SDLG LG6210E User manual

LG6210E
Maintenance Manual
山东临工工程机械有限公司
Shandong Lingong Construction Machinery Co, Ltd

Maintenance Manual──LG6210E Hydraulic Excavator
II
Forward
This maintenance manual includes the
specifications, function information of systems and
units, maintenance instructions, checking and
adjustment methods, schematic diagrams and wiring
diagrams.
Safety
Please refer to "Safety” for safety notes for
maintenance operation on the machine.
Overall
Description I
Please refer to
Operation and Maintenance
Manual for safety problems in operating the
machine.
Maintenance
II
The operating steps are based on the special
purpose tools, E-tools and standard tools available in
the market.
The schematic diagram for E-tool can be found in this
manual.
All the lifting devices such as the belt, sling, and
ratchet wheel shell must confirm to the appropriate
national regulations regarding such devices.
If any lifting device, tool or operating method beyond
the descriptions of this manual is adopted, our
company will not be in such responsibility.
The information and data given in this manual were
valid at time of publication.
We reserve the right to make changes to the
specifications and equipment without prior notice.
Engine
III
Power
Transmission
IV
Braking
System V
Steering
System VI
Frame and
track device VII
Cab and
Interior Trim VIII
Hydraulic
System,
Working
Hydraulic
Pressure and
Other
Equipment
IX
Electrical and
Information
System X

Service Manual──LG6210E Hydraulic Excavator
I
PREFACE...............................................................................................................................................................I
SECURITY.............................................................................................................................................................1
Common precaution...................................................................................................................................1
Security precautions................................................................................................................................................. 1
Safety Devices ......................................................................................................................................................... 1
Clothing and Personal Protective Items.................................................................................................................... 1
Emergency matters preparation............................................................................................................................... 2
Fire Prevention for Oil and Fuel................................................................................................................................ 2
Properly dispose of scrap liquid................................................................................................................................ 2
Working in the dusty environmental ......................................................................................................................... 3
Preparation............................................................................................................................................................... 3
Reasonably and safely use of tools.......................................................................................................................... 4
Security locking system............................................................................................................................................ 4
.Use handrails or ladders.......................................................................................................................................... 5
Precautions when operating .........................................................................................................................5
Maintain the cooling system safety........................................................................................................................... 5
Avoid contacting with high-pressure liquid................................................................................................................ 6
Hoist goods .............................................................................................................................................................. 6
Electric System......................................................................................................................................................... 7
Welding on the machine........................................................................................................................................... 8
Move and operate machinery safely....................................................................................................................... 10
Ⅰ.WHOLE MACHINE DESCRIPTION...............................................................................................................11
1. SUMMARY .....................................................................................................................................................11
Components position......................................................................................................................................... 11
2. SPECIFICATION..............................................................................................................................................12
Standard tightening torque..................................................................................................................................... 12
Tightening torque of split flange screws ................................................................................................................. 13
Tightening torque of hydraulic plug with O ring ...................................................................................................... 14
Tightening torque of rotating nut device with O ring............................................................................................... 14
Engine, specifications............................................................................................................................................. 15
Engine, specifications............................................................................................................................................. 16
Valve clearance, specifications .............................................................................................................................. 16
Fuel pressure, specifications.................................................................................................................................. 16
Coolant, specifications............................................................................................................................................ 17
Engine speed control switch, specifications ........................................................................................................... 17
Electrical system, specifications............................................................................................................................. 17
Engine control, specifications................................................................................................................................. 18
Gauge control unit I-ECU, specifications................................................................................................................ 19
Connecting pins, specifications.............................................................................................................................. 19
Engine control unit E-ECU (EMR2 ), specification.................................................................................................. 20
Vehicle control unit V-ECU, specifications (I-ECU has been assembled.) ............................................................. 21
Battery, specifications ............................................................................................................................................ 24
AC generator, specifications................................................................................................................................... 24
Starting motor, specifications ................................................................................................................................. 24
Battery relay, specifications.................................................................................................................................... 25
Security starting relay, specifications ..................................................................................................................... 25
Preheating, specifications....................................................................................................................................... 25
Battery relay, specifications.................................................................................................................................... 25
Traveling warning, specifications............................................................................................................................ 26
Upper wiper motor, specifications .......................................................................................................................... 26
Cutting switch of battery, specifications.................................................................................................................. 26
Starting switch, specifications................................................................................................................................. 26
Security lever switch, specifications ....................................................................................................................... 27
Manual/auto switch, specifications ......................................................................................................................... 27
Fuse specifications................................................................................................................................................. 28
Slow melt fuse, specification .............................................................................................................................. 28
Relay box, specifications..................................................................................................................................... 29
Resistance box, specification............................................................................................................................. 29
