CLG920E, 922E, 923E (Cummins & ) Service Manual 202009002-En

202009002
CLG920E/922E/923E
Hydraulic Excavator
Service Manual
Applicable Model and Engine Model:
CLG920E/922E/Commins QSB7 (China II/ EU Stage II)

CLG920E/922E/923E Commins QSB7 (China III/ EU Stage IIIA)
CLG922E/India Commins B5.9 (CEV BS II)
September 15, 2020 Contents
CLG920E/922E/923E
Contents
Safety ........................................................ 1-1

Foreword ................................................... 2-1
Structural Function and Maintenance .... 3-1
Parameters ................................................ 4-1
Test and Adjustment ................................ 5-1
Fault Diagnosis ........................................ 6-1
Removal and Installation ......................... 7-1
Attached drawing ..................................... 8-1
Contents September 15, 2020
CLG920E/922E/923E
1-1
September 15, 2020 Safety
CLG920E/922E/923E
1 Safety
1.1 Safety Precautions .............................................................................................................. 1-4
Compressed Air ........................................................................................................................ 1-6
High-Pressure Solution ............................................................................................................. 1-6
Safe Disposal of Waste Liquid .................................................................................................. 1-7
Precautions for Accumulator Application .................................................................................. 1-7
Asbestos ................................................................................................................................... 1-7
Prevent Crushing Or Cutting..................................................................................................... 1-8
Prevent Burn ............................................................................................................................. 1-9
Coolant...................................................................................................................................... 1-9
Oil.............................................................................................................................................. 1-9
Battery..................................................................................................................................... 1-10
Safety Guides of Fire and Explosion....................................................................................... 1-10
Diethyl Ether ........................................................................................................................... 1-11
Pipeline, Pipe and Hose.......................................................................................................... 1-11
Fire Extinguisher and First-Aid Kit .......................................................................................... 1-12
Preventing Thunder ................................................................................................................ 1-12
Cab Protector.......................................................................................................................... 1-12
Top Guard and Front Guard.............................................................................................. 1-12
Measures in Emergencies................................................................................................. 1-13
Inner Space of Cab ................................................................................................................. 1-13
Precautions for Accessories ................................................................................................... 1-13
1.2 Precautions for Lifting and Collaborative Operations........................................................ 1-14
Precautions for Operating Mobile Crane................................................................................. 1-15
Precautions for Operating Bridge Crane ................................................................................. 1-15
Cable Selection....................................................................................................................... 1-16
1-2
Safety September 15, 2020
CLG920E/922E/923E
1-3
CLG920E/922E/923E
Most accidents occurred in product operation, maintenance and repair are resulted from ignoring the basic
safety rules or protective measures. Accidents can be avoided if enough attention is paid to potential risks.
Workers shall be familiar with the potential hazards and conduct necessary training to obtain certain
troubleshooting skills. Incorrect operation, lubrication, maintenance, and repair are all dangerous, and death of
workers may occur in the worst-case scenario. No operation, lubrication, maintenance, or repair is permitted
on any machine before reading and fully understanding the contents of each section.
The safety precautions and warnings are all listed in this manual and on the product. If these warnings are
ignored, it may cause the death of relative personnel.
Hazards are identified with “Safety warning symbols” followed by “signal terminology”, such as “Danger”,
“Warning” and “Caution”. "Warning" identification for safety is as follows:
The meaning of the safety warning symbol is as follows:

Caution! Be careful! For your safety!
Under warning sign, the danger contents are explained with text or diagram. Operations that could possibly
damage the machine are all marked “Caution” or “Warning” on the machine and in this manual. It is impossible
for LiuGong to predict every potential risk in the working environment; therefore, the warnings in this manual
and on the product are somewhat not exhaustive. If any tool, procedure, method or technique applied which is
not recommended by LiuGong, you should make sure of your safety and others’ as well. Also make sure that
no operation, lubrication, maintenance or repairing process you have selected would make the machine
damaged or endangered. The instructions, numerical values and illustrations in this manual are prepared using
the latest available data. Due to the continuous improvements made on the design of this machine, changes in
detail may have not been shown in this manual.
Please contact LiuGong or its dealers if you would like to know about the latest information or if you have any
doubts about the data in this manual.
California Proposition 65
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth
defects and other reproductive harms.
Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after
handling.
1-4
1.1 Safety Precautions CLG920E/922E/923E
1.1 Safety Precautions severe damage or even death.
Please read and be familiar with all safety precau-

tions; otherwise, it may cause severe damage or
even death.
Only trained and qualified workers are permitted to
operate and maintain the machine.
The operator shall wear helmet and safety glasses

of rigid materials and safety shoes, face shield, and
gloves when conducting operations and mainte-
nance.
Do not operate the machine if you feel uncomfort-

able, feel sleepy, or drunk. In this case, it may
cause misjudgment in operation and increase the
possibility of accidents. Please hang the labels “Do
not Operate” or similar warnings on the starting
switch or the operation lever before the mainte-
nance of the machine.
G
IN
Goggles, safety glasses or face shield can protect

N
AR
your eyes from high-pressure fluid during the main-

W
er ot
!
tenance of the battery and the flying debris gener-

op o n
e
at
ated during the engine running and using tools.

d
Please wear the protection mask when removing

spring, elastic parts or adding acid to the battery.
Please wear the safety helmet and goggles when
r:
te
ra
pe
O
welding or cutting by using the welding gun.

e:
at
D
Do not wear casual clothes, jewelry, ornaments, or

keep long hair. Because they may be drawn into the
control system or the moving parts and lead to
1-5
CLG920E/922E/923E 1.1 Safety Precautions
If you work under a loud noise, please wear appro- • Learn about the gesture signals and their
priate hearing protection devices, such as earmuff sources at the workplace, and only receive the
or earplug, to avoid damage to hearing. signals from one person.
• Never keep the maintenance solution in glass
containers.
• Please follow related regulations when dispos-
ing of hazardous substances such as lubricant,
fuel, coolant, solvent, filter, battery and others.
• Use detergents carefully. Do not use inflamma-
ble materials such as diesel or gasoline for
detergents. It may catch fire.
• Ensure that all guard plates and covers of the

machine are fastened to the machine.
• Please ensure that there is no chip, greasy dirt,
and tool on the machine, especially on the
instrument panel, channel and ladder. Put utili-
ties in place, such as the lunch boxes and tools.
When inspecting the opened oil tanks and water
tanks prevent foreign bodies from entering the • Report all necessary repair work timely.
system component. Please clear yourself and
• Persons without permission or authorization
move wrenches and nuts with great care before
cannot stay onto or around the machine.
removing the cover.
• It is prohibited to modify the machine without
LiuGong's consent, and LiuGong will not be
responsible for the aftermath due to modifica-
tion.
1-6
Compressed Air
Compressed air may cause personal injury. Wear
the mask, protection suits and safety shoes when
using the compressed air for cleaning. Do not point
the compressed air at yourself or anyone. The com-
pressed air may penetrate the skin and lead to
severe injury or even death. The maximum pressure
of the compressed air for cleaning should be lower
than 0.2 MPa.
High-Pressure Solution
If the pressured liquid is leaked, even if it is as small

