insufficient. At this time, user
should not inspect oil level correctly. Please
park machine on horizontal ground and stop
engine for 30 minutes above before your
inspection.

Please inspect oil level after stopped engine only.

1. Open engine cover

2. Draw out oil gauge, wipe off oil on it and reinsert

the gauge.

3. Draw out and inspect oil gauge, and keep oil

level between Mark L and Mark H.

Crank shall operate in engine oil while operating

engine if oil level is above Mark H, which shall cause
too higher engine oil temperature, reduce lubricating
performance of engine oil, depress engine power and
damage bearing.

4. Disassemble lubricating oil filler plug and fill

lubricating oil if necessary

Please replace lubricating oil if it is

degenerative or polluted seriously without
considering the maintenance period.

5. Clean lubricating oil filler plug and install it.

6. Close engine cover.

189
 Test & Adjustment

Measure of Engine Speed 4) Rotate speed after set (around rated rotated speed)
two pump overflow valves and turn ON touch-
Detecting and maintenance tools of engine:
type power intensification switch
Mark Parts Name
a. Switch fuel scale to high idling
1 Multifunctional speed indicator
A b. Switch arm to digging overflow position and
2 Connector press touch-type power intensification
switch

Do not touch any high-temperature elements while

installing or disassembling detecting equipment.

Measure engine speed under following states:

� Coolant temperature: in operating range.

� Hydraulic oil temperature: 45-55℃

1. Open engine cover upwards and take out cover

2. Install connector, connect sensor and indicator of

multifunctional speed indicator

3. Measure rotate speed of engine after set

measuring condition.

1) Low idling speed

a. Switch fuel scale to low idling.

b. Move slewing/traveling control rods of

operating device to mid position.

2) High idling speed

a. Turn OFF automatic decelerating button.

b. Switch fuel scale to high idling.

c. Operate any operating device,

slewing/traveling control rod.

Operate control rod lightly with force enough

connecting pilot control pressure switch without
starting operating device, slewing/traveling control
rod.

3) Rotate speed of pump under overflow state

a. Switch fuel scale to high idling

b. Switch arm to digging overflow position

190
 Test & Adjustment

Touch-type power intensification switch shall

loosen automatically in certain period although
keep pressing it.

5) Set rotate speed for automatic deceleration

a. Turn ON automatic deceleration switch.

b. Switch fuel scale to high idling.

c. Move operating device, slewing/traveling

control rods to mid position.

Engine shall decelerate five seconds after

moved all control rods to mid position. Please
measure the rotate speed while automatic
deceleration acting.

4. Disassemble all measuring tools after inspection

and confirm that machine returns normal state.

191
 Test & Adjustment

Test Air Boost Pressure

Measuring tool of air boost pressure:

Mark Parts Name

1 A set of pressure gauge

B
2 Connector (PT1/4)

1. Open engine cover upwards

2. Disassemble air boost pressure measuring plug

(1).

3. Assemble connector and connect the set of

pressure gauge.

4. Start engine and make coolant temperature and

hydraulic oil temperature rise to operating range.

5. Operate engine with middle speed and discharge

oil in hose.

It is possible to discharge oil via inserting half of

1
gauge into hose, closing/closing oil seal on side of
hose repeatedly.

For measuring correctly, please discharge oil

completely.

6. Measure air boost pressure under high idling state

after set following measuring condition:

� Slewing lock switch: ON (high-pressure overflow

valve)

� Operating device, slewing and traveling: arm

digging overflow.

7. Disassemble measuring tools after measure and

confirm that machine returns to normal state.

192
 Test & Adjustment

Measure of Smoke Color

Measuring tools:

Mark Parts Name Assemble filter paper firmly to prevent from air
leakage.
1 Portable color detector
C 5) Turn on power switch of tool (2).
2 Color measurer
6) Accelerate engine abruptly and press acceleration
pedal of tool (2) to exhaust air waste onto filter
� It is possible measure smoke detector (1) and paper.
record formal data with color measurer (2) while
7) Put filter paper collected smoke color onto unused
measuring on site where has no compression air
filter paper (10 pieces above) of filter paper box
or power supply.
and read the value.
� Please rise coolant temperature to operating range
before your measure.

Do not touch any high-temperature parts while

disassembling or installing detecting equipment.

1. Measure with portable color detector (1)

1) Assemble filter into tool (1)

2) Insert air port into exhaust pipe to accelerate

engine abruptly, operate portable color detector (1)
and exhaust waste air onto filter paper.

3) Take out filter paper and compare with provided

graduation.

2. Measure with color measurer (2)

1) Insert probe into outlet of exhaust pipe and fasten

it onto exhaust pipe by using clip.

2) Connect probe, accelerator switch plug and air

hose onto tool (2).

3) Connect power line to AC100V outlet.

Please inspect if power switch of tool (2) is on

position of OFF before connecting power line to
outlet.

4) Loosen nut of oil suction pump cover and

assemble filter paper.

193
 Test & Adjustment

Measure of Compressing Pressure

Measure tools:

Mark Parts Name

1 Compress meter
D
2 Pressure detector

Do not touch exhaust manifold while measuring

compressing pressure to avoid scald, or entangle
clothing into fan or fan belt.

1. Adjust valve clearance correctly.

2. Heat up machine until temperature of engine oil

reaches to 40-60℃.

3. Disassemble nozzle seat assembly (1) of

measuring cylinder.

4. Assemble adapter (3) onto installing element of

nozzle seat and connect crusher gauge (2).

5. Install multifunctional speed indicator.

6. Disconnect parking magnet coil terminal of

engine, adjust adjusting rod of injection pump to
OFF position, start motor to rotate engine and
measure compressing pressure.

Read compressing pressure value while pointer of

crusher gauge stops moving.

Install nozzle seat assembly after measured

compressing pressure.

194
 Test & Adjustment

Measure of Leakage Pressure

Measure tools:

Mark Parts Name

1 A set of leakage detector

E
2 Tools (nozzle)

1. Disassemble engine below cover.

2. Assemble tools (nozzle) onto leakage hose and

connect it with gauge of leakage detector.

3. Start engine and keep running until temperature

of coolant of engine rises to operating range.

4. Measure leakage pressure in high idling state,

under following condition:

� Operating mode: H mode

� Slewing lock switch: ON (high pressure overflow)

� Operating device, slewing and traveling: arm

back, overflow.

Read leakage pressure value if pointer stops

5. Assemble measuring tools after measure and

confirm machine returns to normal operating
condition.

195
 Test & Adjustment

Detect Engine Oil Pressure

Measure tools:

Mark Parts Name

1 A set of oil pressure gauge

F 2 Oil gauge

3 Connector

Please inspect oil pressure if oil pressure indicator,

pressure gauge or other sign indicate that engine oil
pressure is lower than normal value.

1. Disconnect oil pressure switch or lead of sensor.

2. Disassemble oil pressure switch (1).

1

3. Assemble mechanical oil pressure gauge onto

hole of oil pressure switch.

4. Start engine:

� It denotes that oil pressure switch, sensor or oil

pressure gauge is faulted if mechanical oil
pressure indicates that oil pressure is normal.
Please replace oil pressure switch, sensor or oil
pressure gauge.

� Please inspect lubricating system and find out the

problem if mechanical oil pressure gauge
indicates that pressure is lower than normal value.

5. Disassemble all measure tools after the measure

and confirm that machine returns to normal
condition.

196
 Test & Adjustment

Adjust Engine Speed Sensor

Disassemble engine speed sensor (1) before

adjustment, inspect if metal scraps, dust, or damage is
existent. Reassemble it.

1. Screw sensor (1) until contact of it contact with

top side of ring gear (2) of fly gear.

2. Screw back sensor (1) from local position in

regulated angle. 1

Angle: 1±1/6 slewing

Adjust clearance “a” between sensor contact and

topside of gear to 1.25~1.75mm.

1 2
3. Fasten sensor (1) with nut (3).

4. After adjustment, confirm engine speed displayed

by special monitoring function of monitoring
instrument is normal.

3
5. Disassemble all measure tools after the measure
and confirm that machine returns to normal
condition.

197
 Test & Adjustment

Test and Adjust Tension of AC

Generator Belt

IMPORTANT
Looseness of fan belt may cause overheat of engine,
NG charging, or premature abrasion of belt. Tightness
of it may cause damage of water pump, generator
bearing and belt.

1. Inspect once in every ten hours.

2. Close engine, press belt at middle position

Top view
between fan wheel and generator wheel to inspect
the tension. Belt shall drop for 10mm under
pressure of 98N [10kg (22lb)]. Please adjust belt Adjustable plate bolt
if necessary. Depressed volume:
about 10mm
Pressing force:
about 98N (10kg) Adjusting bolt
Inspect if engine belt suffers from abrasion or fracture,
Fan belt pulley Generato
if connecting position is damaged. Please replace belt r
of condition abovementioned occurs.
Fixed bolt

Adjust belt compactness

Please adjust belt if belt is declining, or after replaced

belt.

1. Loosen adjusting bolt of adjusting plate and

fixing bolt of generator.

2. Adjust belt tension via declining generator.

3. Fasten adjusting bolt and fixing bolt after

adjustment.

Adjust belt tension again after ran engine in idling

for five minutes.

198
 Test & Adjustment

Prevent Unexpected Accident of

Engine Control System

In case that engine control device, such as fuel scale,

speed adjustor, pump controller, motor and
potentiometer of speed adjustor are faulted and engine
is out of control, please fix rotate speed engine, and
operate in following steps, to avoid unexpected danger.

The recommended step belongs to provisional

method, please repair immediately after identified
fault. 2 1
1. Disassemble motor connector and potentiometer
connector of speed adjustor.

If fails to disassemble motor and potentiometer

connector of speed adjustor, speed adjustor motor
shall act abruptly and damage mechanism during
operation of engine.

2. Disassemble speed adjustor spring (1) on side of

speed adjustor motor.

3. Disassemble bolt, connect speed adjustor spring

(1) and fix it onto original position.

Decline control rod of speed adjustor motor to

side of fuel injection pump to stop shortening
speed adjustor spring.

Fix speed adjustor rod of fuel injection pump

closing to idling position.

4. Restart engine and drive machine to safe position.

5. Disassemble connector (2) of stop solenoid valve

of engine

Do not touch high-temperature parts or rotating parts

while stopping engine during high-speed operation of
engine.

199
 Test & Adjustment

Inspection and Adjustment of Track � Fill lubricating grease via nozzle until achieve
Tightness correct tightness.

1) Run machine backwards to balance pressure.

2) Inspect droop and adjust crawler according to

� Lubricating grease injected out under action of requirement.
pressure may cause bodily injure.

� Lubricating grease injected out from

decompression valve under action of high
pressure may penetrate human body and cause
injuries and deaths.

� Do not inspect if leakage grease leaks via viewing

decompression valve. Please inspect if crawler
loosens via viewing crawler or adjusting cylinder
of crawler.

� Please loosen decompression valve for one cycle

only.

� Please close decompression valve, consult with

Lonking Agency if crawler fails to loosen

Correct crawler adjustment may extend service life of

crawler and driving element.

Please adjust tightness of crawler according

to current operating condition.

Please loosen crawler to the full under

condition of higher soil viscosity.

1. Measure tightness of crawler

1) Put on ruler onto crawler, of which length

shall be enough for measuring length
between tension roller and carrier roller.

2) Measure maximal droop of crawler via

measuring distance between bottom of ruler
and highest seizing point of crawler. Adjust
droop of crawler to 25~55mm.

2. Tight crawler

� Please clean nozzle before filling lubricating

grease.

� Crawler adjustor locates on track roller bracket.

200
 Test & Adjustment

3. Loosen crawler

Crawler adjustor locates on tension roller bracket.

1) Loosen decompression valve carefully until

crawler loosened. It is possible to loosen it for one
cycle in maximal.

2) Fasten decompression valve with torque of

34N·M after achieved required tightness. Valve Grease Outlet

3) Run machine forwardly and backwards to balance

pressure.

4) Inspect droop and adjust crawler according to

requirement.

Please consult with Lonking agency if fails to adjust

correctly.

4. Traveling device inspection

1) Inspect if carrier roller, track roller and tension

roller suffer from leakage.

2) Inspect surface of crawler, carrier roller, track

roller and tension roller, crawler board and drive
sprocket are abrasive, or if fixing bolts are
loosened.

3) Drive machine on widen ground slowly and ear if

abnormal noise is existent.

4) Please consult with Lonking agency after found

out abnormal abrasion, noise or leakage.

201
 Test & Adjustment

Inspect Clearance of Swing Circle

Measure tools:

Mark Parts Name Rotating platform Rotating platform

G Micrometer gauge
Outer circle Outer circle

Inspecting step for clearance of swing bearing installed

on machine
Inner circle Inner circle

1. Assemble one magnet-type micrometer gauge

onto outer circle (or inner circle) of swing bearing Track frame Track frame
and install probe on terminal surface of inner
circle (or outer circle).
Micrometer gauge

Assemble micrometer gauge onto front or back

terminal.

2. Extend operating device to maximal distance

position and make height of bucket tooth point
from ground same as it of revolving table bottom

At this time, front side of superstructure shall

decline downwards and the rear side shall rise.

3. Set micrometer gauge as zero.

4. Keep verticality between arm and grounding,

depress boom until front side of machine lifts off.

At this time, superstructure shall decline

backwards, front side shall rise up and rear side
shall drop.

5. Reading of micrometer gauge is swing bearing

clearance.

Do not extend hand or foot to underside of chassis.

6. Resume to state of step 2, inspect if pointer of

micrometer gauge return to Zero. Please repeat
step 2-step 5 if micrometer gauge fails to return
to zero.

202
 Test & Adjustment

Measure of Sprocket Abrasion

Measure tools:

Mark Parts Name

H Abrasion meter
Abrasion reference line
P

1. Disassemble crawler board assembly.

Reference line
2. Align abrasion meter P with sprocket.

Align reference line, sprocket wave and abrasion

meter wave.

3. Judge abrasion rate of sprocket.

It is possible to go on using the sprocket if the

wave is above abrasion limit line.

Please replace a new sprocket if the wave reaches

to abrasion limit line.

203
 Test & Adjustment

Measure Hydraulic Oil Pressure for

Equipment,, Swing System and
Work Equipment
Travel Hydraulic Loop
Measure tools of hydraulic oil pressure in operating
device, slewing and traveling hydraulic loop:

Mark Parts Name

1 A set of oil pressure gauge

I 2 Digital oil pressure gauge

3 Pipe connector (10×1.25mm)

It is possible to confirm oil pressure (output

pressure of main pump) in operating device,
slewing loop and traveling hydraulic loop by
using monitoring function (special function of
monitoring instrument) of monitoring
instrument.

1. Preparation before measure 2. Combination of pump, actuating member and

valve

Operation of actuating member, front/rear pump

are absolute while shunting flow from pump, but
Put operating device onto ground, operate control rod different temperature valves are operative.
for several times after stopped engine to release
residual pressure in pipeline. Loosen oil filter cover
slowly to release pressure in oil tank.

1) Disassemble oil pressure measure bolt. 3. Measure of noload pressure

1) Start engine.
2) Assemble pipe connector and connect it onto 2) Measure hydraulic oil pressure while engine
pressure gauge of oil pressure gauge. rotates in high idling speed and all control rod
locate at mid position.

3) Start engine and keep running it until temperature Display hydraulic oil pressure during unloading
of hydraulic oil rises to operating range. of unloading valve.

204
 Test & Adjustment

4. Measure overflow pressure of operating device.

1) Start engine and move cylinder to the course
termination to measure it.
2) Measure hydraulic oil pressure while engine runs
in high idling and cylinder is under overflow state.
Display overflow pressure of main overflow valve,
besides dropping boom.
Display low-pressure overflow pressure, besides
dropping boom and no clicking maximal touch
power switch. Display high-pressure overflow
pressure while pressing maximal touch power
switch.
1) Start engine and lock traveling.
Insert pin (1) into clearance between platform and
drive wheel to lock traveling.
2) Measure hydraulic oil pressure while engine
running in high idling and traveling oil pipe
overflowing.
Main overflow valve displays hydraulic oil
pressure under overflow condition, traveling oil
pipe overflows and the pressure keep high-
pressure overflow.

Excepting dropping boom, constant Level 2

overflow solenoid valve is ON, display high-
pressure overflow pressure while turning ON
slewing lock switch. Therefore, please keep
slewing lock switch on position of OFF.

Boom drops, display pressure during overflow of

safety valve.

Boom drops, overflow pressure is lower than

main overflow pressure.

5. Measure of swing overflow pressure

1) Start engine and move swing lock switch to ON.

1
2) Measure hydraulic oil pressure while engine
running in high idling and slewing oil pipe
overflowing.

Safety valve acts while slewing motor

overflowing.

Overflow pressure of slewing motor is lower than

main overflow pressure.

6. Measure of overflow pressure of traveling oil

pipe.

205
 Test & Adjustment

Measure Output Pressure of Main

Pilot Valve
Measure tools of output pressure of main pilot valve:

Mark Parts Name

1 Oil pressure gauge

J
2 Digital oil pressure gauge

Temperature of hydraulic oil during measuring process:

45-55℃

1. Disconnect hose of measuring oil pipe.

2. Install connector (2) between hose and elbow.

3. Install oil pressure gauge (1) onto connector (2).

4. Run engine in high idling, operate control rod of

measuring oil pipe, and measure oil pressure.

5. Disassemble all measure tools after measure and

confirm that machine returns to normal condition.

206
 Test & Adjustment

Adjustment of Work Equipment and

Swing Pilot Valve
Please adjust in following steps if too bigger clearance
is existent between work equipment and swing pilot
valve.

Drop work equipment onto ground and shut down

engine. Loosen filler cover of hydraulic oil tank slowly
to release pressure in oil tank.

1. Disassemble main pilot valve.

2. Disassemble protecting cover (1).

3. Loosen fastening nut (2) and adjust clearance of

control rod via adjusting position of disc (3).

Clearance of control rod: 0.5 - 3mm

(At position 200mm from rotating center of

control rod), it is possible to reduce clearance of
control rod via fastening the nut (2). Please adjust
according to reducing volume.

4. Fix disc (3) and screw down fastening nut (2) to

regulated torque.

207
 Test & Adjustment

Inspect Hydraulic Drift Position of

Work Equipment
Please inspect in following step and confirm if
hydraulic drift is caused in sealing of cylinder or
control valve of work equipment (cylinder) suffers
from hydraulic drift.
1. Inspect boom and bucket cylinder
1) Please put work equipment onto position shown
in figure and stop engine while measuring
hydraulic drift.
Fill soil or rated load into bucket.
2) Switch control rod to lift position or switch
bucket control rod of digging position.
� Cylinder seal is damaged if dropping speed is
increased.
� Control valve is damaged if speed is not changed.
1) Because upper pose of work equipment (retain
pressure applied on bottom), oil on bottom leaks
to top terminal and increase internal pressure of
top terminal.
2) Bottom pressure shall be rise with certain scale
accompanying with increment of internal
pressure of top terminal to balance pressure
(changed according to leakage volume), repeat
the step.
3) Downward drift shall change down if pressure is
balanced. Operate control rode according to step
abovementioned to open oil pipe of top terminal
and discharge oil to discharging oil pipe (bottom
is closed by single-way valve). Therefore, oil of
top terminal flows to discharging oil pipe and
downward drift changes up.

Turn On starting switch of engine and operate

control rod

It is possible to charge pressure for accumulator

via running engine for 10 seconds about if
necessary.

2. Detect arm cylinder

1) Operate arm cylinder before finishing digging

course to move arm cylinder to 100mm position,
stop engine.

2) Operate arm control rod to move arm to digging

side.

� Cylinder seal is damaged if dropping speed is

increased.

� Control valve is damaged if speed is not changed.

Turn ON starting switch of engine and operate

control rod

It is possible to charge pressure for accumulator

via running engine for 10 seconds about if
necessary.

Please perform operation abovementioned if

hydraulic drift is caused in damage of seal.

208
 Test & Adjustment

3. Detect maintaining valve of boom

1) Put boom into maximal spread position and keep

level of top section of arm, stop engine.

Lock control rod of boom and release pressure in oil

tank.

Do not stand below operating device during operation.

2) Disassemble discharging hose (1) of control valve 1 T

and assemble one blind plug into hose. P

Open one terminal of control valve.

Maintaining valve of boom is damaged if oil leaks

from the opening and operating device suffers
from hydraulic drift.

4. Detect main pilot valve

Measure hydraulic drift of operating device while

accumulator is charged fully and safety lock lever
is on position of unlocking.

Turn ON starting switch of engine and operate control

rod.

It is possible to charge pressure for accumulator via

running engine for 10 seconds about if necessary.

Main pilot valve is damaged (internal fault) if

hydraulic drift is different for locking and unlocking
position

209
 Test & Adjustment

Release Surplus Pressure in Hydraulic

Loop

Disassemble pipe between control valve and hydraulic

cylinder or hydraulic motor and release residual
pressure in following method:

Please open filler cover of oil tank because pressure in

hydraulic oil tank may make impact to pressure of oil
pipe of slewing motor and traveling motor.

1. Stop engine, loosen filler cover slowly to release

pressure in oil tank.

2. Turn ON starting switch of engine, and operate

control rod repeatedly for several times.

Please supply lock valve of main pilot valve with

power source and operate control rod after turned ON
starting switch of engine.

Operate control rod for 2-3 times to discharge pressure

stored in accumulator.

3. Start engine and run it in low idling for 10

seconds to charge pressure for accumulator, and
then, stop engine.

4. Repeat step described in item 2-3 for several

times.

210
 Test & Adjustment

Measure of Oil Leakage

Temperature of hydraulic oil during measure: 45-55℃ Pose for measuring boom cylinder

Please measure oil leakage in cylinder and judge if

hydraulic drift is caused in internal fault of cylinder or
main valve fault if hydraulic drift of operating device
exceeds standard range.

� Main valve is faulted if oil leakage is in standard

range.

� Internal side of cylinder is faulted if oil leakage

exceeds standard value.

Pose for measuring arm and bucket cylinder

1. Measure oil leakage of boom cylinder

1) Start engine and keep running it until temperature

of hydraulic oil rises to operating range. Elongate
boom cylinder to course termination.

2) Disassemble hose (1) on end of cylinder cover

and block terminal of hose with a plug.

1
Do not disassemble hose on bottom of cylinder.

3) Run engine in high idling, start engine and

discharge pressure of bottom of cylinder.

4) Maintain the condition for 30 seconds and

measure oil leakage in one minute.

5) Confirm that machine returns to normal condition

after measure.

211
 Test & Adjustment

2. Measure oil leakage of arm cylinder

1) Start engine and keep running it until temperature

of hydraulic oil rises to operating range. 2
2) Disassemble hose (2) on end of cylinder cover
and block terminal of hose with a plug.

Do not disassemble hose on bottom of cylinder.

3) Run engine in high idling, start engine and

discharge pressure of bottom of cylinder.

4) Maintain the condition for 30 seconds and

measure oil leakage in one minute.

5) Confirm that machine returns to normal condition

after measure.

3. Measure oil leakage of bucket cylinder

1) Start engine and keep running it until temperature

of hydraulic oil rises to operating range. Elongate
bucket cylinder to digging course termination.

2) Disassemble hose (3) on end of cylinder cover

and block terminal of hose with a plug.
3

Do not disassemble hose on bottom of cylinder.

3) Run engine in high idling, start engine and

discharge pressure of bottom of cylinder

4) Maintain the condition for 30 seconds and

measure oil leakage in one minute.

5) Confirm that machine returns to normal condition

after measure.

212
 Test & Adjustment

4. Swing motor

1) Disconnect discharging hose of swing motor and 4

swing connector and assemble one blind plug at
end of hose.

2) Connect one polythene hose to elbow side of

motor and fill leaked oil with metering cylinder.

3) Turn ON swing lock switch.

4) Start engine and operate swing overflow while

engine running in high idling speed.

5) Measure oil leakage after maintained the state for

30 seconds.

After measure of first time, measure again after slew

for 180°.

5. Travel motor

1) Disconnect discharging hose (5) of travel motor

and assemble one blind plug at end of hose.

2) Connect one polythene hose to elbow side of

motor and fill leaked oil with metering cylinder.