Radio with cassette or CD player specifications............................................................................................... 30
CD and MP3 player with recorder...................................................................................................................... 30
DC-DC converter specification............................................................................................................................ 30
Track gearbox specification................................................................................................................................ 30
Rotary gearbox specifications............................................................................................................................ 30
Travel motor, specifications........................................................................................................................... 31
Rotary unit specifications.................................................................................................................................... 32
Frame and the track unit, specifications............................................................................................................ 32

Maintenance Manual──LG6210E Hydraulic Excavator
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Rotary gear ring，specifications ........................................................................................................................ 33
Regulator, specifications..................................................................................................................................... 34
Cab specifications................................................................................................................................................ 34
Operator seat specifications............................................................................................................................... 35
Recommended hydraulic oil specifications....................................................................................................... 35
Hydraulic oil, specifications................................................................................................................................ 36
Hydraulic pressure，specifications ................................................................................................................... 36
Hydraulic tank, specifications............................................................................................................................. 36
Air conditioning unit，specifications................................................................................................................. 36
Proportional solenoid calve specifications........................................................................................................ 38
Main control valve specifications ....................................................................................................................... 38
Pump, specifications............................................................................................................................................ 40
Servo pump specifications.................................................................................................................................. 41
Accumulator specifications................................................................................................................................. 41
Servo-hydraulic selector valve, specifications.................................................................................................. 41
Solenoid valve, specifications ............................................................................................................................ 42
Remote control valve （lever）specifications.................................................................................................. 43
Remote control valve （pedal）specifications................................................................................................. 43
Walking pedal specifications .............................................................................................................................. 43
Straight pedal specification................................................................................................................................ 43
Hydraulic oil cooling system, specifications..................................................................................................... 44
Rotary oil pump, specifications .......................................................................................................................... 45
Rotary solenoid valve .......................................................................................................................................... 46
Solenoid valve, specifications ............................................................................................................................ 47
Servo-hydraulic selector valve, specifications.................................................................................................. 47
Boom specifications ............................................................................................................................................ 47
Boom cylinder specifications.............................................................................................................................. 48
Bucket arm, specifications.................................................................................................................................. 48
Bucket arm cylinder, specifications ................................................................................................................... 49
Bucket cylinder, specifications........................................................................................................................... 50
3TOOLS ...........................................................................................................................................................51
NET 8940-00200 remote control valve connector replacement tools .............................................................. 51
NET 8940-00190 Moving motor guide pins......................................................................................................... 52
NET 8940-00270 rotating ring replacement tool ................................................................................................ 52
NET 8940-00290 alignment pins of track motor................................................................................................. 53
NET 8940-00300 Rotary gear alignment pins..................................................................................................... 53
4MAINTENANCE INSTRUCTIONS；SECURITY INSTRUCTIONS ................................................................................54
Maintenance position........................................................................................................................................... 54
ⅡREPAIR AND MAINTENANCE.......................................................................................................................56
1LUBRICATING;FUEL;OTHER LIQUIDS...............................................................................................................56
1.1 Overview..............................................................................................................................................56
Recommend lubricants........................................................................................................................................ 56
2. MAINTENANCE...............................................................................................................................................58
2.1 Warranty services...............................................................................................................................58
Guarantee View .................................................................................................................................................... 58
Warranty checking 100 hours ............................................................................................................................. 58
Warranty checking 1000 hours ........................................................................................................................... 59
2.2 Maintenance ........................................................................................................................................60
Regular maintenance........................................................................................................................................... 60
Conditions for testing and maintenance plan.................................................................................................... 60
2.2.1 Maintenance plan ........................................................................................................................................ 60
Daily maintenance................................................................................................................................................ 60
Maintenance every 50 hours ............................................................................................................................... 61
Maintenance every 250 hours ............................................................................................................................. 61
Maintenance every 500 hours ............................................................................................................................. 62
Maintenance every 1000 hours ........................................................................................................................... 62
Maintenance every 2000 hours ........................................................................................................................... 63
Maintenance every 4000 hours ........................................................................................................................... 64
Maintenance every 6000 hours ........................................................................................................................... 66
Test running and checking.................................................................................................................................. 67
Machine, checking the external damage, cracking and worn damage............................................................ 67
Cleanser level, checking...................................................................................................................................... 67