When overhauling or replacing pipes for the as a pinhole, it may still penetrate the muscles and
cause personal injury. If shot by the spouted high-
hydraulic system, check if the system pressure
pressure oil, please contact a doctor immediately.
has been released in order to prevent from
being scalded by high-pressure oil. Hydraulic
oil under pressure that spattered will cause
serious harm to the skin.
Be careful to remove the hydraulic pipelines or

joints. When the oil spouts, the released high-
pressure oil may lead to the continuous
movement of the hoses.
Please wear safety goggles and leather gloves

when checking for leakages. Do not use bare
hands, plate or paper plate should be used
instead.
1-7
Safe Disposal of Waste Liquid • Slowly charge the nitrogen into the accumulator
to avoid the breakage of the rubber bag.
• Inappropriate disposal of waste liquid will dam- • The air valve of the accumulator should be
age the environment. Please observe local laws installed upward vertically. The accumulator
and regulations when disposing of waste liquid. shall be stably fixed on the bracket without being
• It is necessary to collect and keep the liquid welded.
spattering during the inspection, maintenance, • Do not drill any hole on the accumulator or carry
test, adjustment and repair of the machine with open fire or heat sources close to the accumula-
a vessel. Proper containers shall be prepared tor.
before opening any fluid cavity or disassembling
the parts containing liquid. Collect with a proper • Do not conduct any welding operation on the
container when draining liquid. Do not use food accumulator.
or drink containers, because they could be • The accumulator is a high-pressure vessel and
drunk by others by mistake. shall be replaced and repaired by professionals
only.
• Release the air before discarding the accumula-
tor.
Asbestos
Inhalation of asbestos powder is harmful to your
health. The product does not contain any asbestos
and LiuGong Machinery Co. Ltd recommends using
genuine LiuGong spare parts. If materials that you
need to deal with containing asbestos fiber, please
observe the following rules:
• Never use compressed gas when cleaning. The
water can be used to sink the dust.
Precautions for Accumulator Appli-
cation • You can use the vacuum cleaner with high filter-
ing properties.
• Read the following requirements and properly • Do not grind the materials containing asbestos
use the accumulator since the accumulator with dust.
the high-pressure nitrogen is dangerous.
• In a possible case, the machine shall be oper-
• The accumulator shall be checked before ated in upstream air.
charging nitrogen. It is prohibited to charge the
accumulator with gas if the accumulator does • Please observe local laws and regulations when
not have a nameplate; the words on the name- disposing of asbestos.
plate are missed so that its type cannot be iden- • Take a bath after contacting asbestos.
tified; if the steel seal marks are incomplete or
cannot be read clearly; or if there are defects on • If necessary, an effective protective mask
the housing and therefore safe use cannot be should be used.
ensured.
• The accumulator can only be charged with nitro-
gen, and it is prohibited to charge with oxygen,
compressed air or other inflammable gas to
avoid explosion.
1-8
• Make sure there's no foreign matter in the vanes

Prevent Crushing or Cutting of engine fan. Fan vanes will throw out or cut off
the tools and other things that dropped or
• Do not have your hands, arms or any other parts pushed in it.
of your body placed between moving parts. For
example, between work implement and cylinder, • Unless otherwise stated, any adjustment is not
between machine and work implement. permitted to be performed when the machine or
engine is running.
• The equipment should be properly supported
when operating under the work implement. Do • If maintenance must be performed when the
not support the work implement depending on machine is running, do not let the machine stay
the hydraulic cylinder. Work implement will drop in an unattended status. Assign a worker to stay
down if the control mechanism moves or in the operator seat and prepare to shut down
hydraulic pipeline leaks. If it is necessary to the engine at any time.
remove the shield during maintenance, then the • Do not use twisted or worn wire rope. Wear
installation of the shield afterward is required. gloves during operation and moving.
• Revolving vane of engine has risks of cutting the • When forcing to extrude the block pin, make
fingers; therefore, it is advised to shut down the sure there is no one around. Wear safety gog-
engine or keeping a safe distance when repair- gles in order to protect your eyes.
ing.
• When hammering please make sure that the fly-
ing debris will not hurt anyone.
1-9
Prevent Burn Oil

After running for a period of time, parts of the Hot oil and parts will cause injury to workers. Do not
machine will be heated and those parts shall be let the hot oil and parts contact your skin.
inspected or repaired after cooled down.
Coolant
At working temperature, the engine coolant is at
high temperature and pressure. The radiator and all
the pipes connected to the radiator contain hot
water or vapor If you touch them, serious burn
would occur.
• Under working temperature, the hydraulic oil

tank is hot and contains pressure.
• When opening the oil filler cap of the hydraulic
oil tank, shut off the engine and cool the filler
cap down until it can be opened by bare hands.
Remove the tank cover slowly to release the
pressure of the hydraulic oil tank to prevent from
being scalded by hot oil.
• When checking the coolant level, the engine • Release the system pressure before disassem-
shall be shut off and the filler cap shall be cooled bling all pipes, fittings, or relevant parts.
to the extent that it can be opened by bare
hands.
• Slowly loosen the filler cap of the cooling system
to release the pressure.
• Coolant contains alkali which may cause injury
and do not let it contact your skin, eyes and
mouth.
1-10
Battery
• Smog discharged from the battery may cause
explosion.
• Do not smoke when you are checking the bat-
tery electrolyte level.
• Electrolyte is an acidic material, and please do
not contact the electrolyte, especially skins and
eyes.
• You shall wear safety goggles and gloves when
inspecting the battery.
• Clean and tighten all the electrode connectors.

Check daily if the wire is loosen or broken.
Before starting, tighten the loose power supply
switch, and repair or replace the worn electric
wires.
• Store the fuel, lubricant into containers with cor-
respondent marks. Prevent being used by non-
staff member.
• Put the cleaning cloth or other combustible
materials with oil soaked into a protective con-
tainer and placed in a safe place.
• Do not perform welding or flame cutting onto the
pipe that contains combustible liquid. Before
welding or cutting, the operation shall be per-
Safety Guides of Fire and Explosion formed until flammable liquid is cleaned com-
pletely.
• All fuels, most lubricant and some refrigerant • Accumulated flammable materials such as fuel,
mixtures are flammables. lubricant or other utilities on the machine shall
be cleaned up.
• Fuel leaking onto the hot surface or electric ele-
ments may cause fire. • Do not operate the machine near an open fire.
Make sure the battery is far away from open fire
• Do not smoke when you are refueling, near refu-
and sparks, and do not smoke at the place of
eling area, or in places that could possibly store
battery charging.
flammables.
• When the machine is started with a jump
method, the (+) cable must be connected to the
battery (+) terminal which is connected with start
motor coil, and (-) of external power is con-
nected with (-) of the starter. If there is no nega-
tive terminal, it shall be connected to the engine
housing.
• Do not charge the frozen battery to avoid the
explosion.
1-11
Diethyl Ether Pipeline, Pipe and Hose