3) Put bearing block (6) below tooth plate of crawler

board and put bearing block (7) into clearance
between crawler bracket and sprocket to lock
crawler board.

4) Start engine and operate swing overflow while

engine running in high idling speed.

Error operation of control rod may cause accident.

Please appoint and confirm signal correctly.

5) Measure oil leakage after maintained the state for

30 seconds.

Please repeat the measure under light-load operating

state of motor for several times (modify relative
position between distributing disc and cylinder, or
relative position between piston and cylinder).

213
 Test & Adjustment

Exhaust
Operating Method and Step
Exhaust Step
Exhaust Item
1 2 3 4 5 6
Exhaust Exhaust
Exhaust
Exhaust from Start from from Start
from
Pump Engine Swing Travel Operation
Operating Content Cylinder
Motor Motor
� Replace hydraulic oil
� Clean filter net ○ ○ ○ ○ ○ ○

� Replace oil filter

element ○ ○
� Repair or replace
pump ○ ○ ○ ○
� Disassemble oil
suction pipe

� Repair or replace
○ ○ ○
main valve

� Replace cylinder
� Disassemble cylinder ○ ○ ○
pipeline
� Replace swing motor
� Disassemble swing ○ ○ ○
motor pipeline
� Replace travel motor
and rotating
connector
○ ○ ○
� Disassemble travel
motor and rotating
connector pipeline

1. Exhaust from main pump

1) Loosen exhaust plug (1) and discharging valve

(2), confirm that oil flows out from exhaust plug.

2) Fasten exhaust plug (1) and discharging valve (2)

if oil flows out

Exhaust plug:

17.64±1.96Nm {1.8±0.2kgm}

Start engine and run it in low idling speed for 10

minutes after finished steps abovementioned.

3) Disassemble all measure tools after measure and

confirm that machine returns to normal condition.

214
 Test & Adjustment

2. Exhaust from hydraulic cylinder

Filler
1) Start engine and run it in idling for five minutes.

2) Lift, drop boom continuously for 4-5 times while

running engine in low idling.

Stop piston rod at position of 100mm from course

termination. Do not release pressure in oil pipe.

3) Run engine in high idling and repeat step 2). Run

engine in low idling, operate piston rod to course
end to release pressure in oil pipe.

4) Repeat step 2) and 3) to exhaust arm cylinder and

bucket cylinder.

Please exhaust and connect piston rod orderly

after replaced cylinder.
3
Note: Do not operate cylinder to the end of course
while connecting piston rod to dropping terminal
of boom cylinder.

3. Exhaust from slewing motor

1) Disassemble oil discharging hose (3) and

assemble one blind plug into hose.

2) Start engine and run it in low idling.

3) Exhaust from motor via rotating upper section

slowly.
4
4) Disassemble all measure tools after measure and
confirm that machine returns to normal condition.

4. Exhaust from traveling motor

1) Take down traveling motor cover

2) Disconnect motor discharging hose (4).

3) Run engine in low idling and inspect if oil flows

out form connector.

4) Connect hose (4) if oil flows out.

5) Disassemble all measure tools after measure and

confirm that machine returns to normal condition.

215
 Test & Adjustment

Memo:

216
 Fault Diagnosis

Chapter Ⅵ
Fault Diagnosis

217
 Fault Diagnosis

218
 Fault Diagnosis

CONTENTS
CONTENTS

Chapter Ⅵ 2177
iagnosis......................................................................................................... 21
Fault Diagnosis
Precautions of Fault Diagnosis......................................................................................................................... 221

Operating Procedure of Fault Diagnosis.......................................................................................................... 223

Precautions of Maintenance..............................................................................................................................224

Inspection before Fault Diagnosis.................................................................................................................... 232

Location Plan of Connector.............................................................................................................................. 233

Connector Number............................................................................................................................................235

Fault Diagnosis of Engine................................................................................................................................ 236

Fault Recovery Procedure and Technology..................................................................................................236

Symptom Sheet of Fault Recovery.............................................................................................................. 236

Charging Fault or Incomplete Charging of Charger.................................................................................... 237

Pollution of Coolant......................................................................................................................................238

Running Off of Coolant................................................................................................................................239

Overheat of Coolant..................................................................................................................................... 240

Overcool of Coolant..................................................................................................................................... 242

Difficult Start of Engine or Fail to Start (No Smoke Emission).................................................................. 243

Difficult Start of Engine or Fail to Start (With Smoke Emission)............................................................... 245

Flameout of Engine...................................................................................................................................... 248

Engine Does Not Rotate or is in Slow Rotation........................................................................................... 249

Noise of Engine is Too Loud........................................................................................................................ 250

Engine Can Start But Fail to Keep Running................................................................................................ 252

Unsteady Engine Idling................................................................................................................................ 254

Excessive Fuel Consumption....................................................................................................................... 256

Excessive Engine Oil Consumption............................................................................................................. 257

Low Pressure of Engine Oil..........................................................................................................................259

High Pressure of Engine Oil.........................................................................................................................261

Engine Output Power is Low........................................................................................................................263

Giving Off Plenty of White Smoke.............................................................................................................. 266

Memo:...........................................................................................................................................................268

219
 Fault Diagnosis

220

Precautions of Fault Diagnosis
Purpose of fault diagnosis is to confirm basic reason of
fault correctly, recover fault rapidly and avoid
recurrence of fault. It is important of realize structure
and function during fault diagnosis. For performing
fault diagnosis effectively, it is possible to realize
condition from operator to confirm possible reason of
fault.
� Park machine onto horizontal ground and confirm
that safety pin, packing block and stop brake are
installed firmly.
� Please unify signal strictly and
approaching of any foreign personnel while
operating jointly with one or above worker.
� Ejecting hot water may cause scald while
disassembling radiator cover while engine is
searing. Please begin overhauling only after
engine cooled down.
� Operate carefully, do not touch any searing parts
or seize any rotating parts.
� Please disassemble cathode (-) terminal of
accumulator firstly while disassembling electric
wire.
� Please release internal pressure
disassembling internal bolt or cover relating to oil
pressure, water pressure or air pressure. Please
insure correct connection while installing
measure equipment.
� Do not disassemble parts before finding out
possible fault point.
Unreasonable disassembly may cause:
� The disassembled parts is foreign to fault, or
disassemble unnecessary parts.
� Fail to find out reason of fault.
Unreasonable disassembly may waste manual work,
parts, oil or butter, and make customer or operator
forfeit confidence on product.
Fault Diagnosis
Please inspect firstly and perform fault diagnosis in
regulated program during fault diagnosis
� Item inquired from customer or operator:
1) If any unreported problem is existent?
2) If machine suffered from abnormity before
occurrence of fault.
3) If the fault occurred abruptly?
4) What’s the condition while fault occurring?
5) What and when did the repairing performed
before occurrence of fault”?
forbid
6) If same fault occurred before?
� Inspection before fault diagnosis
1) If machine suffers from any abnormity?
2) Inspect necessary item before starting machine.
3) Inspect other item.
4) It is possible to inspect necessary item only
because daily maintenance items are examinable
from the appearance.
� Confirm fault
Confirm fault and judge if fault is caused in error
operation.
before
Note Do not perform any inspection or measure
that may emphasize fault if fault condition
reoccurs while operating machine.
� Fault diagnosis
According inspecting and measuring result of item 2-4,
reduce range of fault and confirm fault position
according to fault diagnosis flow.
Note Basic program of fault diagnosis is shown as
below:
1) Make a start on simple position.
2) Make a start on high possibility.
3) Inspect other relevant content.
221
 Fault Diagnosis

� Method for fault recovery

Fault may occur again if fault source is not

recovered.

Please find out fault reason and recover fault

source.

222
 Fault Diagnosis

Operating Procedure of Fault

Diagnosis

223
 Fault Diagnosis

Precautions of Maintenance
To ensure normal operation during a long period, in
advance to prevent the failure or an accident, must be
properly operate and take necessary maintenance,
inspection, fault diagnosis and repair. The chapter
detailed described electrical maintenance procedure in
order to master maintenance method and improve
maintenance quality. The chapter includes two parts:
"the use of electrical equipment" and "the use of
hydraulic equipment," (especially the gear oil and
hydraulic oil).

� Precaution for application of electric equipment

1) Application of lead harness and plug

Lead harness consists of electric wire that be used

for connecting elements, connector is used for
connecting or disconnecting wire, protector or
wireway is used for protecting electric wire.

Different as other electric elements placed in box

and cabinet, lead harness tends to be impacted by
rain, water, heat or vibration directly. In addition,
lead harness is easy of distortion or damage
because frequent disassembly and assembly
during inspection and maintenance. Please used
lead harness carefully.

Major fault of lead harness

① Bad contact of plug (plug contacts with socket

badly)
Crimping position
Bad contact may be caused in NG connection of
plug and socket, distortion of connector terminal
(s), dislocation, rust and oxidation of contact
surface.

② Crimping or NG jointing of connector

Pin of connector contacts with pin of socket at

crimping terminal or welding position. Bad
contact or rapture may occur if connecting
position is stripped because higher force is applied
on electric wire.

224
 Fault Diagnosis

③ Disconnection of electric wire

It is possible to cause damage of crimping

position or welding point, or rapture of electric
wire if draw out connector with hand, hoist
element connecting with electric wire by using
crane, or beat weight against electric wire.

④ Access of high-pressure water

Water may enter into connector in spraying

direction while spray high-pressure water directly
onto connector, although waterproof structure
(immersion-proof structure) is adopted.

It is difficult to exhaust intake water from

connector because waterproof structure is adopted.
Pin may be shortened by water if water enters
into connector. Please dry connector or adopt
other measure before connecting power supply if
water entered into connector.

⑤ Oil and dirt on connector

Oil on connector or oil firm formed on contact

face of connector or socket may cause bad contact
because the non-conducting.

Please wipe off oil, grease or dirt on connector

with cloth or dry it with compression air and spray
contact reducer.

Note

� Please wipe jointing position of connector

carefully to prevent from distortion of pin.

� It is possible to dirt contact point if oil or water

contains in compression air. Please eliminate oil
and water in compression air before cleaning with
it.

225
 Fault Diagnosis

2) Disassembly, assembly, and dryness of connector

and lead harness.

� Disassemble connector

① Hold connector while disassembling it.

Please hold connector with hand while

disassembling it. Loosen screw that be used for
fixing connector, hold connector with one hand,
hold socket with the other hand and draw out it.
Please press stopper with thumb and draw out
connector if a stopper is equipped.

Note Do not draw it with one hand.

② Disassembling from junction column

Please draw out connector parallelly with junction

column while disassembling connector from
junction column.

Note It is possible to damage shell case if draw

connector via twisting it.

③ Treatment of disassembled connector

Please pack connector with plastic bag after

disassembled it to avoid access of dust, oil or
water in connector.

Note It is necessary to pack disassembled connector

with plastic bag because depositing it for long
period may cause bad contact.

226
 Fault Diagnosis

� Assemble connector

① Inspect appearance of connector

1) Inspect if oil, dirt or water is existent at position

of pin (jointing position) of connector.

2) Inspect if pin of connector suffers from distortion,

bad contact, rust or damage.

3) Inspect if appearance of connector is damaged or

broken.

Note Please wipe off oil, grease or dirt on

connector with cloth or dry it with low-
temperature compression air if water
accessed in connector.

Please replace connector if any damage or

rapture is existent.

② Install connector firmly

Align connector correctly and insert it firmly.

Push connector until a sound of “chick” occurs if
a stopper is equipped.

③ Calibration of protuberance of rubber cover and

lead harness misplacement: it is necessary to
calibrate protuberance of rubber cover of
connector if equipped, or calibrate misplacement
of lead harness or wire clip to correct position.

Note It is possible to disassemble clip and adjust

the position if modification of connector is
difficult.

④ Please install disassembled wire clip of connector

back to original position and inspect if clip is
loosened.

227
 Fault Diagnosis

� Dryness of lead harness

Wipe off oil or dirt on lead harness with dry cloth

without cleaning it with water of steam. Do not
spray high pressure water of steam onto lead
harness directly if cleaning with water is
necessary.

Please perform following operation if water

access in connector.

① Disassemble connector and wipe off water with

cloth.

Note Dry connector with air is dangerous because

oil in air may cause bad contact. Please dry
connector with compression air without
water and oil.

② Dry internal side of connector by using drier.

It is possible to dry connector if water access in

connector.

Note Connector and connector accessories may be

distorted or damaged under effect of hot air.
Please adjust blowing time while dry
connector with hot air.

③ Perform connecting test with connector.

After dried connector, disassemble harness and

perform connecting test with connector to inspect
if pin suffers from short circuit caused in water.

Note It is possible to use hot air in drier, spray

contact reducer and reassemble it.

228
 Fault Diagnosis

3) Application of controller box

① Controller box includes one micro computer an

electric control circuit. Please use controller box
carefully because all control with machine is
performed via electric circuit.

② Do not open cover of controller box without cause.

③ Do not put other matter on controller box.

④ Pack connector of controller box with adhesive

tape or plastic bag. Do not touch connecting
position of connector with hand.

⑤ Do not expose controller box to rainy condition.

⑥ Do not put controller box in oil, water, mud or hot

condition, even for a short time.

(Please put it onto proper drying table)

⑦ Precautions for arc weld

Disassemble all lead harness and controller

connecting with controller box and assemble
grounding line closing to welding position while
perform arc welding operation with vehicle body.

� Precaution for circuit fault diagnosis

1) Please shut down power supply before

disconnecting or connecting connector.

2) Inspect if all these relevant connectors are

inserted correctly before fault diagnosis. 4) Please move relevant circuit and connector for
several times to inspect if reading of measuring
Note Inspect it via disconnecting or connecting
apparatus is changed while overhauling circuit
relevant connector for several times.
(measure voltage, resistance, connecting capacity
3) Connect these disconnected connector before next or current).
step.
Note Bad contact of circuit may be existent if
Note If the power has been connected but the reading is changed.
connector is still disconnected, then the extra
anomalies are shown.

229
 Fault Diagnosis

� Precautions for application of hydraulic device

Most fault of hydraulic equipment are caused in

dirt (foreign matter) in oilway because high
precision and pressure of hydraulic equipment.
Operate carefully while filling hydraulic oil or
disassembling hydraulic equipment.

� Mind your working environment

Please avoid filling hydraulic oil, replacing filter

meter or repairing machine under rainy, windy or
dusty condition.

� Disassembling or maintaining hydraulic

equipment on site

It is recommended to replace parts in set because

access of dust in hydraulic equipment during local
disassembling process or maintenance of
hydraulic equipment is dangerous and may make
impact to performance of machine although
repaired it. Please disassemble and maintain
hydraulic equipment in special dustless plant and
test performance with special measure equipment.

� Sealing pipe port

Please seal pipe port with sealing cover, adhesive

tape or plastic bag after disassembled pipe or
equipment to prevent from access of dirt or dust.
It is prohibitive to keep opening of pipe port or
block it with cloth only to avoid access of dirt or
pollution caused in oil leakage.

Do not exhaust waste oil onto ground directly.

Please recycle them and treat them according to
requirement of customer, or store it for future
treatment.

� Prevent from access of dirt or dust while filling

hydraulic oil

Avoid access of dirt or dust while refilling

hydraulic oil. Keep cleanness of filling port, the
periphery, oiling pump and oil tank. It is
recommended to filter dirt accessed during storing
process by using oil filter.

230
 Fault Diagnosis

� Replace hydraulic oil under high temperature

condition
Hydraulic oil or other oil is easy to flow and
exhaust oil dirt in oilway under high temperature
condition. Please replace oil under high
temperature and exhaust waste hydraulic oil as
much as possible (include oil in hydraulic oil tank,
Washing Oil
filter element and oil plug in oilway).

� Rinsing operation
Please rinse impurity, oil dirt and waste oil in
hydraulic oilway by using rinsing oil during
disassembling, assembling or oil replacing
process. In general, it is necessary to rinse for two
times: rinse with rinsing oil firstly and rinse with
regulated hydraulic oil secondly.

� Cleanness
Please rinse with hydraulic oil to exhaust oil dirt
or foreign matter in hydraulic oilway while
starting machine after repaired hydraulic
equipment (pump and control valve etc.), it is
possible to exhaust ultra fine granule (3μ about)
by hydraulic rinsing equipment, which is
irrealizable by filter element in hydraulic
equipment.

231
 Fault Diagnosis

Inspection before Fault Diagnosis

Inspecting Item Standard of Criterion Measure

1. Inspect fuel level and type of fuel — Fill fuel

2. Inspect if impurity is existent in fuel — Clean, discharge

3. Inspect hydraulic oil level — Fill oil

4. Inspect hydraulic oil filter net — Clean, discharge

Lubricating 5. Inspect oil level of slewing mechanism — Fill oil
Oil and
Coolant 6. Inspect oil level of engine (oil level of drain pan) — Fill oil

7. Inspect cooling water level — Fill water

8. Inspect if dust indicator is blocked — Clean or replace

9. Inspect hydraulic oil filter — Replace

10. Inspect final driving oil level — Fill water

1. Inspect if accumulator terminal and wire are loosened or

rusty. — Fasten or replace
Electric
2. Inspect if generator terminal and wire are loosened or rusty. — Fasten or replace
Equipment
3. Inspect if starting motor terminal and wire are loosened or — Fasten or replace
rusty.

Hydraulic 1. Inspect if abnormal noise or smell is existent — Repair

and
2. Inspect if oil leakage is existent — Repair
Mechanical
Equipment 3. Exhaust air — Exhaust

1. Inspect voltage of accumulator (flame out engine) 20-30V Replace

2. Inspect pressure and level of electrolyte of accumulator — Fill or replace

3. Inspect if any wire is discolored, burned or exposed. — Replace

4. Inspect if wire clip is lost or if wire is suspended — Repair

5. Inspect if water leaks onto electric wire (inspect adapter — Disassemble

and terminal carefully) adaptor and dry
Electric
connecting wire
Device

6. Inspect if fuse is burned or rusty.

—
Replace
7. Inspect voltage of engine (engine operate under working
Run for several
condition of 1/2 throttle or above) Replace
minutes
8. Inspect if accumulator relay operates with noise (turn
27.5-29.5V
ON/OFF switch)
Replace
—

232
 Fault Diagnosis

Lo cation Plan of Connector

Location

Fig. 1

233
 Fault Diagnosis

to Boom

Fig. 2

Fig. 3

234
 Fault Diagnosis

Connector Number
Note Positions of connectors listed in the Sheet are denoted in location plan of connector.

For example:

Position of connector J1 is Fig.1, No.18.

Connector No. Pin No. Connecting position Position Connector No. Pin No. Connecting position Position

J1 35 Controller Fig. 1-18 J16-B 1 Generator Fig. 2-5

J2 35 Controller Fig. 1-17 J30-B 1 Preheating plug Fig. 2-4

J5-A 12 Fig. 1-7 J22-A 8 Fig. 1-14

J6-A 12 Harness of electric cabinet Fig. 1-8 J23-A 8 Fig. 1-15

J17-A 12 Fig. 1-9 J24-A 1 Fuse Fig. 1-11

J5-B 12 Fig. 1-7 J27-A 1 Fig. 1-15

J6-B 12 Relay Fig. 1-8 J29-A 1 Fig. 1-13

J17-B 12 Fig. 1-9 J22-B 8 Harness of electric cabinet Fig. 1-14

J8-A 16 Fig. 1-6 J23-B 8 Harness of electric cabinet Fig. 1-15

Harness of stand box
J9-A 16 Fig. 1-5 J24-B 1 Harness of air condition Fig. 1-11

J8-B 16 Fig. 1-6 J27-B 1 Harness of electric cabinet Fig. 1-15

Harness of electric cabinet
J9-B 16 Fig. 1-5 J29-B 1 Harness of electric cabinet Fig. 1-13

J10-A 12 Front harness Fig. 2-8 J32-A 1 Harness of air condition Fig. 1-16

J11-A 4 Rear harness Fig. 3-3 J4-A 8 Fuse Fig. 1-19

J10-B 12 Harness of electric cabinet Fig. 2-8 J4-B 8 Relay Fig. 1-19

J11-B 4 Harness of electric cabinet Fig. 3-3 J7-A 14 Display Fig. 1-4

J12-A 12 Fig. 2-6 J7-B 14 Harness of electric cabinet Fig. 1-4

J13-A 12 Fig. 2-7 J19-A 3 Coil protector Fig. 3-2

J14-A 12 Fig. 2-2 J20-A 3 Coil protector Fig. 3-1

Engine harness
J15-A 6 Fig. 2-3 J21-A 26 Display Fig. 1-2

J16-A 1 Fig. 2-5 J25-A 9 Radio Fig. 1-20

J30-A 1 Fig. 2-4 J26-A 6 Wiper Fig. 1-1

J12-B 12 Harness of electric cabinet Fig. 2-6 J28-A 2 Harness of boom lamp Fig. 2-1

J13-B 12 Harness of electric cabinet Fig. 2-7 J28-B 2 Front harness Fig. 2-1

J14-B 12 Harness of electric cabinet Fig. 2-2 J31 12 RCM Fig. 1-10

J15-B 6 Throttle executer Fig. 2-3 J33-A 13 Manual switch Fig. 1-3

235
 Fault Diagnosis

Fault Diagnosis of Engine

Fault Recovery Procedure and Technology

This manual describes some typical problems in

engine operation, reasons and acceptable solutions to
them. Unless for special notes, all the listed issues are
available for operators to diagnose and repair and as to
those unlisted, please contact with Manufacturer of
Lonking.

Symptom Sheet of Fault Recovery

The fault diagnosis table in this chapter can help to

find out the reasons of fault and remove the fault.
Please read carefully the content in each square frame
from top to bottom and confirm actions for fault
removal according to arrow head direction in the
picture.

Fault diagnosis is with the risk of leading to damage on

equipments or personal injury and casualty. It is
required for well-trained technicians to complete fault
diagnosis and removal work.

236
 Fault Diagnosis

Charging Fault or Incomplete Charging of Charger

Reason Measure

Cable or connector of accumulator

Cleaning/Fasten connector of
becomes loosened, broken or ......
accumulator
rusted (overlarge resistance)

A.C. engine belt is slip ...... Check/Replace belt tension pulley

Engine belt pulley becomes flexible ...... Screw belt pulley

Meter or Light Malfunction ...... Check/Replace meter or light

A.C. engine malfunction ...... Replace A.C. engine

Contact manufacturer of Lonking

237
 Fault Diagnosis

Pollution of Coolant

Reason Measure

There is rust in coolant, not using Release and flush cooling system.
proper mixer of antifreeze and ...... To inject proper mixer of
water antifreeze and water

Check renewal circle of coolant.

Engine belt pulley becomes flexible ...... Screw belt pulley

Meter or Light Malfunction ...... Check/Replace meter or light

A.C. engine malfunction ...... Replace A.C. engine

Contact manufacturer of Lonking

238

Running Off of Coolant
Reason
Water tank or Cab heater leak
Leakage in exterior of engine
Overheat or leakage of pressed air
leads to coolant wastage through
water tank overflow.
Water cooling air compression, lid
or seal washer leak (if there is any)
Leak in lubricant cooler.
Contact manufacturer of Lonking
Fault Diagnosis
Measure
Check water tank heater, hose and
...... connector by eyes to find out leak
point.
If there is any machine oil in
coolant, check whether there is
leakage in gear box or lubricant
cooler.
Check engine and parts by eyes to
...... see if there is any leakage caused
by gasket or washer.
Check if there is any overheat or
low power case in work. (Refer to
......
“overheat of coolant” symptom
tree in this chapter)
Check if there is any machine oil
...... in coolant. To check/replace lid or
seal washer.
Check/replace machine oil cooler
...... and search if there is any coolant
in machine oil.
239
 Fault Diagnosis

Overheat of Coolant

Reason Measure

Liquid surface is too low for

...... Add more coolant
coolant

Cooling fin of water tank is Check cooling fin—and clean or

......
damaged or jammed by impurity. repair if necessary.

Water tank hose is broken ...... Check hose and replace if necessary

Incorrect machine oil surface ...... To add or release engine oil

Damage or loss of cooling fan Check cover; repair, replace or

......
cover install

Fan drive belt is loosened ...... Check belt tension pulley

The fan doesn’t work ...... Check fan sensor

Water tank lid fault or incorrect Check tank lid and replace if
......
position necessary

Louver clapboards of water tank Check louver clapboard and repair

are not totally opened or cover is ...... or replace if necessary. Open water
closed in cold weather. tank cover.