Engine oil level, checking.................................................................................................................................... 68
Coolant level, checking........................................................................................................................................ 68
Hydraulic oil level, checking ............................................................................................................................... 69
Engine oil and filter, replacing............................................................................................................................ 69

Maintenance Manual──LG6210E Hydraulic Excavator
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Draining............................................................................................................................................................. 69
Filling oil............................................................................................................................................................. 70
Fuel filter, replacing ............................................................................................................................................. 70
Additional fuel filter (oil-water separator core), checking / draining............................................................... 71
Water separator filter element, replacing........................................................................................................... 71
Fuel tank sediment, draining............................................................................................................................... 72
Fuel tank ventilation filter, replacing.................................................................................................................. 72
Hydraulic oil servo filter, replacing..................................................................................................................... 73
Main element air filter, cleaning.......................................................................................................................... 73
Main filter of air filter, replacing.......................................................................................................................... 74
Safety filter element of air filter, replacing......................................................................................................... 75
Battery status, checking...................................................................................................................................... 75
Belts and belt tension, checking, replace it if necessary ................................................................................. 76
External radiator / oil cooler outside, cleaning.................................................................................................. 77
Hydraulic tank, oil returning filter, replacing..................................................................................................... 78
Hydraulic oil draining filter, replacing................................................................................................................ 79
Hydraulic oil absorbing filter, cleaning .............................................................................................................. 79
Hydraulic tank, replacing the ventilation filter................................................................................................... 80
Removing .......................................................................................................................................................... 80
Installing ............................................................................................................................................................ 80
Hydraulic tank, hydraulic oil replacing............................................................................................................... 81
Valve clearance, checking / adjusting................................................................................................................ 82
Assembly........................................................................................................................................................... 85
Coolant freezing point, checking........................................................................................................................ 85
Coolant, replacing................................................................................................................................................ 86
Main filter of air conditioning, cleaning.............................................................................................................. 87
Main filter of air conditioning, replacing ............................................................................................................ 88
Cab, pre-filter, cleaning........................................................................................................................................ 89
Cab, pre-filter, replacing...................................................................................................................................... 90
Lubrication, refer to the lubrication chart.......................................................................................................... 90
Rotary motor gear box, changing the oil............................................................................................................ 91
Rotarying ring bearings, lubricating................................................................................................................... 91
Rotary oil bath grease, checking ........................................................................................................................ 92
Cab; door, lid, hinges, fittings and locks, lubricating....................................................................................... 92
Track plate bolts, checking ................................................................................................................................. 92
Track tension / condition, checking ................................................................................................................... 93
Oil level of track gearbox, checking ................................................................................................................... 95
Walking motor gearbox, gear oil replacing........................................................................................................ 95
Loose and missing bolts, checking.................................................................................................................... 95
Hydraulic pressure, checking ............................................................................................................................. 96
2.2.2 Conditional test ........................................................................................................................................... 96
Measurement conditions..................................................................................................................................... 96
Cylinder speed...................................................................................................................................................... 96
Preparation........................................................................................................................................................ 96
Measuring............................................................................................................................................................... 98
Peristaltic of cylinder........................................................................................................................................... 98
Preparation........................................................................................................................................................ 98
Measuring.......................................................................................................................................................... 98
Rotation speed ..................................................................................................................................................... 99
Preparation........................................................................................................................................................ 99
Rotation towards left/right at idle ..................................................................................................................... 100
Preparation...................................................................................................................................................... 100
Measuring........................................................................................................................................................ 100
Measuring clearance of bearing........................................................................................................................ 101
Measuring........................................................................................................................................................ 101
Installation conditions ...................................................................................................................................... 102
Walking speed .................................................................................................................................................... 103
Preparation...................................................................................................................................................... 103
Measuring........................................................................................................................................................ 103
Performance of moving straight ....................................................................................................................... 104
Preparation...................................................................................................................................................... 104
Measuring........................................................................................................................................................ 104
Track running speed.......................................................................................................................................... 105