• Do not warp or hammer the high-pressure pipe-
line, and do not install the broken pipes or hoses
onto the machine.
Ether is forbidden for starting machine. • Repair the loose or damaged pipelines of fuel
and lubricants, pipes, and hoses of the hydraulic
Any attempts to start the engine by using diethyl system in time. Leakage will cause fire hazard,
ether may cause serious damage to the engine and and if repair or replacement is necessary,
worker casualties. please contact the authorized dealer by Liu-
Gong Machinery Co., Ltd.
If the following problems occur, it shall be replaced:
• Damage or leakage of connector.
• The outer layer of hose is worn or cracked, and
reinforced steel wires are exposed.
• Partial bulge of hose.
• Hose with obvious twisting or flattening.
• The reinforced guide wire of the hose is embed-
ded into the outer layer.
• The connector end is misaligned.
Make sure that all clamps, guards and heat shields
are installed correctly to avoid shaking or overheat-
ing by friction with other parts.
When removing the connecting pipe of the A/C
compressor, an open fire is forbidden; otherwise, it
will generate toxic gas which results in poisoning.
1-12
Fire Extinguisher and First-Aid Kit Preventing Thunder

• Be sure to equip fire extinguisher, carefully read Do not access the machine when there is lightning
its use instructions, and be sure to know how to near it.
use it.
If the thunder occurs when you are already sitting in
• The construction site must have a first-aid kit in the cab, please stay in it; and if you're on the
stock. Conduct regular inspections and add ground, please keep away from the machine.
some medicines if necessary.
• You should know how to handle fire hazards
and injuries.
• Save numbers of emergency contacts (such as
doctor, first-aid center, fire station, etc.) for the
emergency situation. Post the contact number
list onto the specified locations to ensure that
the staff knows the correct contact information.
Cab Protector
Top Guard and Front Guard
The protectors are installed to prevent drivers from
falling or splashing objects under some special cir-
cumstances. Make sure to close the window before
hazardous work. All workers except the driver must
Inspect and maintain the fire extinguisher fre- be kept away hazardous zone. Please add TOP-
quently. Follow the recommended ways listed on Guard and FRONT Guard when necessary.
the instruction panel.
1-13
Inner Space of Cab

This LiuGong machine is equipped with a cab meet-
ing the industry standards: “SAE J154” and “ISO
3411”, in which provides the requirements to the
1
cab space.
Any modification of cab shall not occupy the speci-
fied space. Installation of radio, fire extinguisher and
other devices must keep specified space. Any
object brought into the cab shall not occupy the
specified space. Lunchbox or other utilities must be
2 fixed. When driving on an uneven ground or rolling
over, those utilities shall not endanger the cab.
LG906D01001
1. Top guard 2. Front guard Precautions for Accessories
Measures in Emergencies It should be installed and commissioned by qualified
workers. The operators should be trained, and oper-
If case of emergency, break the window using the ation and maintenance shall be performed strictly
escape hammer placed in the cab, and get out of according to the operation instructions.
the cab.
When installing and using the spare accessories,
please read related instructions, manuals, and infor-
mation about the accessories.
Incorrect installation or purchase of accessories will
not only cause safety issues, but it will have a nega-
tive effect on service life and operation of the
machine.
Do not use the accessories unauthorized by Liu-
Gong. Using unauthorized accessories will cause
safety issues, do harm to the normal operation of
the machine and influence its service life.
It is forbidden to make any modification on the
accessories without permission.
LiuGong Machinery Co., Ltd is not responsible for
1. Escape hammer 2. Fire extinguisher the injury, accident and damage of the machine due
(optional)
to using unauthorized accessories.
1-14
1.2 Precautions for Lifting and Collaborative Operations CLG920E/922E/923E
1.2 Precautions for Lifting and within 9.8 kN {1000 kg}. If it is kept vertical, two wire
ropes can lift 19.6 kN {2,000 kg} in total; however,
Collaborative Operations when the suspension angle of two wire ropes pres-
ents 120°, the lifting weight becomes 9.8 kN {1000
1. One worker sends out a cooperative signal to kg}. On the other hand, if the lifting angle is 150°, for
fully keep the contacts among common lifting a load of 19.6 kN {2000 kg}, the two wire
operating workers. The signalman shall send ropes will bear a force of 39.2 kN {4000 kg}.
out a signal and stay in a safe place where the
driver can see easily and understand the
operating state. The signalman shall stand in
front of the lifted load and safely guide lifting
operation.
• Do not stand under the lifted load.
• Do not climb on the lifted load.
2. Check sling, etc. before lifting operation.
3. Gloves shall be wearing during lifting. (Leather
gloves are the best)
4. Visually check the weight to confirm the center
of gravity of the lifted load.
5. Use slings suitable for the weight of the lifted
load or lifting mode. Load may fall if thicker wire 8. Use a pad to avoid damage to wire ropes when
ropes are used for lighter load. installing them on the lifted load with edges and
6. Try to avoid lifting by single wire ropes. Lifted corners. For the lifted loads that could easily
loads may rotate or fall due to looseness. Use slide, an anti-skid device shall be used.
two or more wire ropes for lifting in symmetric 9. Use genuine eye bolt and shackle to fix eyebolt,
mode. wire rope, iron chain, etc.
10. Hang the wire rope at the central part of the
hook for lifting.
Lifted loads may rotate, swing back due to pull If the wire rope is hung on the edge of the hook for
lifting, the rope may slide and even fall off from the
of wire rope or deviate from lifting position if
hook when lifting. The central part of hook has the
only a single wire rope is used for lifting. This maximum intensity.
can cause a dangerous accident, which shall 11. Do not use wire rope in distortion state.
be noted.
7. Lifting angle, in principle, shall be under 60°.

Pay attention to avoiding overlarge lifting angle
between the wire rope and hook when lifting heavy
objects (above 25 kg).
When using more than two wire ropes, the larger
the lifting angle of each wire rope is, the larger the
bearing force is. The following figure shows the
maximum weights at different lifting angles when
using two wire ropes with a bearing force controlled
1-15
CLG920E/922E/923E 1.2 Precautions for Lifting and Collaborative Operations
Precautions for Operating Mobile

Crane
Read operation and maintenance manual of various
models carefully in advance to operate the crane
safely.
Precautions for Operating Bridge