240
 Fault Diagnosis

Test temperature meter and repair

Fault of temperature meter ......
or replace if necessary.

Incorrect thermostat ...... Check/replace thermostat

Disassemble jet pump and check

Too much fuel in jet pump ......
the standardization

Overload of vehicle ...... Decrease load or use lower steering

Measure coolant pressure in

Fault in water pump ......
cylinder

Check/replace water pump

Check if there any leakage in the

There is air in cooling system ...... side of suction pipe with hose clip
on

Check if leakage is caused by

compression of cylinder seal
washer.

Water tank, cylinder lid, lid washer

Check water tank lid and replace if
or coolant channel of cylinder ......
necessary.
body is jammed

Contact manufacturer of Lonking

241
 Fault Diagnosis

Overcool of Coolant

Reason Measure

Louver clapboards of water tank Check louver clapboards and

......
are bonded to open place. repair or replace if necessary.

Fault in Fan ...... Check if fan can work continuously

Check/clean sensor and coolant

Fault in temperature sensor ......
channel

Test/replace sensor

Test temperature meter and repair

Fault in temperature meter ......
or replace if necessary

Check thermostat and replace if

Incorrectness or fault in thermostat ......
necessary

Contact manufacturer of Lonking

242
 Fault Diagnosis

Difficult Start of Engine or Fail to Start (No Smoke

Emission)
Reason Measure

Wrong start steps ...... Check if start steps are correct

Check and fill fuel. Check tube

There is no fuel in fuel tank ...... connector, hose connector and hose
status.

Check if lead is loosened and fuel

shutoff valve is working normally.
Fault in fuel shutoff valve ......
To confirm manual shutoff control
rod is in the place of RUN.

Check fuel transfer pump and

Fault in fuel transfer pump ......
replace if necessary

Check fuel passing through filter

Fuel filter or fuel inlet is blocked ......
and replace fuel filter if necessary.

There is superfluous water in fuel Release oil/water separator and

......
filter replace fuel filter.

Check inlet and outlet system

Inlet and outlet system is blocked ...... resistance. Check inlet filter and
replace if necessary

Check closed crank case

Closed crank case ventilation hose
...... ventilation hose and connector for
leakage or damage
any leakage, jam or damage.

Check closed crank case

Closed crank case ventilation valve
...... ventilation valve for any jam or
leakage or fault
damage.

243
 Fault Diagnosis

Injection pump fails to get fuel or Check fuel flux or air in fuel
there is air mixed in fuel ......
discharging system

Overlarge resistance in oil return ...... Check if oil return tube is blocked

Fault in fuel pump oil return and Check oil return and overflow
......
overflow valve valve and replace if necessary

Keep engine stay in top dead center.

Fuel injection pump is not in
...... Check and adjust oil sprayer
correct timing
correct timing.

Disassemble fuel injection pump

Fault in fuel injection pump ...... and check indication position of
fuel injection pump

Correct timing of cam shaft is

Check gear driving system for
wrong (after engine overhaul or ......
correct timing.
repair)

Contact manufacturer of Lonking

244
 Fault Diagnosis

Difficult Start of Engine or Fail to Start (With

Smoke Emission)

Reason Measure

Incorrect start steps ...... Check if start steps are correct

Make sure all driving units are kept

away. Check engine dragging
rotation rate by using handheld
Too low rotation rate in engine tachometer. (If dragging rotation
......
dragging rate is lower than 150rpm, refer to
symptom tree of “engine non-
rotating or slow rotation” in this
chapter)

Check if lead is loosened and

solenoid valve is working properly.
Electric or manual fuel shutoff
...... Make sure manual shutoff valve
valve is locked
control rod is clipped on injection
pump by checking.

Check if cold start auxiliaries are

Fault in start auxiliaries ......
working properly.

If there fixed a switch valve on

vehicle for controlling air inlet
Air inlet source is incorrect ...... under engine and exterior air inlet, it
should install and set for valve
according to alteration of seasons.

Check and clean out all fragments

Inlet overheat ...... and scraps in the front part of air to
air intercooler

245
 Fault Diagnosis

Check closed crank case ventilation

Closed crank case ventilation hose
...... hose and connector for any leakage,
leakage or damage
jam or damage.

Closed crank case ventilation valve Check closed crank case ventilation
......
leakage or fault valve for any jam or damage.

There is air in fuel system ...... Check if there is air in fuel system

Check fuel from filter and replace

Fuel filter or fuel inlet is blocked. ......
fuel filter if necessary.

Thermal capacity of No. 1 diesel

and other light winter fuel are lower
than those of No. 2 diesel, which
Low quality fuel or using No. 1
...... can lead to higher consumption of
diesel over 0℃[32°F]
fuel. Assess fuel consumption by
using No.2 diesel. Fuel additive can
also lead to lower thermal capacity.

Fault in fuel pump oil return and Check oil return and overflow
......
overflow valve valve and replace if necessary

Ensure fuel oil return tube is

Fuel oil return tube is not vertical ......
vertical to bottom of fuel tank.

Check oil transfer pumps and

Fault in oil transfer pump ......
replace if necessary.

246
 Fault Diagnosis

Keep engine stay in top dead center.

Fuel injection pump is not in
...... Check and adjust oil sprayer
correct timing
correct timing.

Air to air intercooler is jammed Check interior and exterior of air to

...... air intercooler for any jam and
(if there is any) replace if necessary.

Air valve is not sealed correctly ...... Check and adjust air valve

Disassemble and test oil sprayer

Oil sprayer is worn or has fault. ......
and replace if necessary

Make compression pressure check

Engine compression pressure is
...... in order to confirm fault. Repair on
low
need.

Fault in fuel injection pump ...... Disassemble fuel injection pump

Contact manufacturer of Lonking

247
 Fault Diagnosis

Flameout of Engine

Reason Measure

Run engine by temporary fuel tank

Impurity in fuel ......
fuel feeling to verify.

Deflate fuel system and check if

Air in fuel system ......
there is leakage from suction pipe

Leakage of fuel injection pipes ...... Check and replace damaged pipes

Fault in oil return and overflow Check/Replace oil return and

......
valve overflow valve

Fault in oil transfer pump ...... Check/Replace oil transfer pump

Check handspike, spring and

Air valve is adjusted incorrectly ......
adjustment air valve

Oil sprayer/nozzle is jammed or

...... Replace oil sprayer
does not work

Injection pump is not in correct Check injection pump’s correct

......
timing timing

Contact manufacturer of Lonking

248
 Fault Diagnosis

Engine Does Not Rotate or is in Slow Rotation

Reason Measure

Loosen clutch and check load

Engine clutch is chained ......
caused by fault accessories.

Turn crank to check rotation

Crank shaft is bound ......
resistance

Start terminal is loose or rusted ...... Check and screw connector

Accumulator is lack of charging ...... Check accumulator voltage

There no voltage in starter solenoid

...... Check solenoid valve voltage
valve

Fault in solenoid valve or start

...... Replace start generator
generator

Disassemble start generator to

Start generator works but fails to
...... check if there is any damaged gear
rotate engine
tooth or spring on flywheel.

Contact manufacturer of Lonking

249
 Fault Diagnosis

Noise of Engine is Too Loud

Reason Measure

Check belt tension and fasten belt

Fan driving belt is loose ......
if necessary

Fan is loose, damaged or

...... Check fan
unbalanced

Check inlet system and ventilation

Air inlet or vent leakage ......
system for any air leakage.

Inlet pipe or vent pipe touches Check air pipe, chassis and cab for
......
chassis or cab any touch

Engine oil level is higher or lower Check engine oil level and fill or
......
than technical specification discharge engine oil if necessary

Refer to “Oil Technical

Engine oil is too thin or diluted
Specifications” in LG6215 Operation
and Maintenance Manual. If engine
......
oil is in low pressure, refer to
symptom tree of low pressure engine
oil in this chapter.

Engine oil pressure is lower then

...... Check engine oil pressure
technical specification

Absorber is damaged ...... Check absorber

Accessories driving unit is worn Check axial clearance of

(axial clearance exceeds technical ...... accessories driving and check if
standard value) axle is worn

250
 Fault Diagnosis

Coolant temperature is higher than Refer to symptom tree of “coolant

......
technical specification overheating” in this chapter

Switch off drive unit. Check engine

Big noise in drive unit ......
for any noise.

Engine suspension is worn,

...... Check engine suspension
damaged or incorrect

Incorrect adjustment of overhead Measure and adjust overhead

......
mechanism mechanism

Spare part damage in overhead Check rocker, rocker shaft and air
......
mechanism valve for any damage or over wear

Make single-cylinder oil cutoff test

Fault in oil sprayer ......
and replace oil sprayer if necessary

Check flywheel or flexible

Bolt on flywheel or flexible
...... connecting plate and construction
connecting plate is loose or cracked.
bolt

Fluid torque converter is loose ...... Check torque converter

Check operating system for any

Piston or piston ring is worn or
...... leakage. Check piston or piston
damaged
ring for any wear or damage.

Contact manufacturer of Lonking

251
 Fault Diagnosis

Engine Can Start But Fail to Keep Running

Reason Measure

Fill fuel tank. Refer to “Oil

Technical Specifications” in
Oil level is low in fuel tank ......
Operation and Maintenance
Manual

Check accessories or other drive

unit of engine for any fault, arrester
Engine overload ...... dragging and other vehicle load
change that may cause overload.
Disconnect engine gearing

Check fuel shutoff valve (FSOV) to

Fault in fuel shutoff valve ...... keep coil resistance and power
voltage

Idling rotation rate is set too low for

...... Check and adjust low idling bolt.
accessories to work

Check if there is air in fuel system,

There is air in fuel system ...... repair leakage source and discharge
air in system.

Check fuel through filter and

Fuel filter or fuel inlet is blocked ......
replace fuel filter if necessary

Check fuel heater if there is any.

Cold weather causes wax
...... Under certain weather condition, it
precipitation to fuel
needs to install fuel heater.

There is superfluous water in fuel Discharge oil/water separator and

......
filter replace fuel filter

252
 Fault Diagnosis

Use clean fuel in temporary fuel

Fuel is polluted ......
tank to run engine for check.

Check if oil return pipe is blocked

and clean or replace fuel pipe,
Oil return pipe is blocked ......
non-return valve, and oil tank vent
pipe if necessary

Check inlet and vent system

Air inlet and vent system is blocked ...... resistance. Check inlet filter and
replace if necessary

Check crank case vent hose and

Closed crank case vent hose leakage
...... connector for any leakage, jam or
or damage
damage.

Leakage or fault in closed crank Check closed crank case vent

......
case vent valve valve for any jam or damage.

Check oil sprayer and replace any

Wear or fault in oil sprayer ......
oil sprayer in fault.

Keep engine stay in top dead

Fuel injection pump is not in correct
...... center. Check and adjust oil
timing
sprayer correct timing.

Disassemble fuel injection pump

Fault in fuel injection pump ...... and check indication position of
fuel injection pump

Contact manufacturer of Lonking

253
 Fault Diagnosis

Unsteady Engine Idling

Reason Measure

Warm-up to work temperature and

if engine fails to reach work
Engine cold condition ...... temperature, refer to symptom tree
for coolant under normal
temperature

Idling rotation rate is set too low for

...... Check and adjust low idling bolt.
accessories to work

Engine suspension is worn,

...... Check engine suspension status
damaged or incorrect

Check fuel pipe, fuel connector, oil

transfer valve seal components and
Fuel leakage ......
fuel filter for any leakage. Check
fuel pipe in fuel tank.

Check if there is air in fuel system.

There is air in fuel system ...... Repair leakage source and
discharge air in system

Check fuel through filter and

Fuel filter or fuel inlet is blocked ......
replace fuel filter if necessary

Check oil transfer pump and

Fault in oil transfer pump ......
replace if necessary

Fault in fuel pump oil return and Check oil return and overflow
......
overflow valve valve. Replace if necessary.

254
 Fault Diagnosis

Check closed crank case ventilation

Closed crank case ventilation hose
...... hose and connector for any leakage,
leakage or damage
jam or damage.

Closed crank case ventilation valve Check closed crank case ventilation
......
leakage or fault valve for any jam or damage.

Keep engine stay in top dead center.

Fuel injection pump is not in correct
...... Check and adjust oil sprayer
timing
correct timing.

Air valve is not correctly sealed ...... Check and adjust air valve

Make compression pressure check

Engine compression pressure is low ...... in order to confirm fault. Repair on
need.

Make start pressure test on oil

Fault in oil sprayer ......
sprayer

Fault in fuel injection pump ...... Disassemble fuel pump

Contact manufacturer of Lonking

255
 Fault Diagnosis

Excessive Fuel Consumption

Reason Measure

Fuel leakage ...... Check/amend leakage reason

Supplementary load from accessories Check/repair accessories and

......
in fault vehicle parts

Run engine by using good-quality

Bad quality of fuel ...... fuel in temporary tank to verify and
refer to diesel specification.

Check if it is correct to shift,

Operators’ skills are not correct ......
decelerate and idling in work

Air inlet or vent resistance is too Refer to “Too much smoke” in fault
......
much removal logic

Timing of fuel ejector pump is

...... Inspect timing of ejector pump
incorrect

Wear or fault in oil sprayer ...... Disassemble oil sprayer. Test/Repair

Air valve is not sealed ...... Check and adjust air valve

Contact manufacturer of Lonking

256
 Fault Diagnosis

Excessive Engine Oil Consumption

Reason Measure

Check by eyes to see if there is

External leakage ......
engine oil leakage

Over-injection engine oil in crank Ensure oil gauge in correct indicated

......
case position

Engine oil specification is not correct ...... Check engine oil specification

Check if fuel dilution leads to

reduction of engine oil’s viscosity

Verify/shorten replacing cycle of

engine oil

Leakage in engine oil cooler ...... Check if there is engine oil in cooler

Air compressor pump engine oil (If

...... Check/replace air compressor
there is any)

Heavy air leakage expels engine oil Check peripheral region of air tube
......
out of air tube for any evidence of engine oil loss

Check inlet and outlet of

Turbocharger leaks engine oil to inlet
...... turbocharger for any evidence of
or exhaust system
engine oil leakage

257
 Fault Diagnosis

Contact manufacturer of Lonking

258
 Fault Diagnosis

Low Pressure of Engine Oil

Reason Measure

Engine oil level is on the low side ...... Check and fill engine oil

Leakage or incorrect installation of

cylinder cover core and expansion ...... Check cylinder cover
plug

Refer to symptom tree of engine oil

Engine oil filter is diluted ......
pollution

Engine oil filter is blocked ...... Replace engine oil and filter

Check if engine oil pressure switch,

Fault or incorrect installation position
pressure gage, and pressure pickup
of engine oil pressure switch, pressure ......
work normally and installation
gage, and pressure pickup
position is correct or not.

Improper engine oil filter ...... Ensure to use proper engine oil filter

Pressure regulating valve is clipped on

...... Check and replace valve
switch-on position

Engine oil cooler is jammed ...... Check engine oil cooler

After replacing engine oil cooler,

...... Check and take out transport bolt
transport bolt is left in cooler

259
 Fault Diagnosis

Fault in engine oil pump ...... Check engine oil pump

Engine oil suction pipe or oil transfer

Disassemble and check oil bottom
pipe is loose or cracked; leakage in ......
case or oil suction pipe
seal washer or O-ring

Main bearing bolt is loose, worn or not Check torque of main bearing bolt.
......
fastened properly Check if bolt is worn.

Damage or over wear of main bearing, Check main bearing for any damage,
wrong assembly or installation of ...... over wear and spare parts number is
wrong bearing correct or not.

Camshaft neck and No. 1 bush are Check camshaft neck and No. 1 bush
......
severely damaged for any wear.

Contact manufacturer of Lonking

260
 Fault Diagnosis

High Pressure of Engine Oil

Reason Measure

Warm-up to work temperature and if

engine fails to reach work
Engine cold condition ......
temperature, refer to symptom tree
for coolant under normal temperature

Incorrect viscosity of engine oil ...... Ensure to use correct engine oil

Engine oil filter is incorrect ...... Ensure to use correct engine oil filter

Check if engine oil pressure switch,

Fault or incorrect installation position
pressure gage, and pressure pickup
of engine oil pressure switch, pressure ......
work normally and installation
gage, and pressure pickup
position is correct or not.

Pressure regulating valve is clipped on

...... Check and replace valve
switch-on position

Verify correct installation of engine

Incorrect installation of engine oil pump ......
oil pump and O-ring

Contact manufacturer of Lonking

261
 Fault Diagnosis

Engine Output Power is Low

Reason Measure

Check accessories or other drive unit

of engine for any fault, arrester
Engine Overload ......
dragging and other vehicle load
change that may cause overload.

Fuel cutoff control rod (mechanical type) Check if solenoid valve is working
......
is connected partially normally

Ensure throttle rod is correctly

adjusted or has no damage. Make
Engine throttle cannot open completely ...... adjustment or repair if necessary.
Check fuel control rod for reaching
total excursion

Use No. 2 diesel temporarily to run

engine for approval. Check fuel
Bad quality of fuel or incorrect grade ......
grade to see if it is in accordance
with technical specification.

Fuel temperature is higher than technical Fill fuel tank. Ensure fuel heater is
......
specification shut off under warm weather.

Check fuel pipe, fuel connector, oil

transfer valve seal components and
Fuel leakage ......
fuel filter for any leakage. Check fuel
pipe in fuel tank.

Check if there is air in fuel system.

There is air in fuel system ...... Repair leakage source and discharge
air in system

Check fuel through filter and replace

Fuel filter or fuel inlet is blocked ......
fuel filter if necessary

262
 Fault Diagnosis

After replacing engine oil cooler,

...... Check and take out transport bolt
transport bolt is left in cooler

Check if oil return pipe is blocked

and clean or replace fuel pipe, non-
Fuel oil return pipe is blocked ......
return valve, and oil tank vent pipe if
necessary

Check oil transfer pump and replace

Fault in oil transfer pump ......
if necessary

Fault in fuel pump oil return and Check oil return and overflow valve
......
overflow valve and replace if necessary

Engine oil level is higher or lower than Check engine oil level and fill or
......
technical specification discharge engine oil if necessary

Check air filter core and replace if

Air filter is jammed ......
necessary

If there is a switch valve on vehicle

for inlet source under controlling
Air inlet source is not correct ...... engine cover and exterior inlet source,
it shall install and set this valve
according to varied seasons.

Air-fuel oil pip leakage, exhaust gas

Screw pipe connector, repair pipeline,
bypass-valve diaphragm crack or
...... and replace exhaust gas bypass-valve
exhaust gas bypass-valve pipeline
diaphragm
damage.

263
 Fault Diagnosis

Check and clean out all fragments

Inlet overheat ...... and scraps in the front part of air to
air intercooler

Air to air intercooler is jammed

...... Check if intercooler pipeline is jammed
(if there is any)

Air to air intercooler is jammed Check interior and exterior of air to

...... air intercooler for any jam and replace
(if there is any) if necessary.

Check inlet and vent system

Air inlet and vent system is blocked ...... resistance. Check inlet filter and
replace if necessary

Check crank case vent hose and

Closed crank case vent hose leakage or
...... connector for any leakage, jam or
damage
damage.

Leakage or fault in closed crank case Check closed crank case vent valve
......
vent valve for any jam or damage.

Check if there any leakage in

through-hole of air jumper tube, air to
Air leakage between turbocharger and
...... air intercooler connector, hose or
inlet manifold branch
manifold cover. Repair or replace if
necessary

Check if boost pressure is accordance

Wear or fault in turbocharger ...... with technical specification. Check
turbocharger and replace if necessary

264
 Fault Diagnosis

Keep engine stay in top dead center.

Fuel injection pump is not in correct
...... Check and adjust oil sprayer correct
timing
timing.

Air valve is not correctly sealed ...... Check and adjust air valve

Check oil sprayer for any extra seal

Incorrect seal washer for oil sprayer ...... washer. Disassemble superfluous seal
washer and remain one only.

Check oil sprayer and replace any oil

Wear or fault in oil sprayer ......
sprayer in fault.

Make compression pressure check in

Engine compression pressure is low ......
order to confirm fault. Repair on need.

Fault in fuel injection pump ...... Disassemble fuel pump

Contact manufacturer of Lonking

265
 Fault Diagnosis

Giving Off Plenty of White Smoke

Reason Measure

Incorrect start steps ...... Check if start steps are correct

Coolant temperature or inlet manifold Refer to symptom tree for coolant

temperature is lower than technical ...... under normal temperature in this
specification chapter

Use No. 2 diesel temporarily to run

engine for approval. Check fuel grade
Bad quality of fuel or incorrect grade ......
to see if it is in accordance with
technical specification.

Check if there is air in fuel system.

There is air in fuel system ...... Repair leakage source and discharge
air in system

Keep engine stay in top dead center.

Fuel injection pump is not in correct
...... Check and adjust oil sprayer correct
timing
timing.

Check oil sprayer for any extra seal

Incorrect seal washer for oil sprayer ...... washer. Disassemble superfluous seal
washer and remain one only.

Disassemble and test oil sprayer and

Wear or fault in oil sprayer ......
replace if necessary.

Coolant leakage to combustion Refer to symptom tree of interior

......
chamber coolant loss

Disassemble fuel injection pump and

Fault in fuel injection pump ...... check indication position of fuel
injection pump

266
 Fault Diagnosis

Contact manufacturer of Lonking

267
 Fault Diagnosis

Memo:

268
 Disassembly & Assembly

Chapter Ⅶ
Disassembly & Assembly

269
 Disassembly & Assembly

270
 Disassembly & Assembly

CONTENTS

Chapter Ⅶ 2699
ssembly......................................................................................... 26
Disassembly & Assembly
Assembling Technology Rules..........................................................................................................................275

Pipe Connector Torque Parameter.....................................................................................................................284

Fastening Torque of Hydraulic Pipeline............................................................................................................293

Technical Specification of Fastening Torque....................................................................................................294

Disassembling Diagram of Engine Ⅰ..............................................................................................................296

Disassembling Diagram of Engine Ⅱ..............................................................................................................298

Turbocharged Engine........................................................................................................................................ 300

Maintenance Tools............................................................................................................................................ 301

Disassembly of Engine......................................................................................................................................303

Installation of Engine........................................................................................................................................ 307

Disassembly of Start Motor.............................................................................................................................. 312

Installation of Start Motor.................................................................................................................................313

Disassembly of Front Bracket of Engine..........................................................................................................314

Installation of Front Bracket of Engine............................................................................................................ 314

Disassembly of Rear Bracket of Engine........................................................................................................... 315

Installation of Rear Bracket of Engine............................................................................................................. 315

Disassembly of Oil Injector.............................................................................................................................. 316

Installation of Oil Injector.................................................................................................................................318

Disassembly of Front Oil Seal of Crank........................................................................................................... 320

Installation of Front Oil Seal of Crank............................................................................................................. 323

Disassemble of Rear Oil Seal of Crank............................................................................................................ 325

Installation of Rear Oil Seal of Crank...............................................................................................................326

Disassembly of Cylinder Cover........................................................................................................................ 328

Installation of Cylinder Cover.......................................................................................................................... 329

Disassembly of Radiator................................................................................................................................... 333

271
 Disassembly & Assembly

Installation of Radiator......................................................................................................................................334

Disassembly of Engine Oil Cooler....................................................................................................................335

Installation of Engine Oil Cooler...................................................................................................................... 336

Disassembly of Water Pump............................................................................................................................. 335

Installation of Water Pump................................................................................................................................335

Disassembly of Driving Device of Hydraulic Pump........................................................................................ 338

Installation of Driving Device of Hydraulic Pump...........................................................................................340

Disassembly of Coolant Thermostat.................................................................................................................342

Installation of Coolant Thermostat................................................................................................................... 343

Cleanness/Replacement of Outer Element of Air Cleaner............................................................................... 345

Disassembly of Rocker Arm............................................................................................................................. 347

Installation of Rocker Arm................................................................................................................................348

Disassembly of Travel Motor............................................................................................................................350

Installation of Travel Motor.............................................................................................................................. 350

Split Travel Motor............................................................................................................................................. 351

Disassemble Main Body of Travel Motor.........................................................................................................355

Disassembly of Swing Motor and Swing System............................................................................................. 363

Installation of Swing Motor and Swing System................................................................................................363

Disassembly of Central Swing Connector........................................................................................................ 364

Installation of Central Swing Connector...........................................................................................................364

Disassembly of Work Equipment......................................................................................................................365

Installation of Work Equipment........................................................................................................................ 366

Disassembly of Hydraulic Oil Tank Ass'y........................................................................................................ 367

Installation of Hydraulic Oil Tank Ass'y...........................................................................................................368

Disassembly of Track Shoe...............................................................................................................................369

Installation of Track Shoe................................................................................................................................. 369

Disassembly of Driving Wheel......................................................................................................................... 370

Installation of Driving Wheel............................................................................................................................370

272
 Disassembly & Assembly

Disassembly of Track Roller.............................................................................................................................371

Installation of Track Roller............................................................................................................................... 371

Disassembly of Carrier Roller...........................................................................................................................372

Installation of Carrier Roller............................................................................................................................. 372

Disassembly of Front Idler and Tension Spring................................................................................................373

Installation of Front Idler and Tension Spring.................................................................................................. 374

Disassembly of Swing Circle............................................................................................................................ 375

Installation of Swing Circle...............................................................................................................................376

Disassembly of Platform Ass'y......................................................................................................................... 377

Installation of Platform Ass'y............................................................................................................................ 378

Construction Drawing of Main Valve............................................................................................................... 379

Disassembly of Main Valve.............................................................................................................................. 399

Installation of Main Valve................................................................................................................................. 403

Disassembly of Pilot Valve Pipe....................................................................................................................... 405

Installation of Pilot Valve Pipe..........................................................................................................................412

Disassembly of Pilot Valve............................................................................................................................... 421

Installation of Pilot Valve.................................................................................................................................. 427

Disassembly of Swing Motor............................................................................................................................434

Installation of Swing Motor.............................................................................................................................. 436

Disassembly of Counterweight......................................................................................................................... 438

Installation of Counterweight............................................................................................................................438

273
 Disassembly & Assembly

274
 Disassembly & Assembly

Assembling Technology Rules abrasive surface shall suffer from rust, nick and
damage. Please clean exact fitting surface (or
Scope
wipe up with clean cloth) and daub proper
� The Standard regulate assembling technology lubricating oil (grease) after dry out. Oil hole and
rules of product manufactured by Lonking oil groove of parts shall be clean and smooth
holding company. (inspect smoothness by using compression air).