Preparation...................................................................................................................................................... 105
2.3 Emergence measures.......................................................................................................................105
2.3.1 Jump connection starting......................................................................................................................... 105
Start the engine with the actuating cable......................................................................................................... 105
ⅢENGINE SYSTEM ........................................................................................................................................107

Maintenance Manual──LG6210E Hydraulic Excavator
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1OVERVIEW OF THE ENGINE ............................................................................................................................107
BF6M2012C Engine............................................................................................................................................ 107
Engine characteristics curves........................................................................................................................... 110
BF6M2012C engine......................................................................................................................................... 110
Basic examination, engine ................................................................................................................................ 110
Purpose of the basic examination.................................................................................................................... 110
Testing of the basic examination ..................................................................................................................... 111
Troubleshooting................................................................................................................................................. 111
1.1 Cylinder head ....................................................................................................................................112
Cylinder cover, indication.................................................................................................................................. 112
BF6M2012CEngine ......................................................................................................................................... 112
Valve.................................................................................................................................................................... 113
Decisive cylinder cover gasket......................................................................................................................... 113
Measuring projection of piston......................................................................................................................... 113
Installing cylinder cover .................................................................................................................................... 115
Tool.................................................................................................................................................................. 115
Tightening sequence ....................................................................................................................................... 115
1.2 Pistons...............................................................................................................................................116
Piston, indication ............................................................................................................................................... 116
BF6M2012C Engine ........................................................................................................................................ 116
Piston rings, indication...................................................................................................................................... 116
Piston cooling..................................................................................................................................................... 117
1.3 Valves mechanery.............................................................................................................................117
Valves, indication............................................................................................................................................... 117
Valve , adjusting................................................................................................................................................. 117
Assembly ............................................................................................................................................................ 120
1.5 Engine Assembly..............................................................................................................................121
Engine Assembly ............................................................................................................................................... 121
2LUBRICATION SYSTEM...................................................................................................................................122
Lubrication system, indication.......................................................................................................................... 122
Oil flow process chart ...................................................................................................................................... 122
Diagram, oil circuit........................................................................................................................................... 123
Lubrication system, working principle............................................................................................................. 123
Oil pipeline....................................................................................................................................................... 123
Lubricating oil pump......................................................................................................................................... 124
Oil cooling tank................................................................................................................................................ 125
3FUEL SYSTEM...............................................................................................................................................126
3.1 Overview............................................................................................................................................126
Fuel system, indication...................................................................................................................................... 126
Fuel flow system diagram................................................................................................................................ 127
Fuel injection system, indication...................................................................................................................... 128
Oil supply pump............................................................................................................................................... 128
3.2 Fuel pump; filter; oil mesh...............................................................................................................129
Fuel system, leakage.......................................................................................................................................... 129
Oil supply pump, replacing ............................................................................................................................... 130
Fuel filter, replacing ........................................................................................................................................... 131
Additional extra oil filter, replacing .................................................................................................................. 132
3.3 Fuel Tank ...........................................................................................................................................133
Description of the fuel tank............................................................................................................................... 133
3.4 Injectors; oil supply pipelines .........................................................................................................134
Injector, indication ............................................................................................................................................. 134
Injector, replacing one....................................................................................................................................... 135
Fuel rail pressure, checking.............................................................................................................................. 135
Test conditions ................................................................................................................................................ 135
Engine starting conditions................................................................................................................................ 136
The engine is running, but without load........................................................................................................... 137
In the case that the load of engine is too high ................................................................................................. 137
4AIR INTAKE SYSTEM;EXHAUST SYSTEM .........................................................................................................138
4.1 Overview............................................................................................................................................138
Air intake system, instruction........................................................................................................................... 138
Exhaust System, instruction............................................................................................................................. 139
Seal clamp, installation.................................................................................................................................... 139
4.2 Air cleaner with the connecting pipe; air preheater......................................................................140