Crane
Heavy objects that exceed 25 kg must be lifted

12. Pay attention to the followings when lifting. by the crane.
• Roll up the wire rope slowly until it is tensional.

1. Before operation, check wire rope, brake, clutch,
Your hand may be caught easily when contact-
controller, slide rail, over-winding protector,
ing lifting tools, therefore press it down from
residual-current circuit breaker against electric
above instead of holding it.
shock, crane anti-collision device and power
• Stop rolling up after the wire rope is tensional warning lamp for safety ensure.
and confirm the condition of lifted objects away
2. Follow the signal instructions when lifting.
from the ground and contact conditions between
slings and padded objects. 3. Operate the crane in a safe location.
• Firstly, lower the lifted load, and then lift it again. 4. Always confirm the directions of the directional
If the lifted load is unstable, or wire rope and lift- display panel (east/west/south/north) and
ing chain are distorted. operation button.
• The lifted load cannot be tilted. 5. Do not lift load in a tilted angle or travel when the
load swings.
13. Pay attention to the followings when lowering.
6. Do not operate the lifting of horizontal and
• When lowering the lifted load, first stop at 30 cm
vertical travel at the same time.
above the ground, and then lower it gently.
7. Do not use slings to drag.
• Remove the slings after confirming the load is
placed steadily. 8. Try to lift a little before lifting, and then lift after
confirming that it is safe.
• After clearing the distortion or dirt on wire ropes
and chains used during lifting, place them in 9. Take the moving route into consideration in
designated positions. advance and lift to a safe height.
10. Place the control switch on the position that
does not affect operation or passing.
11. Do not shake control switch forcefully when the
crane is operating.
12. Remember the position of the main power
switch to cut off the power rapidly in the
emergency.
1-16
1.2 Precautions for Lifting and Collaborative Operations CLG920E/922E/923E
13. If the crane stops operating due to power

outage, etc., the power switch shall be cut off.
Also, if the power switch is disconnected due to
the electric shock of the residual-current circuit,
confirm whether the relevant machinery of the
switch is in operating states before contacting
again.
14. Stop the operation when you found obstacles
around the machine.
15. After the operation is finished, place the crane
on a designated location, and lift the hook to the
height of 2 m from the ground. Do not hang the
slings on the hook in case of parking.
Cable Selection
1. By referring to the following table, select the
most suitable wire rope according to the weights
of lifting parts.
Wire rope
(Wire rope comply with standard “Z” without plating)
(JIS G3525 6# 6×37 - Class A)
Diameter of Permissible load
mm kN t
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
Note: Allowable load value is 1/6 of the breaking

load of used wire rope (safety coefficient is 6).
2-1
September 15, 2020 Foreword
CLG920E/922E/923E
2 Foreword
2.1 How to Read the Manual .................................................................................................... 2-3
2.2 Marking of Revised Version ................................................................................................ 2-4
2.3 General Torque Specifications............................................................................................ 2-5
2.4 Unit Conversion Table ........................................................................................................ 2-8
2.5 Cable Identification Methods............................................................................................... 2-9
2.6 Coating Materials .............................................................................................................. 2-12
2.7 Weight Table..................................................................................................................... 2-13
2.8 Specifications for Oil Application....................................................................................... 2-14
2-2
Foreword September 15, 2020
CLG920E/922E/923E
2-3
CLG920E/922E/923E 2.1 How to Read the Manual
2.1 How to Read the Manual 3. The materials and technical specifications in the
Manual will change with the variation of
products. All information, diagrams and
Composition of the Service Manual
specifications in the Manual are the latest
The Manual is for new users and technicians. This product information obtained at the time of
manual includes all technical information required publication. LiuGong reserves the right to make
by workshop maintenance. For easy understanding modifications without any notification. If you
and reading, it is divided into technical guide and need the latest technical information, please
workshop guide. consult the local dealer of LiuGong, or the
Service Department of LiuGong Excavator
1. Technical Guide
Marketing Co., Ltd.
1) Safety
2) Foreword
3) Structural function and maintenance standards
4) Test and Adjustment
5) Fault diagnosis
2. Workshop Guide
1) Disassembly and assembly
2) Schematic diagrams of electrical system, A/C
and hydraulic system
Other Reference Manuals
Refer to the following three manuals for basic infor-
mation of structure, operation and maintenance of
the machine. They are distributed to the users in the
form of the vehicle accessories.
1. Part Drawings
2. Operation & Maintenance Manuals
3. Parts manual for Cummins engine
Notice to Users
1. Due to the difference in processing, the
capability of machines has to be tested.
2. Some accessories and optional parts in the
Manual may not be transported to relevant
areas. Consultation with your local dealer is
suggested.
2-4
2.2 Marking of Revised Version CLG920E/922E/923E
2.2 Marking of Revised Version

The versions of the LiuGong service manual have the following meanings:
Second version
Publication month
Publication year
When the version is revised, the year and month will embody revision date of the version, and the last numbers
will reflect revision times of the Manual. For example, 001 represents the first revision, 002 represents the sec-
ond revision, etc.
2-5
CLG920E/922E/923E 2.3 General Torque Specifications
2.3 General Torque Specifications

Unless otherwise expressly stated, bolts involved in this machine shall be tightened in accordance with the
torque requirements specified in the following table.
The required tension torque is expressed in kgf.m. For example, when tightening the bolt or nut with a 1M-long
wrench, rotate the end of the wrench with a force of 12kgf, then it will generate the following torque:
1m×12kgf=12kgf.m.
When the same torque is generated by the 0.25 m wrench: 0.25 m × kgf = 12kgf.m, the force needed is: 12 ÷
0.25 = 48 kgf.
Bolt Wrench Torque

No. Description
specification size (mm) N.m Kgf·m
1 Fixing bolt of the engine shock absorber M22-10.9 34 800 81
2 Fixing bolt of engine support M12-8.8 18 90 9
3 Bolt on flywheel housing M12-8.8 18 60 6
4 Fixing bolt of water tank bracket M12-8.8 18 90 9
5 Fuel tank fixing bolt M16-10.9 24 305 31
6 Hydraulic tank fixing bolt M16-10.9 24 305 31
17 Hexagon
7 Fixing bolt of pump M20-10.9 600 61
socket
8 Fixing bolt of main control valve M12-10.9 18 120 12
9 Slewing drive fixing bolt M20-10.9 30 600 61
14 Hexagon
10 Fixing bolt of slewing motor M16-10.9 305 31
socket
11 Battery fixing bolt M10 30 3
12 Fixing bolt of cab M16-8.8 24 225 23
13 Fixing bolt of revolving frame and slewing bearing M22-10.9 34 800 81
14 Fixing bolt of underframe swivel bearing M22-10.9 34 800 81
15 Fixing bolt of travel speed reducer M16-10.9 24 305 31
16 Sprocket fixing bolt M16-10.9 24 305 31
17 Carrier roller fixing bolt M18-10.9 27 415 42
18 Track roller fixing bolt M18-8.8 27 310 32
19 Track shoe fixing bolt M20-12.9 30 750 76
20 Track guard fixing bolt M18-8.8 27 310 32
21 Counterweight fixing bolt M30-10.9 46 1850 189
2-6
2.3 General Torque Specifications CLG920E/922E/923E
Tightening torque of 24°cone with O-ring sealed pipe fittings
Hose Inner Tightening Torque