� Normative quoted documents 4. Parts such as case body, valve body must connect
with each other tightly. Processing hole
The following standards contain provisions,
connecting with internal chamber after assembly
which through reference in this text, constitute
is impermissible. Do not assemble key jointing
provisions of this Standard. For dated references,
surface of case, bridge, pump valve with glove or
subsequent amendments (exclude correction) to
cotton.
or revisions of any of these publications shall not
apply to this Standard. All parties are subject to 5. Please fill proper lubricating oil (grease) at
agreements based on this Standard are lubricating position after assembled parts and
encouraged to investigate the possibility of elements.
applying the most recent editions of the standards
6. Please provide important elements and complete
indicated below. For undated references the latest
machine with assembling technology flow card
edition of the publication referred to applies.
and execute assembling sequence strictly
GB/T10095 Cylindrical gears - System of according to assembling technology flow card.
accuracy Please execute according to original technology if
no assembling technology flow card is constituted.
GB/T11365 Accuracy of bevel and hypoid gears
7. Do not set down parts and elements directly.
QJ/LG708 Operating regulation of painting
Please ensure cleanness and avoid damaging
technology
painting film.
QJ/LG716 Surface protection of complete
machine, parts and elements
� Assembling rules for fastening element
QJ/LG719 Operating regulation for painting
1. Do not damage thread of bolt and screw during
technology of exported machine
assembling process.

2. Please contact bolt, head of screw and end face of

� General rules
nut with surface of fastened parts equably without
1. All assembling parts and elements must be inclining or knocking it with hammer. Screw and
provided with qualified inspection mark. bolt shall come out from nut for 1-2 thread after
Assemble purchased part or cooperative parts that fastened. Head of countersunk head screw shall
be provided with qualified certificate only. not higher than end face after fastened.

2. Do not assemble painting elements before dry out 3. Do not fasten screw, nut with improper spanner.
of painting. Please fasten them in opposite angle method one

3. No parts shall suffer from foreign matters of by on. Fastening sequence:

scrap iron, burr, oil dirt, mud, painting, steel balls a) Fasten symmetrical parts symmetrically, shown
etc. before assembly. And no fitting surface and as Figure 1, 2 and 5;

275
 Disassembly & Assembly

b) Fasten bar-type connecting element from mid 7. For thread with sealing and anti-looseness
position, shown as Figure 3; requirement, please clean jointing surface of
thread with acetone, daub thread glue (mainly
c) Please fasten fastening element of double line,
applies to bridge case) of corresponding type onto
impair in crossed method orderly, shown as
connecting segment of thread equably after wiped
Figure 4; QJ/LG722-2007;
up it.
d) Please fasten fastening element of double line,
8. Assembling rules of threaded stud
even in crossed method orderly, shown as Figure
6; a) For assembly of threaded stud, please screw in
terminal with shorter thread into machine body,
e) Fasten fastening element with localizing pin from
after daubed with thread agent. Keep screwing it
position around localizing pin, shown as Figure 6;
until fastened bolt.
f) Please fasten fastening element from mid one in
b) It is general to assemble threaded stud via fasten
crossed method orderly if fastening elements
upper nut after fastened two nuts mutually. Please
arranges irregularly in several lines, shown as
assemble thicker nut in advance if two nuts are
Figure 7.
used.
4. For fastening element of important position (for
c) Mark fastening sign after fastened all thread.
example: bolt of driving shaft, bridge bolt,
circular rim bolt, bolt of outer tube of direction 9. Looseness proof of thread connection
and pressure plate bolt of various pipeline), please
a) Please thrill opening pin into hole on tail of bolt
screw in them for 2-3 thread with hand, initially
and groove of nut after fastened castle nut. Please
assemble them with pneumatic spanner orderly
open end of opening pin and stick it with side face
and fasten for 70%~80% in two times. And then
of nut.
fasten them with required torque orderly by using
torque spanner. Finally, inspect in clockwise or b) After fastened nut, bend and stick single-ear or
anticlockwise direction to prevent missing double-ear clamping washer to side of nut and
assembly or fastening fault. connected element to lock nut.

5. Please fasten fastening element of general c) Thrill mild steel wire into hole of each screw
position (position bearing no torque, for example, head to connect screws in line and make them
case cover) by using pneumatic spanner in two brake mutually. Please mind thrilling direction
times according to order described in Item 4.3. and enwind anti-looseness wire of screw head
firmly in rotating direction of thread.
6. Please select proper pretightening force for
assembly of fastening element. It is necessary to d) Please assemble thicker nut in advance while use
provide fastening torque for important connecting two nuts but not use cohesive material to proof
position in product drawing. For torque looseness.
requirement unmarked in product drawing, please
10. Assembly of conical pin
refer to Sheet A1 of Appendix A (probative). In
case that fastening torque provided in sheet Contact rate shall not be less than 50% while
mismatch production, please appoint production assemble conical pin of 4mm above with hole.
department to feed back information to After assembled conical pin with pin head, please
standardization room in time. sink bigger terminal into corresponding element
for 2-3 threads.

276
 Disassembly & Assembly

11. Fastening torque of screw plug daubed with

sealing glue

Dimension of Pipe Fastening Torque (N·m)

thread
3/8 15±2
3/4 24±4
1/2 23±3
1 45±4

Fig. 1 Fig. 2

Fig. 3

277
 Disassembly & Assembly

Fig. 4

Fig. 5

Fig. 6

Fig. 7

278
 Disassembly & Assembly

� Assembling rules of rolling bearing of chamber into chamber of bearing.

1. Precautions for bearing assembled in temperature 6. Do not fill lubricating grease for bearing of oil
difference method lubrication.

a) Cooling assembly: Assemble after depressed
temperature of bearing to -30℃~-40℃;
b) Hot assembly: Assemble after heated bearing to
100℃~120℃;
c) It is possible to assemble bearing with dust cover
or sealing ring in temperature difference method;
d) Please wear protecting glove while assembling in
temperature difference method to avoid of scald or
frostbite;
e) Please assemble completely without intermission.
7. After assembled, internal ring of bearing must
stick onto shaft shoulder or distance ring, of
which clearance shall not insert a clearance gauge
of 0.05mm.
8. It is necessary to assemble disassembled bearing
onto original position after cleaned it without
confusion or reversal.
9. After assembled, axial clearance of conical roller
bearing shall conform to regulation described in
Sheet 1. Please select bigger value if two bearing
center distance are available.

2. Please press in bearing by using pressure machine Sheet 1

or special tool while assembling bearing in
pressing method. Do not transfer pressure via Internal Internal
rolling element. Please knock seat ring with diameter of β=10°~16° diameter of β=10°~16°
interference by using hammer equably after bearing bearing
matted copper bar or other object causing no Clearance mm
damage to surface of assembling element at
＞10~30 0.04~0.07 ＞80~120 0.12~0.20
middle position, if necessary. Do not knock
bearing directly. ＞30~50 0.05~0.10 ＞120~180 0.20~0.30

3. Please make end face with mark outwards while ＞50~80 0.08~0.15 ＞180~260 0.25~0.35
installing bearing. Note: β Denotes contact angle between bowl and
4. External ring of bearing shall well stick with external ring of bearing.
semicircular hole of bearing seat and bearing 10. Bearing shall slew equably and flexibly after
cover. It is possible to inspect clearance in assembled.
coloring method, or inspect it with a clearance
gauge. Bearing seat shall contact equably in range
of 120° symmetrical to center line, contact with
bearing cover equably in range of 90°
symmetrical to center line, while inspecting in
coloring method. While inspecting with 0.03mm
clearance gauge in range abovementioned,
clearance gauge shall not insert 1/3 width of
external ring of bearing.

5. For bearing of grease lubrication, please fill clean

lubricating grease of which volume is 65%~80%

279
 Disassembly & Assembly

� Assembling rules of sliding bearing. 6. Under normal operating condition, temperature

rise of bearing shall not exceed 50℃ and the
1. Precautions for cooling assembly of sliding
maximal temperature shall not exceed 80℃.
bearing
7. Bearing shall operate flexibly after assembled.
a) Please use special liquid nitrogen cooling tank to
Axial clearance of bearing shall conform to
assemble steel cover in cooling method. Put steel
regulation described in Sheet 4.
cover into cooling tank and fill an amount of
liquid nitrogen. Cooling time shall not be shorter Sheet 4 Axial clearance of bearing
than 20min. please assemble steel cover rapidly
after cooled it; Space between Axial clearance Axial clearance
bearings min. max.
b) No fire in range of 2m from cooling tank;
≤400 0.20 0.40
c) Do not touch liquid nitrogen or cooled parts with
hand directly to avoid of frostbite; >400~630 0.30 0.60

d) Please assemble various steel covers in cooling >630~1 000 0.50 1.0
method synchronously. >1 000~1 600 0.75 1.60
2. Oil groove on liner and bearing shell must be
smooth and glabrous.

3. Please press liner into bearing seat with pressure

machine without incline. Please knock it with
hammer equably after matted soft metal mat,
guide arbor and guide ring at middle position.

4. Contact angle between bearing shell and journal

shall conform to regulation described in Sheet 2.

Sheet 2 Contact angle between bearing shell and

journal

Rotate speed of
≤500 >500
shaft r/min

Contact angle 70°~100° 60°~80°

5. Contact spot between bearing shell and journal

shall conform to regulation described in Sheet 3.

Sheet 3 Contact spot between bearing shell and journal

Rotate speed of
≤100 >100~500 >500~1 000
shaft r/min

Contact spot in
zone of 25mm 3~4 5~7 8~10
×25 mm (piece)

280
 Disassembly & Assembly

� Assembling rules of sprocket and chain

1. Do not move assembled sprocket in axial

direction.

2. Geometric center plane of tooth width of

active/passive sprocket shall be concurrent, of
which deflection shall not be higher than 2/1 000
of center distance of two sprockets, refer to
following figure.

3. Please clean sprocket and chain before 2. During assembly of flat key, please make key
assembling them. It is unnecessary to clean contact with two faces of shaft groove equably
purchased chain if the package is in good without generating clearance on fitting surface or
condition and lubricating oil is not hardened and upwarping on two terminals.
dirty. Please assemble it immediately after
3. Contact ratio of operating surface of gib-headed
unpacked it.
key and taper key shall be higher than 70% after
4. Operating edge of sprocket and chain must be assembled. And the rest section shall not fasten on
tightened during meshing process. Sprocket and one segment. Exposed dimension shall be
chain shall mesh smoothly during operating 10%~15% of incline length (exposed dimension
process. of gib-headed key exclude gib head).

5. Sagging volume of inoperative edge of chain 4. Clearance fitting spline and guide key shall slide
shall be in 1%~5% of center distance of two freely without local locking or unequal tightness
sprockets. Droop shall be smaller than 0.2% of after assembled.
center distance while placing chain vertically.
� Assembling rules of gear, gear box and driving
6. It is possible to connect chain with riveting pin if
bridge.
no special connecting ring is provided. Please
mark riveting pin on ring surface of end terminal. 1. Please heat gear with oil of 250℃ above while
assembling gear in heating method.
� Assembling rules of key
2. Axial dislocation allowance of meshing gear of
1. Do not knock key with hammer directly. Please
gear box is 4% of gear width, but not bigger than
mat soft metal mat or parking block that causing
2mm.
damage to surface at middle position of the key.

281

3. Contact spot and side clearance of gear tooth shall
conform to regulation described in GB/T10095
and GB/T11365 after assembled.
4. Test run gear box and driving bridge without load
after assembled them. Please run from low speed
to high speed. Seating time of each transmission
shall not be shorter than 5min and total seating
time shall not be shorter than 30min. Inspect
following items:
a) During gearshift, no gear shall suffer from
locking or inhibition. Transmission mechanism
shall be agile, correct without automatic ungeared
or trip stop;
b) No gear shall send out abnormal noise during
operating process;
c) No jointing position of gearbox, output shaft, pipe
connector or screw plug shall suffer from oil
leakage;
d) No jointing position shall be loosened;
e) No gear shall suffer from impact or lagging after
jointed clutch. Clutch shall not suffer from towing
condition. Transmission control valve shall be
agile and correct;
f) Idling loss, operating oil pressure of each gear
shall conform to requirement of test criterion.
5. During loading test, temperature rise of gear box
shall not be higher than 50℃ and maximal
temperature shall not be higher than 90℃.
6. Please discharge oil and clean completely after
finished test.
� Assembling rules of electric system
1. Switches, relays and other elements of electric
system shall be sensitive, reliable and easy to be
operated and repaired.
2. Electric wire, cable shall be connected correctly.
282
Disassembly & Assembly
The connection shall be firm and reliable without
crevasse or chap etc.
3. Do not weld lead with acidic flux. Existence of
cold joint at welding connector is impermissible.
4. Please lay out wire in harness and arrangement of
wire shall be goodly. Please mark stub with a tab
and protect position of lead that may be damaged
mechanically with sleeve. No lead in sleeve shall
have connector.
5. Please fix winding hasp or hasp of 800mm above
with pipe clamp or weld it onto bracket.
� Assembly of sealing element and application of
sealant
1. Please saturate sealing elements such as sealing
ring, felt gasket, asbestos cord and leather bucket
etc. with oil before assembling them.
2. Inspect if oil seal and sealing ring are damaged
before assembling them, or daub lubricating oil
(grease) on lip of oil seal and surface of sealing
ring if necessary. Please inspect oil seal of
framework before assembling it:
a) If lip of oil seal is damaged;
b) Roughness Ra of chamfer angle and fitting
surface of matching parts shall be 1.6 above
without fin or burr.
3. Do not assemble oil seal and sealing ring while
wearing cotton glove. Please prevent oil seal and
sealing ring from damage while passing key bed,
screw hole or stair. Please assemble oil seal by
knocking it with special tools lightly. Do not
knock oil seal directly.
4. Please clean element with gasoline and dry it out
before using sealant.
 Disassembly & Assembly

� Assembling rules of hydraulic system element

1. Hydraulic hose and steel tube

a) Please clean inner wall of pipes before

assembling them. It is possible to assemble pipe
adopted acid cleaning only after performed
neutralizing treatment and dried it out. Do not use
cotton or glove during assembling process.

b) No pipe shall suffer from default of rust, dent,

cockle, bruise or cracking etc. Winding position
shall be smooth and no hose shall suffer from
distortion.

c) Connecting position of pipeline and sealing

element shall be provided with excellent sealing
performance under operating pressure, and no
fixing interface and moving interface shall suffer
from oil leakage or oil impregnate.

d) Please perform surface protection according to

requirement of QJ/LG716 after assembled hose
and steel tube.

2. Hydraulic cylinder

a) It is necessary to clean elements of hydraulic

cylinder strictly before assembling them. Please
install protecting cover for oil port in time after
pressure test.

b) Do not damage operating surface of piston rod,

cylinder, valve rod and valve hole of various
valves while assembling them.

c) Please perform surface protection with piston rod

and processing surface of assembled hydraulic
cylinder according to requirement described in
QJ/LG716.

d) No port of piston rod and control valve rod of

hydraulic cylinder shall suffer from oil leakage or
oil impregnate.

283
 Disassembly & Assembly

Pipe Connector Torque Parameter

Model parameter of AMC adapter (Sheet I)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Torque Opening
Type Remark
of F end of E end value N•m of spanner

1 G3/8 (O-ring) G1/4(30º) Single pipe with sealing ring 49±4.9 22

2 G1/4 (O-Ring) G1/4(30º) Single pipe with sealing ring 29.4±2.9 19

3 G1/4 (O-ring) G3/8(30º) Single pipe with sealing ring 29.4±2.9 22

4 G3/8 (O-ring) G3/8(30º) Single pipe with sealing ring 49±4.9 22

5 G3/8 (O-ring /30º) G3/8(30º) Single pipe with sealing ring 49±4.9 22

6 G3/8 (O-ring) G1/2(30º) Single pipe with sealing ring 49±4.9 27

7 G1/2 (O-ring) G1/2(30º) Single pipe with sealing ring 98±9.8 27

8 G1 (O-ring) G3/4(30º) Single pipe with sealing ring 215.7±19.6 41

9 G1”1/4 (O-ring + G3/4(30º) Single pipe with sealing ring 350±35 50

retainer) and retainer

10 G3/4 (O-ring) G3/4(30º) Single pipe with sealing ring 147±19.6 36

11 G3/4 (O-ring + G1(30º) Single pipe with sealing ring 210±21 41

retainer) and retainer

12 G1 (O-ring) G1(30º) Single pipe with sealing ring 215.7±19.6 41

13 M14x1.5 (O-ring + G1/4(30º) Single pipe with sealing ring 19

retainer) and retainer

14 M14x1.5 (O-ring) G1/4(30º) Single pipe with sealing ring 32±32 19

15 M14x1.5 (O-ring) G3/8(30º) Single pipe with sealing ring 22

16 M18x1.5 (O-ring + G1/2(30º) Single pipe with sealing ring 27

retainer) and retainer

17 G3/4 (O-ring) 1”7/16 Single pipe with sealing ring 147±19.6 38

18 G1/4 (30º+attaching G1/4(30º) Elbow with attaching nut 29.4±2.9 19

nut)

284
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet II)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Torque Opening
Type Remark
of F end of E end value N•m of spanner

19 G3/8 (30º+ attaching G3/8(30º) Elbow with attaching nut 49±4.9 22

nut)

20 G1/2 (30º+ attaching G1/2(30º) Elbow with attaching nut 58.8±4.9 27

nut)

21 G3/4 (30º+ attaching G3/4(30º) Elbow with attaching nut 117.7±11.7 36

nut)

22 G1 (30º+ attaching G1(30º) Elbow with attaching nut 137.7±13.7 41

nut)

23 G3/8 (30º+ attaching G1/4(O-ring + Single pipe with attaching nut 49±4.9 22/19
nut) retainer)

24 G1/2 (30º+ attaching G1/4(30º) Single pipe with attaching nut 58.8±4.9 27/22
nut)

25 G1/4 (30º+ attaching G1/4 (O-ring + Single pipe with attaching nut 29.4±2.9 19/19
nut) retainer)

26 G1/2 (30º+ attaching G3/8(30º) Single pipe with attaching nut 58.8±4.9 27/22
nut)

27 G3/4 (30º+attaching G1/2(30º) Single pipe with attaching nut 117.7±11.7 36/30
nut)

28 1”7/16 (+nut) 1”7/16 Elbow with attaching nut 41.28

29 G1/4 (30º+attaching G1/4(30º+attaching Single pipe with attaching nut 29.4±2.9 19

nut) nut)

30 G1/4 (O-ring + G1/4 (inner) Single pipe with sealing ring 33±3.3 19
retainer) and retainer

31 G1/4 (O-ring) G1/4 (inner) Single pipe with sealing ring 29.4±2.9 19

32 G3/8 (30º) G1/4 (inner) Single pipe 22

33 G3/8 (O-ring) G1/4 (inner) Single pipe with sealing ring 49±4.9 22

34 G1/2 (30º+nut) G1/2(30º) Elbow with nut 27/25

35 G1/4 (30º+nut) G1/4(30º) Single pipe with nut 19/19

36 G3/8 (30º+nut) G3/8(30º) Single pipe with nut 22/22

37 G1/2 (30º+nut) G1/2(30º) Single pipe with nut 27

285
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet III)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Type Torque Opening Remark
of F end of E end value N•m of spanner
38 G1/2 (30º+ attaching / Single pipe with attaching nut 58.8±4.9 27/22
nut)

39 G1/4 (30º+ attaching 2-G1/4(30º) Three-way pipe with attaching 29.4±2.9 19

nut) nut

40 G3/8 (30º+ attaching 2-G3/8(30º) Three-way pipe with attaching 49±4.9 22

nut) nut

41 G1/2 (30º+ attaching 2-G1/2(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

42 G3/4 (30º+ attaching 2-G3/4(30º) Three-way pipe with attaching 117.7±11.7 36

nut) nut

43 G1 (30º+ attaching 2-G1(30º) Three-way pipe with attaching 137.7±13.7 41

nut) nut

44 G3/8 (30º+ attaching G3/8(30º)-G1/4(30º) Three-way pipe with attaching 49±4.9 22

nut) nut

45 G1/2 (30º+ attaching G1/2(30º)-G1/4(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

46 G1/2 (30º+ attaching G3/4(30º)-G3/4(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

47 G3/4 (30º+ attaching 2-G1/4(30º) Three-way pipe with attaching 117.7±11.7 36

nut) nut

48 G1/4 (30º+ attaching G1/4(30º)-G1/4(30º) Three-way pipe with attaching 29.4±2.9 19

nut) nut

49 G3/8 (30º+ attaching G3/8(30º)-G3/8(30º) Three-way pipe with attaching 49±4.9 22

nut) nut

50 G1/2 (30º+ attaching G1/2(30º)-G1/2(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

51 G3/4 (30º+ attaching G3/4(30º)-G3/4(30º) Three-way pipe with attaching 117.7±11.7 36

nut) nut

52 M12x1.5 (O-groove) G1/4 (inner) Single pipe 19

53 M14x1.5 (O groove) G1/4 (inner) Single pipe 19

54 G1/4 (30º+ attaching G1/4(30º)-G1/4 Three-way pipe with attaching 29.4±2.9 19

nut) (inner) nut
G1/4 (30º+attaching G1/4 (inner) - Three-way pipe with attaching 29.4±2.9 19
nut) G1/4(30º) nut

55 G3/8 (30º+attaching G3/8(30º)-G1/4 Three-way pipe with attaching 49±4.9 22

nut) (inner) nut

286
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet IV)

Connector Type Torque Requirement

S.N.
Specification of F Specification of E Torque Opening
Type Remark
end thread end thread value N•m of spanner

56 G1/2 (30º+attaching G1/2(30º)-G1/4 Three-way pipe with attaching 58.8±4.9 27

nut) (inner) nut

57 G3/4 (30º+attaching G3/4(30º)-G1/4 Three-way pipe with attaching 117.7±11.7 36

nut) (inner) nut

58 G1/4 (30º+attaching G1/4 (inner) 29.4±2.9 19

Elbow with attaching nut
nut)