Preheating coil, replacing.................................................................................................................................. 140
4.3 Inflatable cooler and connecting pipe............................................................................................140
Boost air cooler, indication............................................................................................................................... 140
Boost air cooler connections (hoses, rigid tube), replacing.......................................................................... 141
5COOLING SYSTEM ........................................................................................................................................142

Maintenance Manual──LG6210E Hydraulic Excavator
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5.1 Overview............................................................................................................................................142
Cooling System,instruction............................................................................................................................... 142
Cooling system, operating ................................................................................................................................ 143
Coolant............................................................................................................................................................ 143
Draining the cooling system............................................................................................................................. 145
5.2 Radiator, including assembly and connection..............................................................................145
Coolant, replacing.............................................................................................................................................. 145
Draining the coolant......................................................................................................................................... 145
Filling the coolant in the cooling system.......................................................................................................... 146
5.3 Coolant pumps; thermostat.............................................................................................................146
Thermostat, replacing........................................................................................................................................ 146
Thermostat, checking ........................................................................................................................................ 147
5.4 Fan; fan cover; fan coupler..............................................................................................................148
Fan belt and / or generator belt, compressor belt, replace all belts .............................................................. 148
6ENGINE CONTROL.........................................................................................................................................150
6.1 Overview............................................................................................................................................150
Normal conditions (auto position).................................................................................................................... 150
Emergency ...................................................................................................................................................... 150
6.2 Speed control....................................................................................................................................151
Engine speed control switch description......................................................................................................... 151
Engine speed control switch, checking ........................................................................................................... 151
Checking.......................................................................................................................................................... 151
ⅣPOWER TRANSMISSION............................................................................................................................152
1GEAR BOX....................................................................................................................................................152
1.1 Track gearbox ...................................................................................................................................152
Track gearbox, instruction ................................................................................................................................ 152
Notes of track gearbox operation ..................................................................................................................... 155
Installation ....................................................................................................................................................... 155
Tightening torque............................................................................................................................................. 156
Replacement procedure of gear oil.................................................................................................................. 156
Operation Checking......................................................................................................................................... 157
Track gearbox, maintenance standards........................................................................................................... 157
Seal washer..................................................................................................................................................... 157
Components, replacement standard................................................................................................................ 157
Common tools ................................................................................................................................................. 158
Special tools.................................................................................................................................................... 159
Gasket thickness measurement fixtures.......................................................................................................... 159
Track gear box, removing.................................................................................................................................. 159
Track gear box, installing.................................................................................................................................. 160
Track gear box, replacing the lid ...................................................................................................................... 161
Track gearbox removing.................................................................................................................................... 162
Track gear box, assembly.................................................................................................................................. 166
Preparation...................................................................................................................................................... 166
Tightening torque............................................................................................................................................. 166
Track gearbox, troubleshooting........................................................................................................................ 172
1.2 Rotary gearbox + rotary pinion gear shaft.....................................................................................173
Rotary gear box, instruction.............................................................................................................................. 173
Model Code..................................................................................................................................................... 173
Rotary gear boxes, cross sections................................................................................................................... 174
Function........................................................................................................................................................... 175
Operating......................................................................................................................................................... 175
Turn gearbox, lubricating.................................................................................................................................. 176
Notes about lubrication.................................................................................................................................... 176
Maintenance standard of rotary gear box ........................................................................................................ 177
Seals................................................................................................................................................................ 177
Replacement standard of parts........................................................................................................................ 177
General Tools.................................................................................................................................................. 179
Special tools.................................................................................................................................................... 180
Rotary gearbox, disassembling ........................................................................................................................ 184
Note................................................................................................................................................................. 184
Disassembly.................................................................................................................................................... 184
Rotary gear box assembly................................................................................................................................. 188
Note................................................................................................................................................................. 188
Tightening torque............................................................................................................................................. 188