Series Thread Size
Diameter mm N.m kgf.m
M12×1.5 5 16±1 1.6±0.1
M14×1.5 6.3 16±1 1.6±0.1
M16×1.5 8 26±2 2.7±0.2
M18×1.5 10 37±2 3.8±0.2
M22×1.5 12.5 47±2 4.8±0.2
Light-duty
M26×1.5 16 89±4 9.1±0.4
M30×2 19 116±5 11.8±0.5
M36×2 25 137±6 14.0±0.6
M45×2 31.5 226±11 23.1±1.1
M52×2 38 347±16 35.4±1.6
M14X1.5 5 26±2 2.7±0.2
M16X1.5 6.3 42±2 4.3±0.2
M18X1.5 6.3 53±2 5.4±0.2
M20X1.5 8 63±3 6.4±0.3
M22X1.5 10 79±4 8.1±0.4
Heavy-duty
M24X1.5 12.5 84±4 8.6±0.4
M30X2 16 126±6 12.9±0.6
M36X2 19 179±8 18.3±0.8
M42X2 25 263±12 26.8±1.2
M52X2 31.5 368±17 37.6±1.7
Tightening torque of flange sealing pipe fitting bolt
Bolt Performance Tightening Torque

Series Bolt
Level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
8.8
M12 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
Light-duty
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
10.9
M12 136±6 12.8±0.6
M16 310±15 31.6±1.5
2-7
CLG920E/922E/923E 2.3 General Torque Specifications
Bolt Performance Tightening Torque

Series Bolt
Level N.m kgf.m
M8 25.2±1.2 2.57±0.12
M10 52.5±2.5 5.35±0.25
M12 8.8 96.6±4.6 9.85±0.47
M16 220±10 22.5±1.07
M20 420±20 42.8±2.0
Heavy-duty
M8 33.6±1.6 3.42±0.16
M10 73.5±3.5 7.5±0.35
M12 10.9 136±6 12.8±0.6
M16 310±15 31.6±1.5
M20 577±27 58.9±2.8
Tightening torque of thread angle sealing pipe fitting
Material of
Carbon steel and alloy steel Aluminum product
fastenings
Tightening Torque Tightening Torque
Thread Size
N.m kgf.m N.m kgf.m
G1/8 8.75±1.25 0.90±0.12 / /
G1/4 36±2 3.67±0.2 29.3±2.2 3.0±0.2
G3/8 73.5±4.5 7.5±0.46 49±3 5.0±0.3
G1/2 110±10 11.2±1.0 55±5 5.6±0.5
G3/4 165±15 16.8±1.5 74±4 7.5±0.4
G1 225±25 23.0±2.55 / /
G1-1/4 275±25 28.0±2.55 / /
G1-1/2 285±15 29.1±1.5 / /
Tightening torque of joints
Tightening Torque
Thread Size
N.m kgf.m
M12 24±2 2.4±0.2
M14 30±2 3.1±0.2
M16 30±2 3.1±0.2
M18 30±2 3.1±0.2
2-8
2.4 Unit Conversion Table CLG920E/922E/923E
2.4 Unit Conversion Table

The Manual adopts the ISO International System of Units, and ISO international units are converted into British
units as shown in following figure:
Parameters Metric unit British unit Multiplier

mm In 0.03937
Length
mm ft 0.003281
L US gal 0.2642
Capacity L US qt 1.057
m³ Yd3 1.308
Weight kg lb 2.205
N kgf 0.10197
Intensity
N lbf 0.2248
Nm kgf.m 0.1097
Torque
Nm lbf.ft 0.7375
MPa kgf/cm³ 10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214
Speed
-1 rpm 1.0
min
L/min US gpm 0.2642
Flow rate
mL/rev cc/rev 1.0
2-9
CLG920E/922E/923E 2.5 Cable Identification Methods
2.5 Cable Identification Methods

The wire number, categories, color abbreviation codes and gauges are marked in the circuit diagram. For
example:
Indicates heat-resistant, lower-voltage wire for vehicles, red, with the number of 108
and a diameter of 50.0mm2.
Wire gauge (Note: the ones with no marked wire gauge are all 0.85mm2)
Color abbreviation code
Wire categories
Wire No.
Wire number
Wire number is a digital code for marking wire with three Arabic numerals in accordance with certain rules.
2-10
2.5 Cable Identification Methods CLG920E/922E/923E
Wire categories
The wire categories for construction machinery are AEX, AV, AVS, AVSS, and QVR. See the following table
for the applicable range of ambient temperature of various wires.
No. Wire type Wire name Description Heat resistance

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

Black BLACK BK Blue BLUE BU
Grey GREY GY Green GREEN GN
Red RED RD Yellow YELLOW YL
Brown BROWN BR Pink PINK PK
Violet VIOLET VT Orange ORANGE OR
White WHITE WH Light blue LIGHT BLUE LTBU
Red/green RED/GREEN RD/GN Yellow/blue YELLOW/BLUE YL/BU
Remark: the code composed of two colors indicates double-color wire

For example: “RD/GN” indicates a red-green wire.
2-11
CLG920E/922E/923E 2.5 Cable Identification Methods
Wire specifications
Allowable current and voltage drop of AV wire, and approximate performances of AVS, AVSS and QVR shall
be done uniformly according to following table.
Ambient 30°C 40°C 50°C 60°C 70°C

Temperature {86°F} {104°F} {122°F} {140°F} {158°F}
Allowable
current/voltage A mV/m A mV/m A mV/m A mV/m A mV/m
drop
0.85 18 463 16 412 14 360 11 283 8 206
1.25 23 407 21 372 18 319 14 248 10 177
2 31 338 28 305 24 262 20 218 14 153
3 42 291 38 263 33 228 27 187 19 132
5 57 248 51 222 44 192 36 157 25 109
8 74 213 66 190 57 164 47 135 33 95
Nominal
15 103 176 92 157 30 137 65 111 46 79
sectional
20 135 148 121 133 105 116 85 94 60 66
area (mm2)
30 188 121 168 108 146 94 119 77 84 54
40 210 112 188 110 163 87 133 71 94 50
50 246 103 220 92 190 60 155 65 110 46
60 272 97 243 87 211 75 172 62 121 43
85 335 90 300 80 260 70 212 57 150 40
100 399 83 356 74 309 65 252 53 178 37
Circuit type and color abbreviation code

For general corresponding rules between circuit type and wire color, see the following table.
Circuit type Color Abbreviation Codes

Power cord OR, RD
Signal line WH
Grounding BK, GY
Communication line RD/GN, YL/BU
2-12
2.6 Coating Materials CLG920E/922E/923E
2.6 Coating Materials
Name Specifications Main features and purposes