59 G1/4 (O-ring + G1/4 (30º) Single pipe with sealing ring 33±3.3 19
retainer) and retainer

60 G1/4 (O-ring + G3/8 (30º) Single pipe with sealing ring 33±3.3 22
retainer) and retainer

61 G1/2 (O-ring + G1/2 (30º) Single pipe with sealing ring 95±9.5 27
retainer) and retainer

62 G3/4 (O-ring + G3/4 (30º) Single pipe with sealing ring 210±21 36
retainer) and retainer

63 G3/8 (30º) G3/8 (30º) Single pipe (Ф0.8) 22

64 M33x2 (O-ring + G1 (30º) Single pipe with sealing ring 41

retainer) and retainer

65 G3/8 (30º) G1/4 (30º) Single pipe (Ф0.7) 22

66 G1 (O-ring) G1 (30º) Single pipe with sealing ring 215.7±19.6 41

67 M24x1.5 (O-ring) G3/4 (30º) Single pipe with sealing ring 32

68 M33x1.5 (O-ring) 1”7/16 Single pipe with sealing ring 41

69 M33x1.5 (O-ring) 1”7/16 Single pipe with sealing ring 41

70 G1 (O-ring) 1”7/16 Single pipe with sealing ring 215.7±19.6 41

71 G1/2 (O-ring) G1/4 (inner) Single pipe with sealing ring 98±9.8 27

73 G3/8 (30º+attaching G3/8(30º)-G3/8(30º) Three-way pipe with attaching 49±4.9 22

nut) nut

74 G1/2 (30º+attaching G1/2(30º)-G1/2(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

75 G1/2 (30º+attaching G1/4(30º)-G1/2(30º) Three-way pipe with attaching 58.8±4.9 27

nut) nut

287
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet IV)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Type Torque Opening Remark
of F end of E end value N•m of spanner
76 G1/2 (O-ring) G1/4(30º) Single pipe with sealing ring 98±9.8 19

77 G1/4 (O-ring) G1/4(30º) Single pipe with sealing ring 29.4±2.9 19

78 G3/8 (O-ring) G3/8(30º) Single pipe with sealing ring 49±4.9 22

79 G1 (30º+attaching Three-way pipe with attaching 137.7±13.7 41

G1(30º)-G1(30º)
nut) nut

80 G1/4 (O-ring + Three-way pipe with sealing 33±3.3 19

G1/4(90º)-G1/4(30º)
retainer) ring and retainer

81 G3/4 (30º+attaching Three-way pipe with attaching 117.7±11.7 36

G1/2(30º)-G3/4(30º)
nut) nut

82 G3/4 (30º+attaching Three-way pipe with attaching 117.7±11.7 36

G3/4(30º)-G1/2(30º)
nut) nut

83 1”3/16 (+nut) 1”3/16 Elbow with attaching nut 121.6±4.9 34.9

84 G3/8 (O-ring) G3/8(30º) Single pipe with sealing ring 49±4.9 22

85 G1” (30º+attaching Three-way pipe with attaching 137.7±13.7 41

G1”-G1/4(90º)
nut) nut

15 M14x1.5 (O-ring) G3/8(30º) Single pipe with sealing ring 32±3.2 22

87 1”7/16 (+nut) Single pipe with attaching nut 161.8±9.8 41

88 G1” (O-ring) 1”7/16 (+nut) Single pipe with sealing ring 215.7±19.6 40

89 G3/8 (30º+attaching Three-way pipe with attaching 49±4.9 22

G3/8(30º)-G1/4(30º)
nut) nut

90 G3/4 (O-ring) G3/8(30º) Single pipe with sealing ring 147±14.7 24

91 G3/4 (O-ring + End plug with sealing ring and 210±21 36

retainer) retainer

92 G1/2 (O-ring) End plug with sealing ring 98±9.8 27

93 G1/2 (O-ring + End plug with sealing ring and 95±9.5 27

retainer) retainer

94 G3/4 (O-ring + Single pipe with sealing ring 60±6 22

G3/8(30º)
retainer) and retainer

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 Disassembly & Assembly

Model parameter of AMC adapter (Sheet V)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Torque Opening
Type Remark
of F end of E end value N•m of spanner

95 G1/2 (O-ring) G1/2 (30º) Single pipe with sealing ring 98±9.8 27

96 G3/8 (O-ring) G3/8(30º) Single pipe with sealing ring 49±4.9 22

97 G3/8 (O-ring) G3/8(30º) Single pipe with sealing ring 49±4.9 22

98 M16×1.5 G3/8(30º)

99 G1/2 (30º+attaching Three-way pipe with attaching 58.8±4.9 27

G3/8(30º)-G1/2(30º)
nut) nut

100 G3/4 (O-ring) End plug with sealing ring 147±14.7 36

101 G1/4 (O-ring + Single pipe with sealing ring 33±3.3 22

G3/8(30º)
retainer) and retainer

102 G1” (O-ring + End plug with sealing ring and 330±33 43
retainer) retainer

103 G3/8 (O-ring) End plug with sealing ring 49±4.9 22

104 G1/4 (O-ring + 33±3.3 19

End plug with sealing ring
retainer)

105 G1” (O-ring + Single pipe with sealing ring 330±33 43

1”7/16 (30º)
retainer) and retainer

106 G1/4 (O-ring + Single pipe with sealing ring 33±3.3 22

G3/8 (inner)
retainer) and retainer

107 G1 (O-ring) End plug with sealing ring 215.7±19.6 41

108 G3/8 (O-ring) End plug with sealing ring 49±4.9 22

109 G1/4 (O-ring) End plug with sealing ring 29.4±2.9 19

110 1"3/16 (attaching nut) Three-way pipe with attaching 121.6±4.9 34.9
2-1"3/16
nut

111 G1" (30º+attaching Three-way pipe with attaching 137.7±13.7 41

G1”(30º)-G1/4(30º)
nut) nut

112 G3/4 (30º+attaching

Single pipe with attaching nut 117.7±11.7 36
nut)

113 G3/4(30º+attaching 147±14.7 32

G3/4 (O-ring) Single pipe with sealing ring
nut)

289
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet VI)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Type Torque Opening Remark
of F end of E end value N•m of spanner

114 G1/2 (O-ring) G1/2 (30º+attaching Single pipe with sealing ring 98±9.8 27
nut)
115 G1/2 (O-ring) G3/4 (30º+attaching Single pipe with sealing ring 98±9.8 27
nut)
116 1" (attaching nut) 1" Elbow with attaching nut 137.7±13.7 28.58

117 1" (O-ring) 1"7/16 Single pipe with sealing ring 330±33 41

118 G3/4 (O-ring) 1”7/16 Single pipe with sealing ring 147±14.7 38

119 G3/4 (O-ring) 1”7/16 Single pipe with sealing ring 147±14.7 38

120 G3/4 (O-ring) 1”3/16 Single pipe with sealing ring 147±14.7 32

121 G3/4 (O-ring) 1”3/16 Single pipe with sealing ring 147±14.7 36

122 G3/4 (O-ring) 1” Single pipe with sealing ring 147±14.7 32

123 G3/4 (O-ring) 1” Single pipe with sealing ring 147±14.7 36

124 G3/4 (O-ring) 1” Single pipe with sealing ring 147±14.7 36

125 G3/4 (O-ring) 1” Single pipe with sealing ring 147±14.7 36

126 G3/4 (O-ring) 1” Single pipe with sealing ring 147±14.7 36

127 G1/2 (O-ring) 1” Single pipe with sealing ring 98±9.8 27

128 1”1/16 (O-ring) G3/4 Single pipe with sealing ring 32

129 1”1/16 (O-ring) G1/2 Single pipe with sealing ring 36

130 7/8 (O-ring) G1/2 Single pipe with sealing ring 27

131 7/16 (O-ring) G3/8 Single pipe with sealing ring 22

132 9/16 (O-ring) G3/8 Single pipe with sealing ring 22

290
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet VII)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Type Torque Opening Remark
of F end of E end value N•m of spanner
133 9/16 (O-ring) G1/4 Single pipe with sealing ring 19

134 7/16 (O-ring) G1/4 Single pipe with sealing ring 19

135 M12×1.5 G1/2 Single pipe with sealing ring 27

136 M18×1.5 G3/8 Single pipe with sealing ring 24

137 M14×1.5 G1/4 Single pipe with sealing ring 19

138 M27×2.0 G1/2 Single pipe with sealing ring 32

139 M22×1.5 G1/2 Single pipe with sealing ring 27

140 M12×1.5 G1/4 Single pipe with sealing ring 19

141 G1/2 (O-ring) G3/4 Single pipe with sealing ring 98±9.8 32

142 G3/4 (O-ring) G1” Single pipe with sealing ring 147±14.7 41

143 G3/8 (O-ring + Single pipe with sealing ring 60±6 22

G3/8
retainer) and retainer

144 G1/4 (O-ring) G1/4 Single pipe with sealing ring 29.4±2.9 19

145 G1" (O-ring) G1"1/4 (O-ring) Single pipe with sealing ring 215.7±19.6 50

146 G1" (O-ring) G1" (O-ring) Single pipe with sealing ring 215.7±19.6 41

147 G1" (O-ring) G1" (O-ring) Single pipe with sealing ring 215.7±19.6 41

148 G1" (O-ring) G1" (30º) Single pipe with sealing ring 215.7±19.6 41

149 G1"1/4 (O-ring) G1" (O-ring) Single pipe with sealing ring 294.2±29.4 50

150 G1" (O-ring) G1"1/4 (30º) Single pipe with sealing ring 215.7±19.6 41

151 G3/4 (O-ring) G3/4 (30º) Single pipe with sealing ring 147±14.7 32

291
 Disassembly & Assembly

Model parameter of AMC adapter (Sheet VIII)

Connector Type Torque Requirement

S.N.
Thread specification Thread specification Torque Opening
Type Remark
of F end of E end value N•m of spanner

152 G1" (O-ring) G3/4 (30º) Single pipe with sealing ring 215.7±19.6 41

153 G1/2 (O-ring) G1/2 (30º) Single pipe with sealing ring 98±9.8 27

154 G1/2 (O-ring) G1/2 (O-ring) Single pipe with sealing ring 98±9.8 27

155 G1/2 (O-ring) G1/2 (30º) Single pipe with sealing ring 98±9.8 27

156 G3/4 (O-ring) G1/2 (30º) Single pipe with sealing ring 147±14.7 32

157 G3/8 (O-ring) G1/2 (30º) Single pipe with sealing ring 49±4.9 27

158 G3/4 (O-ring) G3/8 (30º) Single pipe with sealing ring 147±14.7 32

159 G1/2 (O-ring) G3/8 (30º) Single pipe with sealing ring 98±9.8 27

160 G1/2 (O-ring) G3/8 (30º) Single pipe with sealing ring 98±9.8 27

161 G1/4 (O-ring) G3/8 (30º) Single pipe with sealing ring 29.4±2.9 22

162 G1/4 (O-ring) G1/4 (30º) Single pipe with sealing ring 29.4±2.9 19

163 G3/8 (O-ring) G1/4 (30º) Single pipe with sealing ring 49±4.9 22

292
 Disassembly & Assembly

Fastening Torque of Hydraulic Pipeline

Internal diameter of
hose (1/16 inch) 04 06 08 12 16 20
Model

PF thread 1/4 3/8 1/2 3/4 1 5/4

Model C
Torque (N•m) 25 34 64 132 196 225

UNF thread / / / / 23/16--12 /

Model Q2
Torque (N•m) / / / / 196 /

Opening 19 22 27 36 41 50
Torque
spanner
Model of spanner SPN67X19 SPN67X22 SPN120X27 SPN220X36 SPN310X41 SPN560X50

293
 Disassembly & Assembly

Technical Specification of Fastening Torque

Standard fastening torque for universal metric fastening element:

(Unit: Nm)

Metric nut and bolt

Thread dimension Standard fastening torque Thread dimension Standard fastening torque

M6 12±3 M14 160±30

M8 28±7 M16 240±40

M10 55±10 M20 460±60

M12 100±20 M30 1600±200

Fastening torque for bolt of major elements

(Unit: Nm)

Bolt dimension Recommended fastening torque

M16 Travel motor fixing bolt 252±40

M16 driving wheel fixing bolt 252±40

M18 track roller fixing bolt 415±35

M22 Swing bearing fixing bolt 800±70

M20 swing mechanism fixing bolt (optional) 570±60

M20 swing mechanism fixing bolt 570±60

M24 return roller fixing bolt 710±60

M30 Counterweight fixing bolt 1600±200

294
 Disassembly & Assembly

Fastening torque for pipe connector and bolt of air condition system:

(Unit: Nm)

Fastening torque for rotating nut of refrigerant pipe

Important: Daub oil onto O-ring and fasten with two spanner, hereinto, one spanner is torque spanner.

Position Fastening torque

Φ8 pipe 12-15
D5/8 pipe 30-35
D1/2 pipe 20-25
Fastening torque for bolt of flange connector of refrigerant pipe
Compressor 8.0-12
Reservoir 4.0-7.0
Fixing bolt of compressor
M8 bolt (screw), Level 8.8 24.5-29.4

Note Lubricating o-ring while installation of bolt. Fastening with two types of spanner, one of them is torque
spanner.

Technical specification of oil materials (Model CDM6215/CDM6225)

Filling volume and oil designation of various positions are shown as below:

Oiling position Capability Filling volume Designation

Swing reduction box 3.14L 3.14L SAE#140 (GL-4) gear oil
Traveling reduction box --- 2×5L SAE#140 (GL-4) gear oil
Hydraulic oil tank 280L 188L N46 or N68 wear resistant hydraulic oil
Engine oil 18L 16L Class CH supercharged Diesel Engine Oil
According to
Lubricating points --- 2# extreme pressure lithium lubricating grease
requirement
Lubricating grease of gear ring --- 15kg 2# extreme pressure lithium lubricating grease
Fuel tank 380L 340L 0# or10# diesel (summer) -10# diesel (winter)
Cooling system 20L 20L Lonking long life coolant
Coolant tank 3L 1.5L Lonking long life coolant
Refrigerant of air condition 1kg 0.85kg R134a

Application of improper coolant of cooling system may corrupt engine, engine radiator, air condition radiator and
cause damage of parts and elements of engine, radiator and air condition, or leakage of coolant.

295
 Disassembly & Assembly

Disassembling Diagram of Engine Ⅰ

296
 Disassembly & Assembly

1 Bolt M16×195 24 Radiator

2 plate 25 Water Outlet hose of engine
3 Right rear bracket 26 Diesel engine
4 Bolt M12×35 27 Block, Fan
5 Rear shock pad of engine 28 Plate, fan
6 stop plate 29 Fan
7 hose, intercooler Ф63.5×150×60×40 30 Bolt M10×110
8 Clamp 70-78 31 External filter element of air cleaner
9 Stainless steel air outlet pipe, intercooler 32 Internal filter element of air cleaner
10 Washer 16 33 Front shock pad of engine
11 Nut M16 34 Washer M10
12 Left front bracket 35 Clamp 50-70
13 Muffler bracket 36 Clamp 40-60
14 Suction pipe Ф102×7 37 Stainless steel air inlet pipe, intercooler
15 Water Inlet hose , engine 38 water separator
16 Air Cleaner 39 mounting plate, water separator
17 Clamp 40 Air Inlet hose
18 Nut M12 41 hose
19 Washer 12 42 Clamp
20 Air cleaner bracket 43 Bolt M8×25
21 Bolt 12×25 44 Washer 8
22 Fuel pipe Ф10/20×3560 45 Clamp 112-120
23 Fuel pipe Ф10/20×2700

297
 Disassembly & Assembly

Disassembling Diagram of Engine Ⅱ

298
 Disassembly & Assembly

1 Water Pipe Φ8×300 19 Muffler

2 Auxiliary Radiator 20 Muffler Clamp
3 Bracket, Auxiliary Radiator 21 Engine Oil Filter
4 Water Pipe Φ8×1500 22 FF9055 Fuel Filter (Small)
5 Bolt M10×25 23 FF9055 Fuel Filter (Big)
6 Washer 10 24 Fuel Pipe Φ10/20×2700
7 Clamp 25 Coupling
8 Bracket 2 26 Conjunctive Plate
9 Bolt M8×25 27 Bolt M10×30
10 Left Rear Bracket 28 Clamp 12-22
11 Fuel Pipe Φ10/20×700 29 Fuel Pipe Φ4.5/10.4×350
12 Right Rear Bracket 30 Spring Clamp Φ10
13 Washer 12 31 Flexible Shaft Bracket
14 Bolt M12×25 32 Three-Way Connector
15 Connecting Pipe 33 Water Pipe Φ19×900
16 Nut M8 34 Bolt M12×40
17 Washer 8 35 Bending Plate
18 Muffler Bracket 36 Straight Connector M10×1

299
 Disassembly & Assembly

Enginee
Turbocharged Engin

1 To Air Intake Port of Turbocharger

2 Air to Intake Manifold
3 Air Intake Manifold
4 Air Intake Valve

300
 Disassembly & Assembly

Maintenance Tools

Name Tool Number Purpose Figure

Used for disassembling

Hoisting device of engine 3162871
and installing engine

Used for installing

Adapter plate of engine
3163625 engine onto
seat
reassembling bracket

Overhaul stand of
engine inclining type:
Reassembling bracket of 3375194 or
engine 3375193 —Portable

—Fixed type

Used for installing

Installing tool of wearing
3824078 wearing liner of rear oil
liner
seal of crank

301
 Disassembly & Assembly

Name Tool number Purpose Figure

Used for disassembling

Stick resistant and assembling
3824879
lubricating agent threaded stud, bolt
rapidly.

Used for
disassembling/assembli
Replacing tool of
3164659 ng front oil seal of crank.
front oil seal
Applies to rear gear
engine only.

Used for drawing out oil

sprayer. Applies to
Drawer of oil
3825156 engine of which oil
sprayer
sprayer is installed on
rocker cover.

Used for drawing out oil

Drawer of oil sprayer. Applies to
3823276
sprayer engine with external oil
sprayer.

302
 Disassembly & Assembly

Disassembly of Engine
1) Please mark sign on position of hose, pipe,
connecting rod, and electric connector while
disassembling them.

� Accumulator may transgress explosive gas. For

avoiding bodily injures, please keep well
ventilation of engine nacelle before repairing
accumulator. For avoiding generation of arc,
please disconnect cable of cathode (-) and always
connect cable of cathode (-) last of all.

� Please wear safety glass, face shield and

protection clothing while using steam cleaner.
Hot steam may cause serious bodily injures.

� Coolant is deleterious. Please treat waste coolant

according to local EP code.

� Do not open pressure cover of radiator if engine

is hot. Please open it while coolant temperature
dropped to 50°C [120°F] below. Or high
temperature coolant or steam may spray and
cause bodily injure.

2) Disconnect cable of accumulator.

� Clean engine with steam.

� Discharge engine coolant.

� Some state and federal government of USA has

confirmed that used engine oil may be
carcinogenic and generate reproductive toxicity.
Always avoid imbibing steam of used engine oil,
ingesting and contacting used engine oil for long
period.

� For reducing possibility of bodily injure, please

avoid contacting hot engine oil directly.

303
 Disassembly & Assembly

3) Discharge engine oil.

4) Disconnect starting motor cable, engine

grounding wire, and hose, pipe, electric wire,
hydraulic pipeline connecting from driver room
or chassis to engine.

5) Disconnect inlet and outlet pipe.

� Disassemble all engine driving accessories

assembled on chassis.

6) Disconnect throttle rod from control rod of

injection pump.

� Disassemble driving device from flywheel.

� In case that liquid cooling system (air condition)

is used, please wear protecting glass, face shield,
and wrap connecting element with cloth before
disassembling it. Liquid coolant may injure eyes
and skin seriously.

� For protecting environment, please empty cooling

system correctly and avoid dissipating coolant
steam into atmosphere by using special device.
Please recycle coolant.

304
 Disassembly & Assembly

7) Disassemble all parts and elements relating to

disassembly of engine.

8) For avoiding bodily injures, hoisting device of

engine shall be able to safely hoist engine and
transmission gear in whole.

Note In general, it is necessary to disassemble

engine and transmission gear in whole if rear
suspension of engine is connected with
transmission gear.

9) Please select crane (tool number: 3822512) with

proper rated hoisting capacity. Please disassemble
engine after installed hoisting tool onto engine
hoisting bracket.

Note Please put one supporting bracket below

transmission gear to prevent it from falling
if fails to disassemble transmission gear.

10) Please install connecting plate of engine seat (tool

number: 3163625) onto exhausting side of engine
before repairing engine.

Note Please install connecting plate of engine seat

after disassembled turbocharger, if provided.

305
 Disassembly & Assembly

11) Please install connecting plate of engine seat onto

moveable inclining engine reconstruction bracket
(tool number: 3375194 or 3375193).

Note Please install engine onto proper transporting

desk before replacing engine.

12) Close all openings of engine to avoid falling of

dirt and scraping. Please put engine onto proper
engine supporting desk.

13) Please disassemble all residual accessories,

brackets and driving devices used for engine
before replacing it.

306
 Disassembly & Assembly

Inst allation of Engine

Installation
1) Please disassemble all accessories and bracket
from engine while assembling/disassembling
engine.

Note For elements provided for engine, please refer

to corresponding steps described in the Manual.

For avoiding bodily injures, hoisting device of

engine shall be able to safely hoist engine and
transmission gear in whole. Please realize weight
of transmission gear via technical criterion of
equipment manufacturer.

NoteIn general, it is necessary to disassemble

Note
engine and transmission gear in whole if rear
suspension of engine is connected with
transmission gear.

2) Please select crane and hoisting tool with proper

rated hoisting capacity. Please assemble engine
after connected hoisting tool onto ear of engine.

� Please hoist engine and connecting plate of

engine bracket from engine reconstitution bracket
before repairing engine. Disassemble connecting
plate of engine bracket.

Note It is possible to install turbocharger after

disassembled connecting plate of engine
bracket.

� Hoist engine from transporting desk before

replacing engine.

307
 Disassembly & Assembly

3) Disassemble all covers that may masked opening

during disassembling process.

4) Align engine on chassis, fasten installing bolt of

engine. Please refer to torque technical criterion
provided by equipment manufacturer.

� Connect all disassembled accessories installed on

engine and chassis.

Note For preventing from damage, please ensure

all pipeline, hose are disposed and fastened
correctly. Ensure that inlet pipe and outlet
pipe are connected tightly without leakage.

Installation of Throttle Control Rod

1) Install and adjust throttle connecting rod

connecting to control rod of injection pump.

2) Adjust length between mechanical stopping rod

and adjusting ling/connecting rod to achieve
running speed of whole course.

308
 Disassembly & Assembly

3) Fully fill engine with clean, appointed engine oil.

NoteTotal capacity of engine coolant is variable.

Note
Please confirm capacity of whole cooling
system according to instruction of original
equipment manufacturer.

4) Fill new coolant into cooling system.

Installing radiator cover at this time is

significant for exhausting air in cooling system.
Incorrectly exhausting air in cooling system
may damage engine because of overheating
temperature.

5) Inspect completely to ensure that all hoses, leads,

connecting rods and elements are assembled
correctly and fastened.

6) It is possible to avoid starting engine during

supercharging process of main lubricating oil duct
via disassembling lead of fuel solenoid valve or
disconnecting fuel dump valve to cut off fuel.

309
 Disassembly & Assembly

Accumulator may transgress explosive gas. For

avoiding bodily injures, please keep well
ventilation of engine nacelle before repairing
accumulator. For avoiding generation of arc,
please disconnect cable of cathode (-) and always
connect cable of cathode (-) last of all

Do not mesh starting motor for 30 seconds above.

For cooling starting motor, meshing interval of
starting motor shall be 2 minutes. Rotate engine
by using motor until pressure displayed on engine
oil pressure gauge becomes positive value.

7) Connect lead on fuel solenoid valve after

monitored pressure.

8) Operate plunger of oil transfer pump to fill fuel to

low-pressure fuel system.

� Screw discharging screw and operate plunger

until no air containing in fuel flows out from
discharging screw, if equipped.

� Fasten exhaust screw.