Assembly......................................................................................................................................................... 189
Troubleshooting of rotary gearbox................................................................................................................... 195
2HYDROSTATIC DRIVE (HYDRAULIC MOTOR,INCLUDING THE OPERATING SYSTEM).............................................197

Maintenance Manual──LG6210E Hydraulic Excavator
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2.1 Hydraulic motor 1, travel motor ......................................................................................................197
Travel motor,instruction.................................................................................................................................... 197
Operating, the hydraulic motor ........................................................................................................................ 200
Operating, brake valve..................................................................................................................................... 201
Operating, parking brake................................................................................................................................. 202
Operating, displacement conversion valve...................................................................................................... 203
Travel motor, operation precautions................................................................................................................ 205
Installing .......................................................................................................................................................... 205
Pipeline system ............................................................................................................................................... 205
Lubricating....................................................................................................................................................... 205
Travel motor, maintenance standards.............................................................................................................. 205
Maintenance and replacement standards of parts........................................................................................... 205
Gasket............................................................................................................................................................. 206
Replacement standards of parts...................................................................................................................... 206
Pressure relief valve of travel motor, replacing............................................................................................... 209
Travel motor, disasembly.................................................................................................................................. 210
Note................................................................................................................................................................. 210
Travel motor, assembly ..................................................................................................................................... 218
Note................................................................................................................................................................. 218
Brake, assembly.............................................................................................................................................. 219
Troubleshooting of track motor........................................................................................................................ 226
2.2 Hydraulic motor 2, rotary motor......................................................................................................230
Rotary motor instruction ................................................................................................................................... 230
Rotation system, components... ...................................................................................................................... 230
Rotary motor, structure.................................................................................................................................... 231
Rotary motor working principle ........................................................................................................................ 233
Hydraulic motor ............................................................................................................................................... 233
Anti-cavitation valve......................................................................................................................................... 234
Valve (Model: KRD22EK10C).......................................................................................................................... 234
Rebound damping valve.................................................................................................................................. 236
Rotation brake ................................................................................................................................................. 238
Maintenance standards of rotary motor........................................................................................................... 239
Lubrication and exhaust of rotary motor .......................................................................................................... 239
Note about lubrication...................................................................................................................................... 239
Maintenance and replacement standard of parts............................................................................................. 239
Gasket............................................................................................................................................................. 239
Replacement standards of parts...................................................................................................................... 240
Cross safety valve, pressure adjustment......................................................................................................... 241
General Tools.................................................................................................................................................. 242
Special tool...................................................................................................................................................... 242
Rotary motor, replace ........................................................................................................................................ 242
Pressure relief valve of travel motor, replacing............................................................................................... 242
Rotary motor has been removed, replacing the seals .................................................................................... 244
Rotary motor, replacing the brake piston seals .............................................................................................. 245
Pressure reducing valve of rotary motor, replacing ....................................................................................... 247
Rotary motor, disassembly ............................................................................................................................... 248
Rotating motor assembly...................................................................................................................................... 251
Tightening torque. ................................................................................................................................................ 251
Rotary motor troubleshooting............................................................................................................................... 256
Determine the possible causes ............................................................................................................................ 256
Be careful of dirt................................................................................................................................................. 256
Operating components...................................................................................................................................... 256
Motor troubleshooting....................................................................................................................................... 256
Check the oil in the tank.................................................................................................................................... 256
Abnormal noise .................................................................................................................................................. 256
Pressure measurement of all the components................................................................................................ 256
Measuring the displacement of motor.............................................................................................................. 256
Motor can’t rotate............................................................................................................................................... 257
Rotation of motor is reverse.............................................................................................................................. 257
Rotation speed is not up to the set value......................................................................................................... 258
Torque is not enough......................................................................................................................................... 258
Hydraulic motor slides too much...................................................................................................................... 258
Hydraulic is leak from the seals........................................................................................................................ 259
Hydraulic is leak from the mating surface. ...................................................................................................... 259
2.3 Hydraulic pump includes couplers, running including the operation system......................................260
Flexible coupling................................................................................................................................................... 260