• Feature: anaerobic and fast air drying.
1277 Thread locker sealants 1277
• Purpose: used for parts that are not frequently removed
1243 Thread locker sealants 1243 • Used for removable parts (speed sensor in general)
• Feature: rust protection for a long time.
LONG#2 light
Long-term anti-rust agent • Purpose: used for mounting face of main pump, sensor, hydraulic
yellow
fitting, etc.
Molybdenum disulfide lithium
2# • Lubrications for slewing bearing and pin shaft of work implement
grease 2#
• Feature: strong ability of cleaning
High efficient detergent 1755 1755
• Purpose: used for main pump, slewing motor and travel motor
• Feature: heat absorption and vaporization
Refrigerant R134a
• Purpose: used for fluorine filling of air conditioner, etc.
• Feature: high-temperature resistance, self-lubrication and medium
resistance, used for sealing medium (oil, air, vapor, water) pipeline
Anaerobic pipe thread sealant 1567 cone/ taper thread
• Purpose: used for water temperature sensor and engine oil pressure
sensor
Cleaning detergent for
HD-10 • Used for cleaning oil pipe fitting, etc.
electromechanical equipment
Diesel engine sealant 1515 • Used for mounting surface of diesel engine flange
Polyurethane sealant 1924 • Used for waterproof of starter motor and assembly clearance
Mobilux EP None • Used for rust protection of rear cover hinge
2-13
CLG920E/922E/923E 2.7 Weight Table
2.7 Weight Table

The following table indicates the reference value of the weight of each component. When hoisting equipment is
used, please refer to the following table to select the sling.
Components Weight (kg)

Engine assembly (excluding coolant and engine oil) 549
Engine (excluding coolant and engine oil) 490
Hydraulic pump 127
Radiator assembly (excluding coolant, engine oil and fuel) 160
Hydraulic tank (excluding hydraulic oil) 176
Fuel tank (excluding fuel) 191
Revolving frame 1882
Cab 395
Cab seat 46
Counterweight 4300
Main control valve 200
Slewing motor & speed reducer 217
Travel motor & speed reducer 275
Center joint 34.8
Boom 1616
Arm 792
Bucket 800
Boom cylinder assembly 173
Arm cylinder assembly 270
Bucket cylinder assembly 161
Track assembly (single side) 1405/1525 (923E)
Track frame assembly 2711
Idler assembly 142
Slewing bearing 317
Idler tensioner 180
Carrier roller 18
Sprocket 56
Track roller 34.7
2-14
2.8 Specifications for Oil Application CLG920E/922E/923E
2.8 Specifications for Oil Application

Oil change interval and approximate filling capacity (QSB6.7 engine)
Oil change interval (working
Category Approximate filling capacity (L)
hours)
Engine oil 500 25L
Gear oil of swing reduction gear 1000 3.4L
Gear oil of travel reduction gear 1000 (5.5L×2) L
Hydraulic oil 2000 Oil tank 210L (system 330L)
Fuel -- 420L
Cooling system 2000 25L
Technical specification of oil (QSB6.7 engine)

Fuel category Parts Oil specification Ambient temperature
Bucket, swing bearing of Molybdenum disulfide lithium
-20~40°C (-4~104°F)
Lubricant arm and boom, and grease 2# ★
swiveling gear EP2 or RO2 -20~40°C (-4~104°F)
5W-40 (API CH-4) -35~40°C (-31~104°F)
Engine crankcase, fuel
Diesel engine oil injection pump and 10W-30 (API CH-4) -30~30°C (-22~86°F)
regulator
15W-40 (API CH-4) ★ -25~40°C (-13~104°F)
0# ★ Above 4°C (above 39.2°F)
-10# Above -5°C (above 23°F)
Diesel fuel -20# Above -14°C (above 6.8°F)
-30# Above -29°C (above -20.2°F)
-50# Above -44°C (above -47.2°F)
Antifreeze (100% stock solution)
Antifreeze -30~40°C (-22~104°F)
and water with proportion of 42:58
Swing reduction gear SAE85W-140 (API GL-4) -20~45°C (-4~113°F)
Gear oil
Travel reduction gear SAE80W-90 (API GL-4) -20~45°C (-4~113°F)
ISO VG 32 -20~20°C (-4~68°F)
Hydraulic oil Hydraulic system ISO VG 46 ★ -20~40°C (-4~104°F)
ISO VG 68 -10~40°C (14~104°F)
The oil marked with ★ is the oil filled when the machine is transported out of the factory.
2-15
CLG920E/922E/923E 2.8 Specifications for Oil Application
Time interval of oil change and approximate of filling capacity (India Cummins B5.9 Engine)
Oil change interval (working
Category Approximate filling capacity (L)
hours)
Engine oil 500 20L
Gear oil for slewing drive 1000 4.6L
Gear oil for travel speed reducer 1000 (3.4L×2) L
Hydraulic oil 2000 Oil tank 210 L (system 330 L)
Fuel As required 420L
Cooling system 2000 30L
Technical specification of oil (B5.9 engine)

Oil Category Application Location Oil Specifications Ambient Temperature
Slewing bearing and Kunlun EP lithium-base grease, type -20 ~ 40°C (-4 ~ 104°F)
Lubricant slewing gear of bucket, N★
arm and boom EP2 or RO2 -20 ~ 40°C (-4 ~ 104°F)
5W-40 (API CH-4) -35 ~ 40°C (-31 ~ 104°F)
Engine crankcase, fuel
Diesel engine oil injection pump and 10W-30 (API CH-4) -30 ~ 30°C (-22 ~ 86°F)
regulator
15W-40 (API CH-4) ★ -25 ~ 40°C (-13 ~ 104°F)
0# ★ Above 4°C (above 39.2°F)
-10# Above -5°C (above 23°F)
Diesel fuel Fuel tank -20# Above -14°C (above 6.8°F)
-30# Above -29°C (above -20.2°F)
-50# Above -44°C (above -47.2°F)
Anti-freeze fluid (100% primary liquid)
Anti-freeze fluid Radiator -30 ~ 40°C (-22 ~ 104°F)
and water with proportion of 42:58
Slewing drive SAE85W-140 (API GL-4) -20 ~ 45°C (-4 ~ 113°F)
Gear oil
Travel speed reducer SAE80W-90 (API GL-4) -20 ~ 45°C (-4 ~ 113°F)
ISO VG 32 -20 ~ 20°C (-4 ~ 68°F)
Hydraulic oil Hydraulic system ISO VG 46 -20 ~ 40°C (-4 ~ 104°F)
ISO VG 68 ★ -10 ~ 40°C (14 ~ 104°F)
The item marked with ★ is the oils filled before ex-factory.