Torque: 9 N•m [80 in-lb]

310
 Disassembly & Assembly

� Do not disassemble radiator cover from hot

engine. Do not take down pressure cover until
temperature of coolant dropped to 50℃ [122°F].
High-temperature coolant or steam may cause
bodily injures.

� Run engine in low idling for 2-3 minutes.

� Shut down engine and wait for 5-7 minutes until

engine oil flowed to crankcase oil tray, and then,
re-inspect oil level of engine oil and liquid level
of coolant.

Note Fill engine oil or coolant of proper volume

into engine, if necessary.

9) Run engine in speed of 1000 - 1200 rpm for 8-10

minute to inspect if operation is normal, or if
abnormal noise, leakage of coolant, fuel or engine
oil are existent.

Note Repair all elements suffers from leakage or

fault. Please refer to corresponding step.

311
 Disassembly & Assembly

Disassembly of Start Motor

Disassemble cable from negative (-) terminal of

accumulator.

1) Open engine cover.

2) Disconnect lead between engine and starting

motor.

3) Disassemble three bolts and starting motor.

Note In case that a cage ring is equipped for

starting motor, please disassemble cage ring,
clean surface of starting motor, cage ring and
flywheel casing with steel brush.

4) Measure distance between front terminal face of

flywheel ring gear and installing flange of starting
motor by using inside micrometer or slide calipers.

Note Measure also includes all packing blocks

disassembled in advance.

Interval of start motor

mm in

49.28 Min. 1.94

52.32 Max. 2.06

Note Please increase or reduce packing block until

achieved correct starting motor interval if
necessary.

312
 Disassembly & Assembly

Installation of Start Motor

1) For engine equipped with wet-type flywheel
casing, please daub sealing glue of 1.5-2.0mm
[0.06-0.09 in] onto starting motor installing
flange of flywheel casing.

Note In case that a cage ring is necessary, please

daub sealing glue onto side of cage ring
contacting with starting motor.

2) Install three bolts, starting motor and packing

block of starting motor (if applicable).

Torque value: 43 N•m [32 ft-lb]

313
 Disassembly & Assembly

Disassembly of Front Bracket of

Engine
Disassemble four installing bolt and front bracket of
engine.

Installation of Front Bracket of

Engine
Install front bracket and installing bolt.

Torque value: 68 N•m [50 ft-lb]

314
 Disassembly & Assembly

Disassembly of Rear Bracket of

Engine
Disassemble four bolts and rear bracket.

Installation of Rear Bracket of Engine

Install hoisting bracket and bolt.

Torque value: 71 N•m [52 ft-lb]

315
 Disassembly & Assembly

Disassembly of Oil Injector

� Please keep to application advice of manufacturer

while cleaning with solvent, acidic material or
basic material. Please wear protecting glass and
protecting cloth to prevent from bodily injures.

� Some solvent is flammable and venomous, please

read instrument of manufacturer carefully before
your application.

Oil sprayer shall rotate in oil sprayer hole if the

nut is rusty and loosened. Opening of the hole
may damage cylinder cover besides localizing
ball of oil sprayer seriously. Please dip pressing
nut in rustproof solvent for 3 minutes above.

Disassemble cable at negative (-) terminal of

accumulator.

1) Open engine cover upwards.

2) Disconnect corresponding pipeline.

3) Knock oil sprayer with forcer to loosen all rust.

4) Loosen pressing nut with 24mm sleeve spanner

and fix oil sprayer with adjustable spanner
synchronously.

5) Disassemble oil sprayer by using drawer of oil

sprayer (tool number 3823276). The drawer is
used for disassembling oil sprayer simply.

316
 Disassembly & Assembly

6) In general, it is necessary to knock oil sprayer

with drawer and move it upwards and downwards
to disassemble oil sprayer.

7) Disassemble pressing clip bolt of oil sprayer.

Incline pressing clip upwards and slide them out.

8) Disassemble oil sprayer from cylinder cover by

using oil sprayer drawer (tool number 3825156).

317
 Disassembly & Assembly

Installation of Oil Injector

1) Assemble oil injector and new copper sealing
washer. (Use one copper washer only)

Assembling skill: it is possible to maintain

position of washer during installing process easily
via daubing a layer of clean engine oil between
washer and oil sprayer.

� Oil sprayer produced before 1991 adopts 9mm

terminal. While oil sprayer produced in 1991 or
after 1991 adopts 7mm terminal, it can’t be used
in the engine.

� It is possible to use 7mm oil sprayer as 9mm oil

sprayer via installing a special adapter liner on the
terminal.

2) Daub a layer of anti-sticking complexing agent on

thread of pressing nut and clearance between top
terminal of nut and oil sprayer (parts number
3824879).

Note Align projecting portion of oil sprayer to gap

in hole.

There is a O-ring on upper side of pressing

nut of current Bosch oil sprayer. Please push
O-ring into groove after fastened oil sprayer.

Torque value: 60 N•m [44 ft-lb]

318
 Disassembly & Assembly

3) Put oil sprayer into cylinder cover in correct

direction.

4) Install pressing clip and fasten it.

Torque value: 10 N•m [89 in-lb]

319
 Disassembly & Assembly

Disassembly of Front Oil Seal of

Crank
Note It is possible to disassemble front crank oil
seal of front gear engine after disassembled
front gear room cover. Please disassemble
front gear room cover according to
following disassembling step.

1) Support front gear room cover onto flat operating

surface by using wood block. Pack out front gear
room cover from used seal by using proper forcer
and hammer from rear side to front side.

Note There is installed with an additional dustproof

sealing element on front side of front crank
oil seal of engine.

2) Disassemble front crank sealing from front gear

room cover by using tools (parts number
3164659).

Item NO. Description Quantity

1 Replacing screw assembly 1

2 Crank sealing erector 1

Inner hexangular bolt, M12

3 2
x 1.25 x 60 mm

Metal screw, 10 x 25.4 mm

4 25 (display 6)
[1 in] (L)

Drill head. 3.57 mm [9/64

Unmarked 1
in]

Note It is possible to disassemble and install crank

sealing without disassembling front gear
room.

320
 Disassembly & Assembly

3) Install replacing screw assembly (1) onto front

terminal of crank.

� Install two M12 x 1.25 x 60-mm inner hexangular

bolt (3).

4) Lubricate erector screw with anti-sticking or

proper lubricating grease.

Fix screw of erector and install crank sealing

erector onto erector screw assembly (2). Rotate
crank sealing erector and push it to sealing until
resist it onto front gear room.

Drill hole carefully in vertical direction to reduce

damage possibility of front cover and crank.

Disassembling skill: it is necessary to use

compact right-angled drill because the limit space,
or reduce drill head drilling hole on metal plate.

Note Thickness of flange of crank sealing erector

is 8mm [0.32 in].

5) Mark at position of 18 mm [0.71 in] of drilling

hole with adhesive tape to control drilling depth,
and daub lubricating grease on drill to absorb
metal scraping. Please stop to clear scraping
frequently.

� Drill a hole with depth of 10 mm [0.39 in] after

resisted crank sealing erector onto front gear
room. Ensure that adhesive tape marked with
signal does not departure from original position.

321
 Disassembly & Assembly

6) Install a metal screw (4) on sealing to fix crank

sealing erector completely.

� Drill five hole with depth of 10 mm [0.39 in] and

assemble five metal screws.

Note Please ensure that six metal screws are

provided with thread and drilled through
internal/external seal case. Please fasten
metal screw so that to draw out
internal/external case of seal in whole.

Do not use impact spanner or pneumatic tools to

prevent from damaging tools.

7) Slowly rotate erector screw clockwise until

disassembled seal. Do not exceed torque value.

Torque value: 33 N•m [45 ft-lb]

Note Please stop disassembling operation while

drawing out metal screw from seal or
drawing out internal case only. Rotate
erector screw anticlockwise to reverse
internal case enforcedly. Disassemble metal
screw, localize direction of tools lightly, drill
several new holes and install metal screw
onto new position.

8) Disassemble tools and discard used seal after

finished disassembly.

322
 Disassembly & Assembly

Installation of Front Oil Seal of Crank

1) It is possible to install front crank oil seal of front
gear engine only after disassembled front gear
room cover. Assemble front crank oil seal into
front gear room cover of engine.

2) Assemble oil seal into front gear room cover by

using tool (parts number 3164659).

3) Install erector screw assembly (1) onto front

terminal of crank. Install two M12x1.25x60mm
inner hexangular bolts (3).

Do not use impact spanner or pneumatic tools to

prevent from damaging tools.

4) Put new front crank oil seal on front terminal of

crank and slide it to direction of front gear room
cover with hand as much as possible.

Note Fix four angles of seal with crank.

323
 Disassembly & Assembly

5) Fix erector screw and install crank sealing erector

(2) onto erector screw assembly synchronously.

Note Slowly rotate erector clockwise until insisted

it onto seal.

Do not fasten erector screw assembly excessively

after contacted crank sealing erector with front
cover, to prevent from damaging tools.

6) Fix erector and rotate erector screw anticlockwise

until contacted erector with front gear room cover.

7) Disassemble maintenance tool.

324
 Disassembly & Assembly

Disassemble of Rear Oil Seal of Crank

1) Please disassemble rear crank oil seal after
disassembled flywheel casing. Support flywheel
casing onto flat operating surface by using wood
block. Pack out used oil seal from flywheel
casing by using proper forcer and hammer.

2) It is possible to disassemble rear crank oil seal

only after disassembled bracket of rear crank oil
seal.

� After disassembled bracket of rear crank oil seal,

support bracket onto flat operating surface by
using wood block.

� Pack out used oil seal from bracket by using

proper forcer and hammer.

325
 Disassembly & Assembly

Installation of Rear Oil Seal of Crank

For preventing seal from leakage, please remain

no engine oil on sealing surface of sealing lip/hole.

1) For installing easily, please daub neutral soap on

external neck of sealing case (A).

Note For engine equipped with lip-type rear crank

sealing, the new sealing is provided a sealing
guide tools (B). Please remain the sealing
onto sealing guide tool while installing
sealing onto front side of crank.

Please replace rear crank sealing with new sealing

of same type.

2) Put new rear crank sealing (please use sealing

guide tool if necessary) onto front terminal of
crank and slide it to flywheel casing with hand.

Note Fix four angles of sealing with crank.

3) Take down oil seal guider.

4) Each new lip-type crank oil seal is provided with

two one-off oil seal drivers:

� For front gear engine, one-ff oil seal driver is

marked sign for front gear system, which shall be
used for assembling oil seal into correct depth of
hole of rear oil seal bracket.

� For rear gear engine, one-ff oil seal driver is

marked sign for rear gear system, which shall be
used for install oil seal with flywheel casing hole
flatly.

Note It is possible to install rear crank sealing by

using maintenance tools (parts number
3824078) used for installing rear crank
sealing/wearable liner assembly.

� Please knock rear crank oil seal lightly with one

plastic hammer to help installing oil seal if no
one-off oil seal driver is provided.

326
 Disassembly & Assembly

5) Assemble sealing into correct depth of shell body

by using one-off sealing driver matched to rear
crank seal.

� Press oil seal into shell body by using plastic

hammer until tool withstood shell body.

� Knock point 12, 3, 6, 9 of tool to press in oil seal

equably to avoid bending oil seal bracket.

6) It is possible to install rear crank oil seal only after

installed the bracket.

327
 Disassembly & Assembly

Disassembly of Cylinder Cover

1) Disassembly crew of cylinder cover.

Do not damage spire of oil sprayer while

disassembling cylinder cover installed with oil
sprayer. Do not put cylinder cover installed with
oil sprayer onto firing level downwards, to
prevent end of oil sprayer from damage.

Element weight achieves or excesses 23 kg [51 lb].

Please hoist the element by using hoisting
equipment or under cooperation of other
personnel to avoid of bodily injures.

Do not put cylinder cover onto firing level to

avoid damage of the top face.

2) Disassemble cylinder cover from cylinder body in

vertical direction.

Weight of cylinder cover

Quantity of
kg 1b
cylinder

4 36 79

6 51.3 113

328
 Disassembly & Assembly

Installation of Cylinder Cover

Element weight achieves or excesses 23 kg [51 lb].

Please hoist the element by using hoisting
equipment or under cooperation of other
personnel to avoid of bodily injures.

1) Put cylinder cover onto cylinder body and put it

into localizing pin.

Weight of cylinder cover

Quantity of
kg 1b
cylinder

4 36 79

6 51.3 113

2) Install push pipe into tappet of air valve.

3) Lubricate sleeve of push pipe with clean engine

oil.

4) Lubricate air valve rod with clean engine oil.

329
 Disassembly & Assembly

5) Loosen rocking arm adjusting screw completely.

Note Align bearing seat of rocking arm to

localizing pin.

6) Install bearing seat.

7) Inspect if length of all cylinder cover bolts are

correct by using service software.

� Lubricate thread and lower bolt head of 8-mm

bearing seat bolt with clean engine oil.

� Install bolt and fasten it with hand.

8) Lubricate thread and low bolt head of 12-mm

bearing seat/cylinder cover bolt with clean engine
oil.

� Install bolt and fasten it with hand.

9) Lubricate thread and low bolt head other cylinder

cover bolt with clean engine oil.

� Install bolt into cylinder cover and fasten it with

hand.

Note Ensure installing long bolt into hole below

oil sprayer.

� Length of engine bolt produced in 1991 is same as

length of engine bolt qualified since then, but be
provide longer thread zone.

330
 Disassembly & Assembly

� Do not use engine bolt qualified before 1991 onto

B series engine produced in 1991 or after 1991.
because the thread of bolt qualified before 1991
not mismatching with engine qualified in 1991 or
after 1991, Otherwise it may damage engine.

� Bolt of B series engine produced in 1991 or

engine qualified since 1991 then can be used on
engine qualified before 1991 because the bolt and
thread is meshing with all qualified engines.

Note It is possible to identify cylinder cover bolt

via angle mark on the topside. Please fasten
cylinder cover bolt by using three-step
“Torque and angle” described below.

10) Fasten all these 26 bolts according to SN.

Torque value: 90 N•m [66 ft-lb]

11) Fasten long bolt according to SN (4, 5, 12, 13, 20,

21).

Torque value: .120. N•m [89 ft-lb]

12) Fasten short bolt to meet correct fastening

requirement of cylinder cover (No.1, 2, 3, 6, 7, 8,
9, 10, 11, 14, 15, 16, 17, 18, 19, 22, 23, 24, 25
and 26).

Torque value: 90 N•m [66 ft-lb]

� Rotate bolt for 90 degree according to SN.

Torque angle gauge - 3/4 inch driving head.

331
 Disassembly & Assembly

13) For making screw rotate to required angle

accurately, please align bolt to “small dot” and
“window” marked on bolt head, or use
recommended maintenance tools: 3/4 inch torque
angle gauge.

� Mark on cylinder cover closing to small dot of

bolt head. The mark is used for helping fastening
bolt to required angle.

� Rotate bolt until sign marked on cylinder cover

entered into “window” of bolt head.

Weight of cylinder cover

Quantity of
kg 1b
cylinder

4 36 79

6 51.3 113

332
 Disassembly & Assembly

Disassembly of Radiator
1) Exhaust coolant of engine.

Engine coolant: About 32L

2) Open engine hood (1).

3) Disassemble water inlet pipe (2) and water outlet

pipe (3). 2

4) Disassemble oil inlet pipe (4) and oil outlet pipe

(5) of oil radiator.

5 4

333
 Disassembly & Assembly

6 7
5) Disassemble air inlet pipe (6) and air outlet pipe
(7) of oil radiator.

6) Disassemble other pipeline of radiator.

7) Disassemble fixing bolt (8) of brace bar (10) and

radiator, fixing bolt (9) of brace bar (10) and
platform, and thread block (11). 8

8) Disassemble build-in bolt of protecting cover of

fan blade, disassemble protecting cover of fan
blade

10 9 11

9) Disassemble bolt of covering element (12) and 12 13

covering element (13).

10) Disassemble radiator and platform fixing bolt

(14).

11) Hoist out radiator by using 1.5m 1T double-head

hook.

Radiator: 103 kg

Installation of Radiator
14
Install in opposite order of disassembly.

334
 Disassembly & Assembly

Disassembly of Engine Oil Cooler

1) Disassemble cover bolt, shell body, sealing
gasket and cooler element of engine oil cooler.

335
 Disassembly & Assembly

Installation of Engine Oil Cooler

Note Disassemble dispatching plug on cooler core.

� Please use correct parts while installing new

engine oil cooler. Replace it with parts of same
number or search correct parts number on
website of QuickServe OnLine.

1) Assemble engine oil cooler cover, bolt, sealing

washer, and engine oil cooler.

2) Please fasten in following sequence if engine

filter is installed in engine oil cooler cover in
lower level.

Note Fasten bolt 6 and 8 and fasten in order

shown in figure.

Torque value: 24 N•m [212 in-lb]

3) Please fasten in following sequence if engine

filter is installed in engine oil cooler cover in
high level.

Torque value: 24 N•m [212 in-lb]

336
 Disassembly & Assembly

Disassembly of Water Pump

1) Disassemble two installing bolts, water pump and
sealing ring.

Installation of Water Pump

1) Install new sealing ring into water pump groove.

2) Install water pump (with sealing) and installing

bolt.

337
 Disassembly & Assembly

Disassembly of Driving Device of

Hydraulic Pump

Accumulator may transgress explosive gas. For

avoiding bodily injures, please keep well
ventilation of engine nacelle before repairing
accumulator. For avoiding generation of arc,
please disconnect cable of cathode (-) and always
connect cable of cathode (-) last of all

1) Disassemble accumulator.

2) Disconnect all hydraulic pipes from pump.

3) Disassemble gear of hydraulic pump.

4) Clean sealing gasket materials on hydraulic

pump by using putty knife and clean cloth.

338
 Disassembly & Assembly

� Please keep to application advice of manufacturer

while cleaning with solvent, acidic material or
basic material. Please wear protecting glass and
protecting cloth to prevent from bodily injures.

� Please wear proper protecting glass and face

shield while using compression air because flying
scrap or dirt may cause bodily injures.

5) Clean hydraulic pump gear with solvent.

Dry it with compression air.

6) Inspect if driving gear of hydraulic pump suffers

from crack, gear abruption or other damage.

7) Inspect if internal diameter of driving gear hole

suffers from excessive abrasion or damage, and
replace it if necessary.

339
 Disassembly & Assembly

Installation of Driving Device of

Hydraulic Pump
1) Use new sealing gasket and install hydraulic
pump.

2) Connect all hydraulic pipes onto pump.

3) Fasten installing bolt.

Torque value: 62 N•m [46 ft-lb]

Accumulator may transgress explosive gas. For

avoiding bodily injures, please keep well
ventilation of engine nacelle before repairing
accumulator. For avoiding generation of arc,
please disconnect cable of cathode (-) and always
connect cable of cathode (-) last of all

4) Connect accumulator.

340
 Disassembly & Assembly

5) Operate engine and inspect if leakage occurs.

341
 Disassembly & Assembly

Disassembly of Coolant Thermostat

1) Disassemble three bolts, shell body of thermostat,
ear, thermostat and oil seal of thermostat.

2) Disassemble water outlet bolt.

� Disassemble connector of water outlet.

� Disassemble thermostat.

342
 Disassembly & Assembly

Installation of Coolant Thermostat

Keep using thermostat correctly. Do not operate

engine before installing thermostat. Coolant shall
flow into water pump port via bypath. Operation
of engine without thermostat may cause excessive
heating of engine. Assembly of thermostat of
incorrect specification may cause superheating or
supercooling of engine.

1) Localization of thermostat is shown as the figure.

� Install ear and sealing gasket of thermostat onto

thermostat and shell body of thermostat.

� Align washer to bolt hole. Install bolt and fasten

it with hand.

� Notch direction of rubber oil seal is opposite to

cylinder cover.

2) Install assembled parts according opposite

sequence of disassembly.

� Install thermostat, oil seal of thermostat, shell

body of thermostat, sealing gasket, ear and three
bolts.

Torque value: 24 N•m [18 ft-lb]

Keep using thermostat correctly. Do not operate

engine before installing thermostat. Coolant shall
flow into water pump port via bypath. Operation
of engine without thermostat may cause excessive
heating of engine. Assembly of thermostat of
incorrect specification may cause superheating or
supercooling of engine.

343
 Disassembly & Assembly

3) Assemble thermostat into thermostat case.

Note Please install a new sealing ring onto

external edge of thermostat flange each time
after reinstalled thermostat.

4) Install bolt for connector of water outlet.

Fasten bolt.

Torque value: 10 N•m [89 in-lb]

344
 Disassembly & Assembly

Cleanness/Replacement of Outer
Element of Air Clean er
Cleaner

Please inspect raw filter if information screen

displays warning or image, or machine exhaust
black smoke.

1) Open left rear door of machine.

2) Open left front door of machine.

3) Press out outlet pipe lightly to remove dust.

4) Loosen four clips of air filter and disassemble

cover of air filter.

5) Disassemble raw filter element from shell body

of air filter.

6) Clean air filter cover and internal side of shell

body of air filter.

7) Inspect sealing ring of air filter cover. Please

replace sealing ring in time it is damaged or
abrasive.

� Do not clean filter element in knocking or

impacting method.

� Do not use filter element of which pleat, washer

or sealing ring is damage, to avoid damaging
engine.

� Please clean filter element and dry out it

completely before installing filter element into
the shell body.

345
 Disassembly & Assembly

8) Clean and inspect raw filter element.

� It is possible to clean raw filter element with

compression air, pressure water or abstergent.
Maximal pressure shall not exceed 0.25Mpa
while cleaning with pressure water.

9) Spray water flow or air flow along internal side

and external side of the pleat.

� It is possible to clean raw filter element with

warmed water or household foamless abstergent.

� Clean internal/external side of pleat and dry out

raw filter element completely by using air.

10) Inspect if pleat, washer or sealing ring is

damaged after cleaned raw filter element.

11) Pack cleaned raw filter element and store it at

clean and dry position.

12) Install clean raw filter.

13) Install air filter cover and lock hasp firmly. Please
install air filter cover correctly.

14) Please replace filter element if one of following

condition occurs.

� Air filter block indicator of monitoring panel

keep lighting.

� Machine still send out black smoke after installed

raw filter element.

� It is possible to clean raw filter for six times.

Please replace it after application of one year.

15) Close left door.

� Replace refined filter element while not use it

after cleaned it.

� Please replace refined filter element

synchronously while replacing raw filter element.

� It is necessary to replace refined filter element if

filter block alarm is still displayed on information
screen or machine sends out black smoke after
assembled cleaned raw filter element.

346
 Disassembly & Assembly

Disassembly of Rocker Arm

Rocker
1) Loosen locking nut of adjusting screw, loosen
adjusting nut until stopped it.

2) Disassemble bolt from rocking shaft seat and

disassemble shaft seat and rocking arm.

347
 Disassembly & Assembly

Installation of Rocker Arm

Rocker
1) Initial installation of rocking arm is one part of
cylinder cover installation because the two
elements share one installing bolt.

2) Fastening residual 8mm bearing seat bolt of

rocking arm.

Torque value: 24 N•m [18 ft-lb]

Rotate adjusting bolt until contacted it with

sleeve of push rod so that push rod could keep
contacting with tappet and adjusting screw while
setting air valve clearance for rotating engine, or
push rod may be bending or damaged

348
 Connection of Undercarriage pipeline

Central Swing Connector

349
Right travel motor Left travel motor
Disassembly & Assembly
 Disassembly & Assembly

Motorr
Disassembly of Travel Moto
1) Disassemble bracket.

For ensuring safety, please drop operating device

onto ground, stop engine and loosen filler cover
of hydraulic oil tank to release internal pressure.

2) Disassemble four fixing bolts of protecting cover,

washer (1) and (2), and disassemble protecting
cover (3).

3) Disassemble corresponding hose (4), (5), (6), (7).

4

5
6

4) Disassemble installing bolt, washer (8) and (9)

from traveling motor (11), and hoist out traveling
motor (11).

Traveling motor: 320 kg

Do not damage sealing surface assembled on

bottom of hose.

Installation of Travel Motor

1) Install in opposite direction of disassembly.

Installing bolt of traveling motor: 300 N•m

2) Fill hydraulic oil to regulated level with filler,

start engine to cycle oil in hydraulic system and
inspect oil level again.