Flexible coupling, removing.............................................................................................................................. 261
Flexible coupling, installation ........................................................................................................................... 261
2.4.Rotary joints; pipeline..........................................................................................................................262

Maintenance Manual──LG6210E Hydraulic Excavator
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Rotating joints description .................................................................................................................................... 262
Rotary joints,assembly...................................................................................................................................... 263
Rotary joints, tools............................................................................................................................................. 264
Common tools ................................................................................................................................................. 264
Special tools.................................................................................................................................................... 265
Rotary joint soft hose (valve - rotary joints), replacing................................................................................... 266
Rotary joint hose (Rotary joints - motor), replacing........................................................................................ 267
Rotary joints, dismantling ................................................................................................................................. 268
Rotary joints, assembly..................................................................................................................................... 270
Rotary joint,checking and troubleshooting ..................................................................................................... 273
Inspection after assembly..................................................................................................................................... 275
Troubleshooting................................................................................................................................................. 276
3UPPER ROTARY SYSTEM................................................................................................................................277
Rotary Gear Description....................................................................................................................................... 277
Ring gear lubricating pipe, replacing ............................................................................................................... 278
ⅦFRAME AND TRACK EQUIPMENT ............................................................................................................279
1FRAME .........................................................................................................................................................279
1.1 Overview.............................................................................................................................................279
Upper structure, dissembbly................................................................................................................................. 279
Upper structure, installing................................................................................................................................. 279
1.2 Counter weight....................................................................................................................................280
Additional weight and mining equipment.............................................................................................................. 280
Counter weight, removing................................................................................................................................. 280
Balancing weight, installing Important! Move the control locking lever downwards to lock the system. . 281
1.3 Frame, the lower part of body.............................................................................................................282
Underframe / chassis, indication ...................................................................................................................... 282
2TRAVELLING DEVICES(WHEELS;TRACK;TIRES;HUB).....................................................................................282
Select the track pieces....................................................................................................................................... 282
The method selecting track pieces................................................................................................................... 282
2.1.Front idle control, including the front fork.....................................................................................284
Guiding wheel, specification............................................................................................................................. 284
Guiding wheel, measuring................................................................................................................................. 285
Measuring thread surface and flange wear...................................................................................................... 286
Guiding wheel,dissembly or assembly tools................................................................................................... 287
Guiding wheel, dissembling.............................................................................................................................. 287
Guide wheel assembly....................................................................................................................................... 289
Front guide wheel, replacement........................................................................................................................ 290
2.2 Sprocket teeth...................................................................................................................................291
Sprocket, wear measurement............................................................................................................................ 291
Measure the profile of sprocket tooth .............................................................................................................. 292
Measure sprocket tooth width........................................................................................................................... 292
Sprocket, replacement....................................................................................................................................... 292
2.3 Steel Track.........................................................................................................................................293
Track, adjust the track tension.......................................................................................................................... 293
Track chain,specification................................................................................................................................... 294
Track chain ......................................................................................................................................................... 294
Track chain, wear limitation .............................................................................................................................. 294
Track chain，wear measurement ..................................................................................................................... 296
Measure the wear of track connection pitch.................................................................................................... 296
Measure wear of the outside diameter of bushing.......................................................................................... 296
Wear measurement of connection height........................................................................................................ 297
Measure the wear of the height track plate...................................................................................................... 298
Track chain, removing ....................................................................................................................................... 299
Track chain, installing........................................................................................................................................ 300
Main pin ,assembly ............................................................................................................................................ 301
Track chain assembly, removing...................................................................................................................... 302
Track chain assembly, assembling .................................................................................................................. 303
Track chain assembly, removing...................................................................................................................... 305
2.4 Supporting sprocket; sliding rail..................................................................................................306
Description of the top roller .............................................................................................................................. 306
Supporting sprocket; measuring...................................................................................................................... 306
Measure the wear of outside diameter of supporting sprocket thread.......................................................... 307
Measure the wear of flange width of supporting sprocket............................................................................. 308
Top rollers,dissembly and assembly tools ...................................................................................................... 308
Top roller, dismantling....................................................................................................................................... 309
Supporting wheel, assembly............................................................................................................................. 309
Top roller, replacing one.................................................................................................................................... 311