2-16
2.8 Specifications for Oil Application CLG920E/922E/923E
1. The oil with the same specification but different brands cannot be used together. If other oils must
be used, please clean the system first.
2. The lubricant should be changed on time. Even though the oil is very clean, yet it may deteriorate if
it is placed for a long time.
3. The selection of fuel should depend on the lowest temperature of the location where the machine is
used.
4. Please contact LiuGong when you are using the oil purchased in the market, that has not been
listed above.
3-1
September 15, 2020 Structural Function and Maintenance
CLG920E/922E/923E
3 Structural Function and Maintenance

3.1 Power System ..................................................................................................................... 3-5
3.1.1 Diesel Engine Related Parts ............................................................................................ 3-5
3.1.2 Water Radiator, Hydraulic Oil Radiator, and Intercooler .................................................. 3-5
3.2 Track Travel System ........................................................................................................... 3-6
3.2.1 Travel Frame and Tensioner............................................................................................ 3-6
3.2.2 Idler .................................................................................................................................. 3-8
3.2.3 Carrier Roller.................................................................................................................. 3-10
3.2.4 Track Roller.................................................................................................................... 3-12
3.2.5 Sprocket ......................................................................................................................... 3-14
3.2.6 Track .............................................................................................................................. 3-15
3.2.7 Slewing Bearing ............................................................................................................. 3-16
3.3 Hydraulic System .............................................................................................................. 3-17
3.3.1 Layout Diagram of Hydraulic Unit .................................................................................. 3-17
3.3.2 Hydraulic Elements ........................................................................................................ 3-20
3.3.2.1 Main Pump Assembly ........................................................................................... 3-20
3.3.2.2 Main Control Valve................................................................................................ 3-39
3.3.2.3 Center Connector................................................................................................ 3-113
3.3.2.4 Explosion-Proof Valve......................................................................................... 3-115
3.3.2.5 Hand Pilot Valve.................................................................................................. 3-117
3.3.2.6 Travel Pilot Valve ................................................................................................ 3-120
3.3.2.7 Cushion Valve ..................................................................................................... 3-123
3.3.2.8 Solenoid Valve .................................................................................................... 3-127
3.3.2.9 Travel Motor & Speed Reducer........................................................................... 3-131
3.3.2.10 Slewing Motor & Speed Reducer ...................................................................... 3-144
3.3.2.11 Cylinder ............................................................................................................. 3-157
3.3.2.12 Hydraulic Tank Assembly.................................................................................. 3-160
3.3.3 Hydraulic Principle ....................................................................................................... 3-164
3.3.3.1 Main Hydraulic Circuit ......................................................................................... 3-164
3.3.3.2 Pilot Circuit .......................................................................................................... 3-174
3.3.3.3 Neutral Flow Control Circuit (With Control Spool in the Neutral) ........................ 3-178
3.3.3.4 Negative Flow Control Circuit (With Control of Spool Moving)............................ 3-182
3.3.3.5 Boom Lifting Working Circuit............................................................................... 3-186
3.3.3.6 Boom Lowering Working Circuit.......................................................................... 3-190
3-2
Structural Function and Maintenance September 15, 2020
CLG920E/922E/923E
3.3.3.7 Arm Stretching Working Circuit .......................................................................... 3-194

3.3.3.8 Arm Retraction Working Circuit (With Regeneration) ......................................... 3-198
3.3.3.9 Arm Retraction Working Circuit (Without Regeneration) .................................... 3-202
3.3.3.10 Bucket Retraction Working Circuit.................................................................... 3-206
3.3.3.11 Bucket Stretching Working Circuit .................................................................... 3-210
3.3.3.12 Left Slewing Working Circuit............................................................................. 3-214
3.3.3.13 Rotating Priority Pipeline (Rotating Opposite Bucket Rod Priority Function) ... 3-218
3.3.3.14 Right Slewing Working Circuit .......................................................................... 3-222
3.3.3.15 Travel Forward (Fast) ....................................................................................... 3-226
3.3.3.16 Travel Backward (Slow).................................................................................... 3-234
3.3.3.17 Bilateral Travel and Boom Rising Compound Operation.................................. 3-240
3.4 Work Implement ............................................................................................................. 3-244
3.4.1 Sizes of Components .................................................................................................. 3-244
3.4.2 Arm Part ...................................................................................................................... 3-247
3.4.3 Bucket Part.................................................................................................................. 3-250
3.5 A/C System .................................................................................................................... 3-252
3.5.1 Layout Diagram of A/C Pipeline .................................................................................. 3-252
3.6 Electrical System ............................................................................................................ 3-253
3.6.1 Engine Control............................................................................................................. 3-253
3.6.2 Display System............................................................................................................ 3-254
3.6.2.1 Ordinary Display ................................................................................................ 3-255
LCD Display Section....................................................................................................... 3-257
Display Key Panel ......................................................................................................... 3-260
Software Introduction...................................................................................................... 3-262
User Mode ...................................................................................................................... 3-263
3.6.2.2 Smart Display ..................................................................................................... 3-267
LCD Display Section....................................................................................................... 3-269
Display Key Panel .......................................................................................................... 3-271
User Menu ...................................................................................................................... 3-276
3.6.3 Electrical Control System ............................................................................................ 3-284
3.6.3.1 Work Mode ......................................................................................................... 3-284
3.6.3.2 Automatic Idling Function ................................................................................... 3-285
3.6.3.3 Transient Power Boosting Function.................................................................... 3-287
3.6.3.4 Overheating Protection Function ........................................................................ 3-288
3-3
CLG920E/922E/923E
3.6.3.5 Traveling Speed Control Function....................................................................... 3-289

3.6.3.6 Various Components........................................................................................... 3-289
3.6.4 Descriptions of Partial Circuits ..................................................................................... 3-304
3.6.4.2 Transient Pressure Boosting Circuit.................................................................... 3-305
3.6.4.3 Start Circuit ......................................................................................................... 3-306
3.6.4.4 Digging Function Circuit ...................................................................................... 3-311
3.6.4.5 Flattening Function Circuit .................................................................................. 3-312
3.6.4.6 Charging Circuit .................................................................................................. 3-313
3.6.4.7 Working Circuit of Pump Proportional Solenoid Valve ........................................ 3-315
3-4
CLG920E/922E/923E
3-5
CLG920E/922E/923E 3.1 Power System
3.1 Power System 3.1.2 Water Radiator, Hydraulic Oil

Radiator, and Intercooler
3.1.1 Diesel Engine Related Parts
1. Intercooler hydraulic oil 7. Degassing pipe

radiator 8. Inter-cooler tube
1. Left front engine support 6. Right front engine 2. Water radiator 9. Fan shield
2. Engine shock absorber support 3. Hydraulic oil radiator 10. Inter-cooler tube
at fan side 7. Right rear engine 4. Refrigerant reservoir 11. Water radiator outlet pipe
3. Left rear engine support support 5. Fan 12. Shroud
4. Engine shock absorber 8. Coupler 6. Water radiator inlet pipe
at flywheel housing side 9. Main pump flange (note:
5. Muffler Rexroth main pump is
equipping with flange)
3-6
3.2 Track Travel System CLG920E/922E/923E
3.2 Track Travel System