3) Relief air

350
 Disassembly & Assembly

Split Travel Motor

1) Discharge oil

Disassemble discharging plug and discharge oil

from traveling reduction box.

Traveling reduction box: About 5L

2) Disassemble installing bolt, apply force onto

screw ① to open the cover (1).

Disassemble cover (1) via ear bolt ②.

3) Disassemble washer (2).

351
 Disassembly & Assembly

4) Disassemble 1# planetary bracket assembly (3).

5) Open 1# planetary bracket assembly in following

sequence.

� Push pin (4) and draw out shaft (5) from

planetary bracket (6). Disassemble shaft (5) and
pin (4) orderly.

� Disassemble thrust washer (7), gear (8), bearing

(9) and thrust washer (10).

6) Disassemble 1# solar wheel shaft (11).

� Disassemble solar wheel.

� Disassemble 2# solar wheel (12).

352
 Disassembly & Assembly

7) Disassemble thrust washer (13).

8) Disassemble gear ring (14) via ear bolt ③.

9) Disassemble 2# planetary bracket assembly (15).

10) Disassemble 2# planetary bracket assembly in

following sequence.

� Push pin (16) and draw out shaft (17) from

planetary bracket (18).

� Disassemble thrust washer (19), gear (20),

bearing (21) and thrust washer (22).

353
 Disassembly & Assembly

11) 2# planetary assembly

� Disassemble locking plate (23).

� Disassemble nut (24) by using tool D1.

12) Disassemble wheel hub assembly from traveling

motor via ear bolt ④.

13) Disassemble wheel hub assembly in following

sequence.

� Disassemble floating oil seal (26).

354
 Disassembly & Assembly

� Disassemble bearing (27) and (28) from wheel

hub (29).

14) Disassemble floating oil seal (30) from traveling

motor (31).

Disassemble Main Body of Travel

Motor

Clean all parts and inspect if dirt or damage is

existent. Please daub sliding surface of all parts
with engine oil before your installation.

1) Disassemble wheel hub in following sequence.

� Press bearing (27) and (28) into wheel hub (29)

by using pushing tools.

355
 Disassembly & Assembly

� Install floating oil seal (26) by using tools D3.

Note Clean oil and grease from O-ring and contact

surface of O-ring.

� Inspect if angle of floating oil seal is in range of

1mm after installed floating oil seal.

� Daub one layer of engine oil onto sliding surface

after installed floating oil seal.

� Install floating oil seal (30) onto traveling motor

(31) by using tools D3. Installing step is same as
last step.

� Assemble wheel hub (25) onto traveling motor by

using ear bolt ④, press and install bearing by
using pushing tools and hammer.

2) Assemble nut in following sequence.

� Push internal bearing ring (27) by using tools D2.

Note Thrust: 10.7 – 15.7 Nm {1.1 – 1.5 kgm}

� Please rotate wheel rub for 2-3 times before

pushing internal bearing ring.

356
 Disassembly & Assembly

� Measure dimension a described in step 1).

� As a absolute part, measure thickness b of nut

(24).

� Calculate a – b = c.

� Fasten nut (24) with tools D1 until achieved

dimension c.

� Measure tangential force of wheel hub relative to

rotating direction of shell body of motor by using
spring balance ⑤.

Note Tangential force: 450N {45kg} in maximal

Tangential force is maximal force at beginning of

rotation.

� Install locking plate (23).

357
 Disassembly & Assembly

Note Install locking plate as shown as following

figure.

� Install thread of bolt.

Thread agent (LT-2)

Note Do not daub thread agent (LT-2) onto thread

section of nut.

� Installing bolt: refer to torque sheet.

3) Assemble 2# planetary bracket assembly in

following sequence.

Note Replace thrust washer (19), (22) and pin (16)

with new one.

� Please remove residual metal in internal diameter

of hole before assembly because some residual
matter may be remained while inserting pin into
terminal surface e of side hole of planetary
bracket.

� Assemble bearing (21) onto gear (20), assemble

top/bottom thrust washer (19) and (22) and
assemble gear groupware into planetary bracket
(18).

� Align shaft to pin hole of planetary bracket and

knock installing shaft (17) lightly with plastic
hammer.

Note Rotate planetary gear without damaging

thrust washer while installing shaft.

� Insert pin (16).

Note Do not make any tri-groove (position f) fall

into narrow position (g) of planetary bracket
while inserting pin (16) in this method.
Please insert pin according to actual
planetary bracket. Please inspect carefully
and find out thin position on side of
planetary bracket. Please make groove evade
the thin position while inserting pin.

358
 Disassembly & Assembly

Note Knock pin position of planetary bracket after

inserted pin.

Confirm that gear (20) rotates flatly after

assembled planetary bracket assembly.

4) Install 2# planetary bracket assembly (15).

Note Align topside of these three gear shafts of

planetary bracket assembly (15) to these
three holes on terminal face of shell body of
motor, and assemble them.

5) Gear ring

Assemble O-ring onto terminal of wheel hub and

install gear ring (14) by using ear bolt ③.

Note Clean grease and oil from fitting surface of

gear ring and wheel hub.

Never add washer sealing glue onto fitting

surface of gear ring and wheel hub.

6) Install thrust washer (13).

359
 Disassembly & Assembly

7) Install 2# solar wheel (12).

8) Assemble 1# planetary bracket assemble in

following sequence.

Note Replace thrush washer (7), (10) and pin (4)

with new one.

Please remove residual metal in internal diameter

of hole before assembly because some residual
matter may be remained while inserting pin into
terminal surface h of side hole of planetary
bracket

� Assemble bearing (9) onto gear (8), assemble

top/bottom thrust washer (7) and (10) and
assemble gear groupware into planetary bracket
(6).

� Align shaft to pin hole of planetary bracket and

knock installing shaft (5) lightly with plastic
hammer.

Note Rotate planetary gear without damaging

thrust washer while installing shaft.

� Insert pin (4)

Note Do not make any tri-groove (position f) fall

into narrow position (g) of planetary bracket
while inserting pin in this method. Please
insert pin according to actual planetary
bracket. Please inspect carefully and find out
thin position on side of planetary bracket.
Please make groove evade the thin position
while inserting pin.

Note Knock pin of planetary bracket after inserted

pin.

� Confirm that gear (8) rotates flatly after

assembled planetary bracket assembly.

360
 Disassembly & Assembly

9) Install 1# planetary bracket assembly (3).

10) Install 1# solar shaft (11).

11) Install washer (2).

Note Measure dimension “ii” after installed washer.

It denotes that installation is incorrect if
dimension “ii” exceed 15mm. Please try to
install correctly and inspect again if
necessary.

361
 Disassembly & Assembly

12) Hoist and install cover (1) by using ear bolt ②

and fasten installing bolt by using angle spanner
⑥.

Note Installing surface of cover: washer sealant

(LG-6).

Note Install bolt:

Installing torque: refer to torque sheet.

Additional fastening angle: rotate for 100 -

110°

362
 Disassembly & Assembly

Disassembly of Swing Motor and

Swing System
1) Release residual pressure in hydraulic oil pipe.
Please refer to “Release hydraulic oil” in Chapter 5
1
Adjustment of the Manual.
4
2
For safe factor, please drop operating device onto 3
ground, stop and loosen filler cover of fuel tank
to release pressure in tank. Move safety lock to
locking position.

2) Disassemble slewing motor hose (1), (2), (3), (4)

and (5).

3) Disassemble other hose connecting with slewing

motor.
7
4) Disassemble installing bolt (6), disassemble
slewing motor and slewing mechanism assembly.

5) Hoist and disassemble slewing motor and slewing

mechanism assembly (7).
6

Please hoist slewing motor and slewing

mechanism slowly to avoid damaging hose and
other parts.

Hoist assembly carefully until drew out

connecting part.

Slewing motor and slewing mechanism assembly:

210kg

Installation of Swing Motor and

Swing System
1) Install in opposite sequence of disassembly.

Installing bolt: 600Nm

2) Fill hydraulic oil to regulated level via filler, start

engine to cycle oil in hydraulic oil and inspect
level again.

363
 Disassembly & Assembly

Disassembly of Central Swing

Central
Connector
1) Release residual pressure in hydraulic oil pipe.
Please refer to “Release residual pressure in
hydraulic system” in Chapter “Test and
Adjustment”.

Mark all pipe with label to prevent from

installing error.

2) Disassemble hose (1) ~ (8) between travel motor

and central swing connector.

3) Disassemble other relevant hoses and mark with

label.

4) Draw out pin (9) on side of central swing

connector, disassemble bolt (10) and brake disc
(11).

5) Disassemble fixing bolt (12) of central swing

connector (13).

6) Disassemble central swing connector (13).

Central swing connector: 38kg

Installation of Central Swing

Central
Connector
1) Install in opposite sequence of disassembly.

2) Fill hydraulic oil to regulated level via filler

(hydraulic oil tank), start engine to cycle oil in
hydraulic oil and inspect level again.

3) Exhaust air from traveling motor. For details,

please refer to “Air exhaust of parts” in “Test and
adjustment”.

364
 Disassembly & Assembly

Disassembly of Work Equipment

� Fully spread arm and bucket, drop work

equipment onto ground and move safety locking
5
rod to locking position.
4
� Release residual pressure in hydraulic oil pipe.
3
Please refer to “Release residual pressure in
hydraulic system” in Chapter “Test and
2
Adjustment”.

1) Disassemble lubricating grease hose (1).

2) Hoist boom cylinder (2) and disassemble locking

bolt (3).

3) Disassemble plate (4) and cylinder pin (5) orderly.

Please inspect quantity and thickness of all

installing washers, store them at safe position for
future installation.

4) Start engine and take back piston rod.

� Well attach piston rod with rope, drop cylinder

onto platform, or support it via putting one
supporting below cylinder after disassembled
nozzle on bottom edge.

� Disassemble boom cylinder of the other side in

same method.

� Disassemble lamp on work equipment if hook

contacts lamp while hoisting work equipment.

5) Disassemble two arm cylinder hoses (6) and two 10 9

bucket cylinder hoses (7).

Note Please attach hose with rope on side of valve

to plug up overflow of oil.

6) Hoist out work equipment, disassemble plate (9)

and pin (10) on bottom.

365
 Disassembly & Assembly

7) Hoist out work equipment (11) and disassemble it.

Work equipment: 5000kg

Installation of Work Equipment

Install in opposite sequence of disassembly.

� Fasten locking nut until clearance between plate

and nut reached to 0.5 - 1.5 mm

� Insert antiwear gasket I4 and adjusting gasket I5

on both side of pin hole of arm 2, adjust thickness
of washer according to actual condition to make
clearance maintain in range of 0.5~1mm.

� Clearance of pin shaft is 0.5~1mm. Please fill

adjusting gasket according to dimension of
clearance if clearance is bigger than regulated
dimension.

� Store O-ring in sealing state before using it.

Please lock one adapter or pipeline after daubed
lubricating oil during assembling process.

� Daub antiwear lubricating grease on internal

surface of liner while installing pin.

� Fill lubricating grease after assembled pin:

lubricating grease.

� Exhaust air from oil tank. For details, please refer

to “Air exhaust of parts” in “Test and adjustment”.

� Fill hydraulic oil to regulated level via filler

(hydraulic oil tank), start engine to cycle oil in
hydraulic oil and inspect level again.

366
 Disassembly & Assembly

Disassembly of Hydraulic Oil Tank

Ass'y
1) Disassemble upper cover element that make
impact to disassembly of oil tank.

Discharge oil of hydraulic oil tank.

Hydraulic oil tank: About 188L

1
2

2) Disconnect oil pipe (1) and (2) that connecting

with oil tank and other relevant hose.

3) Disassemble harness connecting plug (3).

4) Disassemble bolt (4) that be used for connecting

oil tank and platform from bottom of oil tank.

367
 Disassembly & Assembly

5) Disassemble bolt and fixing bolt (5) of side

bracket.

5
6
6) Hoist and disassemble hydraulic oil tank ass'y (6).

Hydraulic oil tank ass'y: 201kg

Installation of Hydraulic Oil Tank

Ass'y
1) Install it in opposite sequence of disassembly.

2) Fill oil (hydraulic oil tank) to regulated level via

filler, start and run engine to cycle oil in system.
Inspect oil level again.

Hydraulic oil tank: about 280L

3) For details relating to exhaust, please refer to

“Exhaust of parts and elements” in “Measure and
adjustment”.

368
 Disassembly & Assembly

Disassembly of Track Shoe

1) Please remove butter from tension cylinder (mind

Spread direction
your safety) to maintain cylinder in shortest state
before disassembling rail chain of track.

2) Knock out end node of track with tools.

1600mm

Installation of Track Shoe

1) Hoist two pieces of track shoe to special field
with special hoisting tools and spread it. Internal
side distance of two tracks is 1600mm.

2) Hoist substructure onto track shoe and align

connector of it to lower groove of drive wheel,
maintain tension cylinder in shortest state and
enclose end pin of track with special hoisting
tools.

3) Adjust connector of track shoe to lower groove of

driving wheel, clean crawler pin and sleeve, fill
butter into sleeve and knock pin into track shoe
by using special tools.

4) Fill butter into tension device by using butter

filler after installed track shoe.

5) After tightened track clearance between bearing

wheel, guide wheel and driving wheel shall be in
range of 30-40mm.

369
 Disassembly & Assembly

Disassembly of Driving Wheel

1) Disassemble work equipment. For details, please
refer to “Disassembly of work equipment”.

2) Rotate work equipment for 90° and jack up

machine by using work equipment, and then
insert bearing block (2) between track frame and
work equipment.

3) Disassemble installing bolt and draw out driving

wheel (1) lightly. Install ring bolt and nut into
installing bolt hold, and then hoist away driving
wheel (1).

Driving wheel: 36kg

Installation of Driving Wheel

1) Oil travel drive:

Screw off two filler hold plug of travel drive 1 by 1 2 3 4

using inner hexangular tools, fill gear oil into
drive until oil reached to scale, and then, fasten
plugs.

2) Install travel drive and driving wheel:

� Clean dirt from surface oil travel drive 1 and

driving wheel 2.

� Assemble travel drive 1 and driving wheel 2 onto

upper section of assembly and fasten them with
M16×50 bolt. Install assembled travel drive onto
travel drive bracket.

It is possible to pretighten 80% torque with

pneumatic press while fastening bolt 4 of travel
drive and driving wheel, namely, 240N•m, and
then, fasten completely by using torque
spanner. Please fasten bolts in opposite angle
method;

� Please pay attention to installing direction while

installing travel drive 1, and assemble oil plug
with face upward.

370
 Disassembly & Assembly

Disassembly of Track Roller

1) Drop work equipment onto ground, loosen butter
nozzle (1) and release tightness of track.

Do not loosen butter nozzle for one cycle above

because tension cylinder of crawler has higher
pressure. Please move machine frontward or
backward if lubricating grease flows out
difficultly.

2) Disassemble installing bolt of track roller and

rotate work equipment for 90°. Jack up machine
with work equipment and disassemble track roller
(2) facing to external side of machine.

Installation of Track Roller

1) Install it with opposite sequence of disassembly.

2) Adjust tension of track shoe. (For details, please

refer to content relating to test and adjust tension
of track shoe in “Test and adjustment”)

Thread of installing bolt of track roller: Thread

agent (LT-2).

3) Put bolt on external side of chassis and assemble

track roller onto installing position. Operate
control rod of work equipment to drop machine
onto ground slowly, and then, fasten installing
bolt partly. Operate control rod of work
equipment to drop machine onto ground
completely and fasten installing bolt completely.

Torque moment of torque spanner: 450N•m

371
 Disassembly & Assembly

Disassembly of Carrier Roller

� Drop work equipment, loosen butter nozzle (1)
and release tension of track

Do not loosen butter nozzle for one cycle above

because tension cylinder of track has higher
pressure. Please move machine frontward or
backward if lubricating grease flows out
difficultly.

� Jack track to disassembling position by using

hydraulic jack, and then, disassemble carrier
roller (2).

Installation of Carrier Roller

1) Hoist track with special hoisting tools.

2) Install carrier roller into bracket while not remain

clearance between bracket and carrier roller.
Please ensure that marking position is horizontal
with connecting line of roller center.

372
 Disassembly & Assembly

Disassembly of Front Idler and

Tension Spring
1) Disassemble track shoe (For details, please refer
to “Disassembly of track shoe”).

2) Hoist front idler and tension spring (1), draw out

them from front terminal and disassemble them.

Front idler , tension spring: 264kg

3) Disassemble tension spring (3) from front idler

(2).

Front idler: 129kg

Tension spring: 135kg

373
 Disassembly & Assembly

Installation of Front Idler and Tension

Spring
1) Install front idler:

� Put idler cusion (1), front idler (2) onto installing

bracket of front idler according to Fig. 1, align
holes and lock with washer (3) and bolt (4).

� Adjust butter nozzle to make it face to marked

side of front idler.

Fig.1

3
2) Hoist front idler 图
一
� Clean installing seat of front idler to remove dust
and abnormal matter from surface of it.

� Daub proper butter onto installing seat of front

idler.

� Hoist front idler onto installing seat and install it

correctly (butter nozzle faces to external side of
travel frame).

374
 Disassembly & Assembly

Disassembly of Swing Circle

1
1) Disassemble rotating platform assembly.

2) Hoist away swing circle (1).

Swing circle: 348kg

375
 Disassembly & Assembly

Installation of Swing Circle

1) Install swing circle.

� Clean installing surface of swing circle.

� Hoist swing circle upon travel frame and make

backfire point of internal ring, namely, the Point S
locate upon/below traveling direction.

� Align hole and fasten with bolt 3 and washer 4 in

order shown in Fig. 1. Please fasten bolt in
opposite angle method. Please fill wood bar
below spanner while fastening nut to ensure
levelness of torque spanner.

A
2) Install lubricating pipeline of swing circle
according to position A, B and C shown in right
figure without distortion. Daub thread agent at
connecting position of hose and swing circle.

3、4

376
 Disassembly & Assembly

Ass''y
Disassembly of Platform Ass
1) Fully spread arm and bucket, drop work
equipment onto ground and move safety locking
bar to locking position.

2) For disassembly of work equipment, please refer

to “Disassembly of work equipment”.

3) For disassembly of counterweight, please refer to

“Disassembly of counterweight”.

4) Disassemble these four boom cylinder hoses (1). 1

Plug up hose to stop flowing of oil.

5) Hoist boom cylinder (2).

6) Disassemble bolt, washer, pin (3), (4) and (5).

Hoist and disassemble boom cylinder (2).

Disassemble opposite boom cylinder in same

method.

Boom cylinder: 168kg

3 5

377
 Disassembly & Assembly

7) Disassemble install bolt engine cover.

8) Hoist engine cover (6) by using proper hook and

hoisting device.

Please disassemble any parts that interfere with

hook while disassembling swing platform.

6
9) Disassemble cover element that may be interfered
or damaged during hoisting process.

10) Disassemble counterweight device (refer to

disassembly and installation of counterweight).

11) Release system pressure.

12) Disassemble hose on central swing connector and

other hose making impact to disassembly.

For convenience of future installation, please

mark disassembled hose.

13) Hoist swing platform assembly, disassemble

installing bolt and hoist swing platform assembly.

Do not impact central swing connector while

disassembling swing platform assembly.

Platform assembly: 6500kg

Ass''y
Installation of Platform Ass
1) Install it in opposite sequence of disassembly.

Installing bolt of swing platform: 800Nm

(94.5±10.5 kgm)

2) Fill hydraulic oil to regulated level via filler, start

engine to cycle oil in hydraulic system, inspect oil
level again.

3) Exhaust from travel motor.

378
 Disassembly & Assembly

Construction Drawing of Main Valve

Neutral Position (Fig. 1)

379
 Disassembly & Assembly

Neutral Position (Fig. 2)

380
 Disassembly & Assembly

Neutral Position (Fig. 3)

381
 Disassembly & Assembly

Neutral Position (Fig. 4)

382
 Disassembly & Assembly

Negative Control Action (General Action)

383
 Disassembly & Assembly

Negative Control Action (Micro Action)

384
 Disassembly & Assembly

Boom Raise Operation

385
 Disassembly & Assembly

Boom Lower Operation

386
 Disassembly & Assembly

Arm Out Operation

387
 Disassembly & Assembly

Arm In Operation

388
 Disassembly & Assembly

Piston Pressure of Arm Cylinder Rises

389
 Disassembly & Assembly

Bucket In Operation

390
 Disassembly & Assembly

Bucket Out Operation

391
 Disassembly & Assembly

Swing

392
 Disassembly & Assembly

Travel

393
 Disassembly & Assembly

Main Pressure Relief Valve

394
 Disassembly & Assembly

Action of Main Pressure Relief Valve

Interface Pressure Relief Valve

395
 Disassembly & Assembly

Function of Interface Pressure Relief Valve

Oiling function

396
 Disassembly & Assembly

Neutral Position of Boom Spool

397
 Disassembly & Assembly

Boom Lower

398
 Disassembly & Assembly

Disassembly of Main Valve

Please prepare following tools before disassembling
main valve:

Specification and other

Tool Qty
(mm)

Please assemble soft metal

Bench clamp
1 such as copper plate at
(soft jaw)
clamping jaw.

Inner hexangular
1 5, 6, 10, 12, 14
spanner

Sleeve spanner 1 27, 36, 41

32 (main overflow valve),

Spanner 1
41

� Please disassemble, assemble hydraulic element

at clean location because the accuracy.

� Except treatment abovementioned, please avoid

dust intruding into internal side of main valve.

� Please seal interfaces with cover while

disassembling control valve from main machine.
Please confirm if cover are assembled completely
and clean external side of whole element
assembly before disassembly. Please perform
operation on proper operating desk after lay clean
paper, rubber plate on it.

� Please place weighted bearing at firm position of

main body while transporting, moving main
valve. Do not support extruded position such as
spring cover, overflow valve etc.

� Please disassemble and perform test (overflow

character, leakage test, flow resistance etc.) with
element at proper location, and prepare cleaning
liquid, operating oil and lubricating oil before
your operation.

1) Put main valve onto operating desk.

399
 Disassembly & Assembly

Please disassemble at clean location without

damaging surface of flange disc.

2) Disassemble linear traveling valve block.

� Loosen and disassemble inner hexangular bolt,

disassemble linear traveling valve block in
groupware state.

3) Disassembly of main overflow valve

� Loosen and disassemble inner hexangular bolt,

disassemble spring cover.

� Take out valve core, spring, spring seat, baffler,

bolt from valve body in groupware state.

Do not damage valve body while taking out valve

core groupware from valve body.

4) Disassembly of covers

Disassemble inner hexangular bolt and take down

cover.

400
 Disassembly & Assembly

5) Disassemble interface overflow valve from valve

body.

6) Disassemble oil plug from valve body.

7) Loosen and disassemble inner hexangular bolt,

disassemble locking valve groupware.

8) Disassembly of negative control overflow valve

� Disassemble oil plug.

� Disassemble negative control overflow valve.

401
 Disassembly & Assembly

9) Disassemble single-way valve

� Please disassemble oil plug, spring and cone

valve orderly.

� Loosen and disassemble inner hexangular bolt,

disassemble cover, spring and cone valve orderly.

� Loosen and disassemble, disassemble spring and

cone valve.

� Disassemble single-way valve groupware.

10) Loosen and disassemble inner hexangular bolt,

disassemble boom priority valve.

402
 Disassembly & Assembly

Installation of Main Valve valve (611).

Note Digital in bracket denotes parts number in � Assemble cone valve components, spring,
structure diagram. negative control relief valve (2*611) into valve
body A (101).

� Fasten oil plug (551) with regulated torque.

� Note: No sealing element shall suffer from
shaped default or scar generated during
application. 3) Assembly of lock valve

� Daub lubricating grease or operating oil at � Assemble O-ring onto valve body.
position assembling sealing element or packing � Fasten inner hexangular bolt with regulated
sealing element to ensure abundant lubrication. torque.
� Do not stretch sealing element to irrecoverable
degree.
4) Assembly of interface relief valve
� Do not assemble O-ring in rotating method. Wrest
� Assemble O-ring (561) onto relief valve.
of O-ring after assembled may cause oil leakage,
because irrecoverable shape. � Assemble interface relief valve (602) and (603)
into valve body and fasten them with regulated
� Please fasten installing bolts by using torque
torque.
spanner with regulated torque.