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Installation............................................................................................................................................................ 311
2.5 Bottom roller .....................................................................................................................................312
Bearing wheel specification.............................................................................................................................. 312
Bearing wheel,wear limitation........................................................................................................................... 313
Measure the wear of outside diameter of roller thread................................................................................... 314
Measure the wear of flange width of roller....................................................................................................... 314
Bearing wheel, installing ................................................................................................................................... 315
Bearing wheel, dissembly and assembly tools ............................................................................................... 316
Roller, dismantling............................................................................................................................................. 316
Bearing wheel, assembly................................................................................................................................... 318
Track plate, replacing one................................................................................................................................. 320
2.7 Spring kit; tensioning device...........................................................................................................321
Spring group description................................................................................................................................... 321
Spring group, dismantling................................................................................................................................. 322
Spring group, dissembly ................................................................................................................................... 323
Track tension spring(Tensioner) assembly, replacing.................................................................................... 324
ⅧCAB AND INTERIOR TRIMMING................................................................................................................326
1. CAB .......................................................................................................................................................326
Cab specifications (Refer to overview)............................................................................................................. 326
Cab, removing .................................................................................................................................................... 326
Cab, installing..................................................................................................................................................... 326
Fiber plastic device, description....................................................................................................................... 327
Fiber plastic device, removing.......................................................................................................................... 327
Fiber plastic device, installing .......................................................................................................................... 328
2OPERATOR SEAT ..........................................................................................................................................329
The operator seat specifications (Refer to Overview)..................................................................................... 329
Operator seat instructions................................................................................................................................. 329
Operator seat, tightening torque....................................................................................................................... 330
Seat, replacing.................................................................................................................................................... 330
3AIR CONDITIONING UNITS...............................................................................................................................331
3.1 Overview ..........................................................................................................................................331
Air-conditioning unit, specifications (Refer to Overview)............................................................................... 331
Air-conditioning unit, instruction...................................................................................................................... 331
Air Conditioning Components .......................................................................................................................... 334
Air conditioning switch...................................................................................................................................... 338
Automatic air conditioning switch..................................................................................................................... 338
Air conditioning switch function........................................................................................................................ 339
Control system, indication ................................................................................................................................ 342
Temperature setting......................................................................................................................................... 343
Initial heating mode.......................................................................................................................................... 343
Air mixture throttle control................................................................................................................................ 343
Blower fan speed control................................................................................................................................. 343
Model throttle control....................................................................................................................................... 344
Gas inlet control............................................................................................................................................... 344
Memory and Replay......................................................................................................................................... 344
Protection of compressor................................................................................................................................. 345
Self-diagnostics and instruction of system status............................................................................................ 345
Emergency mode ............................................................................................................................................ 346
Expansion valve ................................................................................................................................................. 346
Expansion valve ,description........................................................................................................................... 346
Expansion valve, operation.............................................................................................................................. 347
Evaporator .......................................................................................................................................................... 348
Evaporator,instruction...................................................................................................................................... 348
Compressor........................................................................................................................................................ 348
Compressor,instruction.................................................................................................................................... 348
Condenser........................................................................................................................................................... 350
Condenser,instruction...................................................................................................................................... 350
Dry Filter.............................................................................................................................................................. 350
Dry cleaner, instructions.................................................................................................................................. 350
Drier................................................................................................................................................................. 350
Pressure Switch............................................................................................................................................... 351
Safety valve..................................................................................................................................................... 351
Drier, replacing................................................................................................................................................... 352
Refrigerant hose................................................................................................................................................. 352
Blower motor...................................................................................................................................................... 353
Ceramic resistor................................................................................................................................................. 353
3-point relay........................................................................................................................................................ 354
Actuator, foot / face driver................................................................................................................................. 355