5) Assembly of oil plug

1) Assembly of check valve.
� Assemble O-ring for oil plug (533).
� Assemble cone valve (511), (515), (516), spring
� Assemble oil plug (533) into valve body and
(521) and (523). Assemble sealing O-ring (561)
fasten it with regulated torque.
for oil plug (551) and (552). Fasten them with
regulated torque.
6) Assembly of main spool
� Assemble cone valve (517), spring (521),
assemble O-ring (162) and (163) for these two � Assemble spool components assembled into
covers (253), and fasten inner hexangular bolt corresponding spool hole of valve body A (101)
(272) with regulated torque. and valve body B (102).

� Assemble cone valve (513), spring (522),

assemble O-ring (561) onto oil plug, and fasten
them with regulated torque.
Please assemble spool components into valve
� Assemble O-ring (561) for check valve
body slowly without pressing it enforcedly.
component (555) and fasten it with regulated
torque.

2) Assembly of negative control relief valve

� Assemble O-ring (561) for negative control relief

403
 Disassembly & Assembly

7) Assembly of covers

� Assemble valve core cover (202), (204) and (205)

onto opposite side of the spring groupware and
fasten them by using inner hexangular bolt (273)
with regulated torque.

Confirm if cover is assembled with O-ring (2169)

and (264).

� Assemble valve core cover (201), (203), (206)

and (207) onto side of the spring groupware and
fasten them by using inner hexangular bolt (273)
with regulated torque.

Confirm if cover is assembled with O-ring (261)

and (262).

8) Assembly of linear traveling valve block and

boom priority valve block.

� Assemble O-ring into valve body.

� Fix inner hexangular bolt with regulated torque.

404
 Disassembly & Assembly

Disassembly of Pilot Valve Pipe

� Prepare capacious location for placing

disassembled parts and elements and a firm
operating desk to prevent parts from falling or
rolling during operation.

� Prepare tools and relevant files.

� Parts and elements are processed critically, please

operate carefully and prevent elements from
falling or impacting with each other.

� Do not knock, prize, cut parts and elements to

prevent from assembling fault, oil leakage, or
performance reduction caused in flash line,
distortion or damage, although parts and elements
are massive.

� Improper treatment or strewing during

disassembling process may make parts and
elements rust under action of humidity and
foreign matter. Please adopt antirust, dust proof
measure while interrupt operation unavoidably.

1) Clean pilot valve with white spirit.

Note Plug up interfaces with blind plug.

2) Fix pilot valve onto table vice by using buffer

plate (soft plate such as copper plate etc.).
disassemble pedal cover from upper direction of
pedal.

3) Loosen inner hexangular bolt by using inner

hexangular spanner to disassemble pedal.

405
 Disassembly & Assembly

4) Loosen inner hexangular bolt by using inner

hexangular spanner to seat.

5) Disassemble corrugated cover from cover plate.

6) Loosen inner hexangular bolt by using inner

hexangular spanner.

Note Please loosen it with stronger force because

daubed thread glue #241.

7) Align round bar (φ8 below) to one terminal of

cam shaft. Knock it lightly with hammer to
disassemble it.

406
 Disassembly & Assembly

8) Disassemble locating screw, fastening nut

together with cam.

Note Record position relation between cam and

cover plate.

Mind ejection of push bar during disassembling

process.

9) Loosen inner hexangular bolt with inner

hexangular spanner.

10) Disassemble cover plate.

Note Record position relation between cover plate
and buffer case.

Mind ejection of push bar, push bar liner under

action of buffer spring during disassembling
process (push bar liner may not eject because of
resistance of O-ring).

11) Take out push bar from push bar liner

Note Record position relation between push bar

and push bar liner.

� Do not damage surface of push bar.

� Mind ejection of push bar liner during

disassembling process.

407
 Disassembly & Assembly

12) Disassemble lubricating grease ring, NHU sealing

ring together with push bar liner.

Note Record position relation between push bar

liner and buffer case.

Mind ejection of plunger under springy action of

buffer spring during disassembling process.

13) Take out plunger from buffer case.

Record position relation between plunger and

buffer case.

14) Disassemble buffer spring from buffer case.

Note Record position relation between buffer

spring and buffer case hose.

15) Take out spring seat from buffer case.

Note Record position relation between spring seat

and buffer case hole.

408
 Disassembly & Assembly

16) Take out steel ball by using magnet.

Note Well keep steel ball without missing.

17) Loosen inner hexangular bolt by using inner

hexangular spanner.

18) Disassemble buffer case.

Note Record position relation between buffer case

and valve body.

Mind ejection of throttle valve under springy

action of reset spring during disassembling
process.

19) Disassemble O-ring from valve body.

409
 Disassembly & Assembly

20) Disassemble throttle valve groupware, reset

spring from valve body.

Note Record position relation between valve body

holes.

21) Lay cover plate onto platform, align special tool

to liner and knock it with hammer lightly to
disassemble liner.

22) Fix cam groupware onto table vice, loosen

locking nut with spanner to disassemble locking
nut and fixing screw.

Note Please store localizing screw in cam

groupware form because neutral position
adjustment is necessary while assembling
localizing screw.

410
 Disassembly & Assembly

23) Disassembly of throttle valve groupware: stand

lower terminal of sliding valve vertically and put
it onto flat operating desk, press spring seat and
disassemble these two rounding washer by using
smaller flat head screwdriver.

Do not damage sliding surface.

Spring seat is provide with pressing allowance of

4mm above.

24) Separate sliding valve, spring seat, second

pressure setting spring and washer.

25) Disassemble lubricating grease cup from push bar

liner.

26) Disassemble NHU sealing ring from push bar

liner with smaller plastic plate.

Do not touch inner surface of push bar liner.

27) Disassemble O-ring from push bar liner.

411
 Disassembly & Assembly

Installation of Pilot Valve Pipe

� Same as disassembly, prepare operating desk,
tools and relevant files.

� Pay attention of general precautions of

disassembly.

� Remove all metal scrap and foreign matter found

during assembly. Please confirm that no parts and
elements suffer from NG condition of flying line,
damage, bruising etc., or remove it with oilstone
if necessary.

� In principle, replace O-ring and NHU sealing ring

with new one.

� Do not damage O-ring and NHU sealing ring

while assembling them (daub some lubricating
grease).

� Please use lubricating grease while disassembling

parts and elements, to prevent them from falling.

� Please fasten bolt with installing torque shown in

assembling section diagram.

� Please plug up all interface with blind plug to

avoid intrusion of foreign matter, after completed
assembly.

1) Assemble washer, second pressure setting spring

and spring seat onto sliding valve orderly.

Note Washer is used for presetting adjustment of

spring that used for second pressure setting.
Thickness of each sliding valve assembly
may be different.

2) Stand up lower terminal of sliding valve

vertically and put it onto flat operating platform.
Press spring seat and assemble two pieces of
semicircular washer into upper section of spring
seat without superposition.

412
 Disassembly & Assembly

3) Make acute angle side (without arc side) of

washer upward and assemble head of sliding
valve carefully.

acute angle side

Spring seat is provided with pressing allowance

of 4mm above.

4) Assemble resetting spring into valve body.

Note Assemble according to position before

disassembly.

5) Assemble throttle valve groupware into valve

body according item 4).

Note Assemble according to position before

assembly.

Do not make lower terminal of sliding valve

impact with angle of valve body excessively
while assembling throttle valve groupware.

mind the angle of valve

6) Assemble O-ring onto valve body.

7) Install buffer case together with valve body by

using inner hexangular bolt and fasten it with
regulated torque.

Note Assemble according to position before

assembly.

413
 Disassembly & Assembly

Two socket bolts are equably to installed, which

to make sure that buffer case can installed firmly
in parallel state.

8) Attract steel balls with weak magnet or assemble

them into buffer case with nipper.

9) Assemble spring seat into buffer case.

Note Assemble according to position before

assembly.

10) Assemble buffer spring into buffer case.

Note Assemble according to position before

assembly.

414
 Disassembly & Assembly

11) Assemble buffer spring into buffer case.

Note Assemble according to position before

assembly.

Do not make buffer springs occludes with each

other.

12) Assemble plunger.

Note Assemble according to position before

assembly.

13) Assemble O-ring onto push bar liner.

14) Assemble NHU sealing ring into push bar liner.

415
 Disassembly & Assembly

NHU seal ring

Note Please mind direction while assembling NHU
seal ring.

� Please daub a layer of lubricating grease onto

NHU seal ring before assembly.

15) Assemble lubricating grease cup into push bar

liner.

16) Assemble push bar into push bar liner.

� Daub hydraulic operating oil onto push bar before

assembling it.

� Do not insert it enforcedly to avoid damaging

edge of NHU sealing ring.

17) Assemble push bar groupware into buffer case

according to Item 15), 16), 17) and 18).

416
 Disassembly & Assembly

18) Press liner onto cover plate with special tool 1

and press it by knocking it with hammer lightly.

Do not knock liner out from inner side of cover

plate while pressing it.

19) Assemble cover plate onto buffer case.

Note Assemble according to position before

assembly.

Mind bulging of cover plate caused in springy

action of buffer spring.

20) Fasten inner hexangular bolt with regulated

torque.

Please install cover plate flatly without deflection.

21) Assemble localizing screw onto cam and

assemble locking nut casually.

417
 Disassembly & Assembly

22) Assemble cam onto cover plate.

Note Assemble according to position before

assembly.

23) Press cam and insert cam shaft from external side.

24) Daub thread glue #241 or similar product onto

surface of inner hexangular localizing screw.

25) Fasten inner hexangular localizing screw with

regulated torque.

418
 Disassembly & Assembly

26) Adjust height of localizing screw to make upper

surface of cam parallel with lower surface of
cover plate so that cam could rotate leftwards and
rightwards. Fasten nut with regulated torque after
confirm that cam is on neutral position without
looseness.

Please adjust these four pieces of push bars to

proper position by using localizing bolt to prevent
from looseness of control rod in neutral state, or
error action occurs while starting engine.

27) Incline cam backwards and daub lubricating

grease on topside of push bar. Fill lubricating
grease into lubricating grease cup of push bar
liner.

Please daub lubricating grease with soft materials

while not damage push bar or surface of push bar
liner.

28) Insert upper terminal of wave cover into cam and

insert the lower terminal into groove of cover
plate.

Note Please spray rust preventative oil onto parts

and elements in wave cover before inserting
lower terminal of wave cover into groove of
cover plate.

29) For ensuring dust proof, or water proof

performance of wave cover, please insert into
groove properly without distortion during
assembling process.

419
 Disassembly & Assembly

30) Assemble seat and fasten inner hexangular bolt

with regulated torque.

31) Assemble pedal and fasten inner hexangular bolt

with regulated torque.

32) Assemble pedal cover onto pedal.

420
 Disassembly & Assembly

Disassembly of Pilot Valve

1) Clean guide valve by using white spirit.

Please plug up oil opening with blind pin.

2) Fix guide valve onto hand vice by using copper

plate (or leading).

3) Disassemble valve case from lower terminal of

wave pipe and take down it from upper terminal.

Please take down electric wire via hole of valve

case although a switch is provided.

4) Loosen locking nut and adjusting nut with

spanner, and take down whole body of handle.

5) Put spanner into clearance between adjusting nut

and two surface of circular plate to loosen
adjusting nut, take down nut and circular plate.

421
 Disassembly & Assembly

6) Loosen connector by rotate it with jig leftwards.

Disc, liner, pressure bar shall float while

loosening connector if reset spring is tightened.

7) Take down washer and dolly.

Only old model uses washer.

8) Liner shall wedge in valve case because

resistance of O-ring if reset spring is faintish,
please take out it by using flat head screwdriver.

422
 Disassembly & Assembly

� Please use external groove of liner to prevent it

from damage caused in eccentric loading
� Mind ejection of pin under action of resetting
spring while drawing out it.

9) Draw out throttle valve groupware and resetting

spring from valve case.

Please pre-record position relation between

throttle valve groupware and valve case hole.

10) Loosen and take out inner hexangular bolt by

using inner hexangular spanner.

11) Take down interface plate and O-ring from valve

case.

� Take down bearing shell from valve case.

423
 Disassembly & Assembly

12) Stand up lower terminal of sliding valve onto flat

operating platform while disassembling valve
body, drop spring seat and take down these to
semicircular washer with smaller screwdriver.

Do not scuff surface of sliding valve, or drop

spring seat for 6mm above.

13) Separate sliding valve, spring seat, spring and

washer.

Please manage these elements as an assembly.

14) Draw out pressure bar from liner.

15) Take down O-ring and sealing ring from liner by

using flat head screwdriver.

424
 Disassembly & Assembly

16) Take down locking nut and draw out wave pipe.

17) Take down handle cover.

Please take down the cover if no switch is

provided.

425
 Disassembly & Assembly

18) Loosen screw with cross head screwdriver and

take down screw and nut.

It is possible to take out roller if two switches are

provided.

19) Loosen screw with cross head screwdriver, take

down screw, nut and flat washer.

20) Divide the handle into two halves.

It is possible to take out switch rod, switch and

switch seat if a switch is provided.

21) Cleanness of elements

� Clean elements with white spirit (rough cleaning).

� It is possible damage surface of polluted element

without soaking them. Please soak them fully
until dirt and oil floats.

� Polluted white spirit may damage element and

depress performance after assembled. Please pay
attention to pollution management of white spirit.

426
 Disassembly & Assembly

Do not dry element with compression air because dirt

and moisture in air may damage element or generate
rust.

� Put white spirit into sluicing vessel and soak

elements, rotate vessel slowly until cleaned
elements completely. Wipe off white spirit on
surface by using clean cloth.

22) Rust prevention of elements

Daub anti-rusting agent onto elements.

Depose directly after cleaned may cause rust and

reduce performance.

Installation of Pilot Valve

1) Assemble bearing shell, O-ring into pump case.

2) Fix inlet plate onto pump case by using inner

hexangular bolt and sealing ring.

427
 Disassembly & Assembly

Holding position spring pin may insert into pump

case hole.

3) Fasten inner hexangular bolt with regulated

torque.

Fasten these two bolts slowly and alternately.

4) Insert washer, spring and spring seat into sliding

valve orderly.

5) Stand up lower terminal of sliding valve onto flat

operating platform, press spring seat and insert
two pieces of washer into spring seat without
superposition.

Close sharp corner position of washer to head of

sliding valve and assemble it.

6) Assemble spring into pump case.

Assemble throttle valve groupware into pump

case.

� Pressing distance of spring seat shall not exceed

6mm.

� Assemble it to disassembling position.

428
 Disassembly & Assembly

7) Assemble O-ring onto liner.

8) Assemble sealing ring into liner.

Assemble rib section of sealing ring into liner,

shown as the figure.

9) Assemble pressure rod into liner.

Daub operating oil onto surface of pressure rod.

10) Assemble liner groupware into pump case.

� It is possible to baffle groupware with action of

O-ring if reset spring is weak.

� Assemble four liner groupware into dolly and fix

them with connector casually if reset spring is
stronger.

429
 Disassembly & Assembly

11) Assemble disc and washer (only old model uses

washer).

12) Fix connector onto pump case by using jig with

regulated torque.

13) Assemble connector for circular plate

Screw in disc until contact with four pressure rods

equably (no screwing excessively).

14) Assemble adjusting nut and fix spanner on two

surfaces of circular plate, and fasten adjusting nut
with regulated torque.

Do not modify position of circular plate while

fastening it.

15) Fix handle rod by using screw with regulated

torque.

430
 Disassembly & Assembly

16) Please assemble switch element into handle if a

switch is provided.

Switch seat, switch and switch rod are provided

with installing groove.

17) Install residual handle.

18) Install cover and fix by using smaller screw and

nut with regulated torque.

Please install and fix with roller, replacing cover,

if a switch is provided.

19) Fix residual screw with regulated torque.

Please confirm clearance between roller and

handle.

20) Fix screw , flat washer, nut with regulated torque.

431
 Disassembly & Assembly

Daub fastening oil #241 onto thread of screw .

21) Install handle cover.

22) Install wave pipe. Installation of locking nut

handle groupware is completed.

23) There is a adjusting nut hold in 60-120° direction

of pump case hole of electric wire and pipe.
Please introduce electric wire and pip through the
hole.

432
 Disassembly & Assembly

24) Assemble bearing shell onto circular disc and

thrill electric wire and pipe through it.

Please reserve moving allowance during

operation.

25) Confirm direction of handle, fix adjusting nut

with spanner and fasten handle by using locking
nut with regulated torque.

26) Daub lubricating oil on rotating section of

connector, circular plate and contact surface of
pressure rod.

It is possible to achieve better effect by using

spraying lubricating grease for rotating section of
connector.

27) Assemble lower terminal of wave pipe onto pump

case.

28) Put anti-rust agent into oil port and plug up it with
blind plug.

433
 Disassembly & Assembly

Disassembly of Swing Motor

1) Dimension of bolt and fastening torque
� The sheet contains dimension and fastening
torque of all bolts of the decelerator.
3) Disassemble gear driving motor from main body,
take down oil port and oil plug, exhaust gear oil
and put it onto proper operating platform.

� The sheet only introduce typical torque value.

Please fasten with recorded torque value of Dump gear oil into clean vessel and inspect if
assembling diagram. abrasive powder is existent.

Inner 4) Loosen inner hexangular bolt and take down

Fastening
Symbol Name Dimension hexangular hydraulic motor.
torque
hole
5) Take down 1# sidereal wheel.
Inner
M14 Length 6) Take down 1# bearing bracket in groupware mode
602 hexangular 12mm 1600kgcm
130 and take out 1# sidereal wheel in original state.
bolt
7) Disassembly of 1# bearing bracket groupware.
901 Oil plug PT1/2 10mm 660kgcm

902 Oil plug PT1/4 6mm 220kgcm Note Do not disassemble 1# pin from 1# bracket if
unnecessary
2) Tools

� Hexangular spanner (width of double face 12. 10. Mark pin and planetary gear with signal to avoid
6); of mismatch.
� Sleeve spanner, adjustable spanner, double head 8) Take down 2# sidereal wheel.
spanner, hammer, plastic hammer, screwdriver,
torque spanner; 9) Take down 2# bearing bracket groupware.

� Special gear tool, liquid sealing material (Three
Bond No1217). Heating oil groove (heated and
pressure application 80℃~100℃).
� Please disassemble carefully without damaging
element.
� Clean parts and elements with washing oil and dry
with compression air.
� During disassembling process, perform fine
finishing with surface by using oil and degrease it
after ripped liquid sealing element with knife.
� Fastening torque is described in Item 1).
10) Disassemble 2# bearing bracket groupware.
Note Do not disassemble 2# bearing bracket
ulteriorly if unnecessary. Keep the state and
detect parts and elements. It is recommended
to replace 2# bearing bracket groupware in
set, or replace parts and elements according
to following essentials if necessary.
� Take out spring pin and draw out 2# pin.
� Draw out 2# planetary gear and side plate
horizontally.
11) Take out inner gear ring.
Insert flat head screwdriver into these two groove
on jointing surface of case body and gear ring of
gear motor. And take out it without damaging
jointing surface.

434
 Disassembly & Assembly

Do not reuse disassembled 2# pin.

12) Take out retainer from driving shaft.

13) Put shaft end onto operating platform downwards

with supporting of flange. Knock center position
of shaft with plastic hammer and draw out shaft
downwards.

Remain automatic adjusting roller bearing in case

body. Main damage caused in falling of shaft.

Note Do not disassemble ulteriorly if unnecessary.

� It is recommended to replace driving shaft

groupware abovementioned in set. Or replace
parts according to following requirement if
necessary.

� Do not disassemble ulteriorly after confirmed no

abnormity is existent.

14) Support element of driving shaft, knock and draw

out sealing cover of bearing, and automatic
adjusting roller bearing.

Note Do not reuse disassembled oil sealing

element.

15) Take out oil sealing element from motor case.

435
 Disassembly & Assembly

Installation of Swing Motor

1) Assembly of driving shaft groupware.

� Insert sealing ring of bearing into driving shaft.

� Daub adequate lubricating grease onto internal

side of automatic adjusting roller bearing, knock
it and press it correctly. Confirm feeling rebound
while knocking internal ring. Daub adequate
lubricating grease as shown as Figure.

Mid position of automatic adjusting roller bearing

is separated. Please fill lubricating grease from Lubricating
both sides before assembling shaft. grease

2) Put case body onto flat operating platform.

3) Hoist via bolt at shaft end of driving shaft

groupware and assemble it into gear motor case.

Note Keep level state of external ring of bearing

and knock in it lightly.

External ring of bearing may incline, although

knock it lightly. Please draw out external ring, put
it flatly and knock it lightly, while not knock it
heavily.

4) Put shaft end into case body downwards with

supporting of flange.

Please assemble oil sealing ring horizontally

without damaging it.

5) Assemble oil sealing ring into case body.

6) Press internal/external ring of automatic adjusting

roller bearing by knocking it with special jig.

436
 Disassembly & Assembly

motor, hoist it vertically, align spline, assemble

oil motor and fasten inner hexangular bolt.

19) Assemble oil plug into case body after enwound it

Please control dimension of end face of internal
with sealing tape
ring from shaft end by using jig.
20) Fill gear oil via filler.
7) Assemble retainer

8) Fill lubricating grease from filler, enwind oil plug

with sealing materials and assemble it into case
body.
� Assemble oil gauge and duct casually to confirm
9) Assemble 2# bearing bracket groupware. oil level.

� Align side plate to pin hole.
� Insert planetary gear.
� Confirm that position of hold applies to assembly
of spring pin. Knock 2# pin lightly in same
direction of hole of 2# bearing bracket.
� Assemble PT1/4 oil plug onto assembling
position of duct during transportation, and
assemble duct and oil gauge after assembled
rotating motor. (Wipe off sealing glue of bolt,
enwind new sealing tape after degreased, and
assemble it.)

10) Daub liquid sealing materials onto jointing

surface of case body and internal gear ring.

11) Confirm position of jointing mark and assemble

inner gear ring onto case body, fix casually by
using four pieces of M14*130 inner hexangular
bolt or inner hexangular bolt (fastening torque is
800kgf.cm above) assemble flat washer for bolt
without damaging jointing surface of motor.

12) Assemble 2# bearing bracket into internal side of

gear ring.

13) Assemble 2# sidereal gear.

14) Assemble 1# bearing bracket groupware (must

assemble it with special jig).

15) Assemble 1# bearing bracket groupware and

confirm if center side plate is inserted into
excrescent position of 2# sidereal gear.

16) Assemble 1# sidereal gear.

17) Take casual fastening bolt and daub liquid sealing

materials onto hydraulic motor installing surface
of inner gear ring.

18) Assemble retainer onto driving shaft of hydraulic

437
 Disassembly & Assembly

Disassembly of Counterweight
1) Connect ear bolt ① with counterweight 1 and
hoist it. ①

2) Disassemble installing bolt 2.

1
3) Hoist counterweight 1 by using rope or block
chain.

Do not impact engine, radiator or cooler.

Counterweight: 4024 kg

Installation of Counterweight
1) Install in opposite sequence of disassembly.

Thread of counterweight installing bolt:

Thread agent (LT-2)

Counterweight installing bolt: 1600N•m

2) Adjust upper/lower edge clearance by using

washer.

Install flat counterweight in the method.

Clearance between counterweight and left rear
door, right door and platform is 10±2mm,
segment difference is 0~5mm.

438
 Appendix

Chapter Ⅷ Appendix

439
 Appendix

440
 Appendix

CONTENTS

Chapter Ⅷ Appendix................................................................................................................... 439

Appendix
Electrical Schematic Diagram...........................................................................................................................443

Hydraulic Schematic Diagram..........................................................................................................................444

441
 Appendix

442
Electrical Schematic Diagram CDM6215/CDM6225
Diagram（CDM6215/CDM6225
CDM6215/CDM6225）

443
Hydraulic Schematic Diagram CDM6215/CDM6225
Diagram（CDM6215/CDM6225
CDM6215/CDM6225）

高低速

升压

(离车安全)
操纵供油

破碎锤（备用）

444
Proposal on Service Manual Amendment

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Name: Page:

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Date: more need modification, please write in the opinion column.)

Fax:

Your opinion/proposal:

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If paper is insufficient, please use more.

Reply:

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