3.2.1 Travel Frame and Tensioner
1. Idler 4. Sprocket 7. Tensioner

2. Travel frame 5. Track roller
3. Carrier roller 6. Track
3-7
CLG920E/922E/923E 3.2 Track Travel System
Criteria
No. Item Measures
Standard size Allowable limit
Installation Installation Installation Installation
Free length
length load length load
7 Tensioner Replace
840mm 144.2KN
- - -
{33.1 In} {32416 lbf }
Criteria
No. Item Standard Measures
Tolerance Repair limit
size
110 mm +3 mm {+0.12 In} 115 mm
Vertical width of Travel frame Surfacing repair
{4.3 In} +1 mm {+0.04 In} {4.5 In}
8 idler guiding
plate 108 mm 0 mm {0 In} 105 mm Surfacing repair or
Idler
{4.3 In} -1 mm {-0.04 In} {4.1 In} replacement
240 mm +3 mm {+0.12 In} 245 mm
Horizontal width Travel frame Surfacing repair
{9.5 In} +1 mm {+0.04 In} {9.7 In}
9 of idler guiding
plate 238 mm 0 mm {0 In} 235 mm Surfacing repair or
Idler
{9.4 In} -1 mm {-0.04 In} {9.3 In} replacement
3-8
3.2.2 Idler
3-9
No. Check items Standard Measures
Outer diameter of Standard size Repair size

1
protruding parts 538 mm{21.2 In} ——
Outer diameter of wheel
2 500 mm{19.7 In} 490 mm{19.3 In}
face
3 Thickness of wheel face 15 mm{0.6 In} 10 mm{0.39 In} Surfacing or
Difference between wheel replacement
4 19 mm{0.75 In} 24 mm{0.94 In}
faces
5 Overall width 158 mm{6.2 In} ——
6 Width of wheel face 38.5 mm{1.5 In} ——
Standard Tolerance Standard Limiting

size Shaft Hole clearance clearance
Clearance between shaft
7 -0.03 mm{- +0.17 mm
and bushing 0.15-0.25 mm
75 mm 0.0012 In} {0.0067 In}
{0.0059-0.0098 ——
{2.9 In} -0.08 mm +0.12 mm
In}
{-0.0032 In} {0.0047 In}
Standard Tolerance Standard Replace the

——
size Shaft Hole interference bushing
Interference between idler
8 +0.11 mm
and bushing +0.05 0.01-0.11 mm
85 mm {0.0043 In}
0 mm {0.0004-0.0043 ——
{3.4 In} +0.06 mm
{0.002 In} In}
{0.0024 In}
Clearance between bushing Standard value Clearance limit
9 and neck strap (the sum of
clearances on both sides) 0.3-1.0 mm{0.0012-0.0394 In} ——
3-10
3.2.3 Carrier Roller

3-11
Outer diameter of Standard size Repair size

1
protruding parts 136 mm{5.4 In} ——
Outer diameter of wheel
2 120 mm{4.7 In} 108 mm{4.3 In}
face
3 Thickness of wheel face 47 mm{1.9 In} ——
4 Width of wheel face 22.5 mm{0.89 In} 16.5 mm{0.65 In}
5 Protruding width 81 mm{3.2 In} ——
Standard Tolerance Standard Limiting

size Shaft Hole clearance clearance
Clearance between shaft
6 -0.10 mm{- +0.242 mm Replace
and bushing 0.28-0.382
47.5 mm 0.004 In} {+0.0095 In}
mm{0.011- ——
{1.9 In} -0.14 mm{- +0.18 mm
0.015 In}
0.0055 In} {+0.0071 In}
Standard Tolerance Standard

——
size Shaft Hole interference
Interference between the
7 +0.09 mm 0.01-0.12
carrier roller and bushing
φ53 mm {2.1 {+0.0035 In} ±0.03 mm
——
In} +0.04 mm mm{±0.0012 In} {0.0004-
{+0.0016 In} 0.0047 In}
Axial clearance of the Standard value Clearance limit

8
carrier roller 0.25-0.9 mm {0.0098- 0.035 In} ——
3-12
3.2.4 Track Roller

3-13
Outer diameter of the Standard size Repair size

1
flange 193 mm {7.6 In} ——
Outer diameter of
2 160 mm {6.3 In} 148 mm {5.8 In}
wheel face
Thickness of wheel Replace
3 41 mm {1.6 In} 35 mm {1.4 In}
face
4 Overall width 224 mm {8.8 In} ——
5 Width of wheel face 51.5 mm {2 In} ——
6 Width of flange 24 mm {0.94 In} ——
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between
7 -0.215 mm 0.215-0.510
shaft and bushing +0.195 mm
65 mm {2.6 {-0.0085 In} mm
{+0.0077 In} ——
In} -0.315 mm {0.0085-
0 mm {0 In}
{-0.0124 In} 0.02 In}
Standard Tolerance Standard Interference Replace the

size Shaft Hole interference limit bushing
Interference between
8 the track roller and +0.10 mm
bushing 0 mm {0 In} 0.05-0.16
73 mm {+0.004 In}
-0.06 mm mm {0.002- ——
{2.874 In} +0.05 mm
{-0.0024 In} 0.0063 In}
{+0.002 Inz
Clearance between Standard value Clearance limit
bushing and neck strap
9
(the sum of clearances 0.3-1.2 mm {0.012-0.047 In} ——
on both sides)
3-14
3.2.5 Sprocket

1 Wear on sprocket teeth Repair limit: 6 mm {0.24 In}
Standard size Repair limit Replace
2 Width of sprocket teeth
65 mm {2.6 In} 60 mm {2.4 In}
3-15
3.2.6 Track

Standard size Repair limit
1 Track pitch
190 mm {7.5 In} 193 mm {7.6 In}
2 Height of track link 105 mm {4.1 In} 96 mm {3.8 In}
Surfacing or
3 Height of track shoe grouser 26 mm {1.0 In} 16 mm {0.63 In}
replacement
4 20 mm {0.79 In}
5 Length of track shoe top 14 mm {0.55 In}
6 19 mm {0.75 In}
3-16
3.2.7 Slewing Bearing
CLG920E922E03001

Standard clearance Maintenance limit
Axial clearance of bearing
1 0.2-1.25mm Replace
(When installed onto the chassis) 3.2mm (0.13 In)
(0.0078-0.049 In)
3-17
CLG920E/922E/923E 3.3 Hydraulic System
3.3 Hydraulic System

3.3.1 Layout Diagram of Hydraulic Unit
(1) When using Kawasaki system, the layout diagram of the hydraulic device is as follows:
3-18
3.3 Hydraulic System CLG920E/922E/923E
1. Bucket cylinder 11. Left travel motor & speed reducer A5: P2 pump flow adjustment
2. Arm cylinder 12. Octuple solenoid valve A6: P1 pump flow adjustment
3. Boom cylinder P1: Inlet oil of octuple solenoid valve
A7: Transient power-boosting
4. Slewing motor & speed reducer T1: Return oil of octuple solenoid valve
5. Right travel motor & speed reducer A8: Boom priority
P2: Boom lift pilot signal
6. Main pump 13. Bypass valve block
A1: Pilot unlock
7. Accumulator 14. Center joint
A2: Travel shift 15. Right-hand pilot valve
8. Breather valve
A3: Arm second speed 16. Left-hand pilot valve
9. Return oil filter
10. Main control valve A4: standby 17. Travel pilot valve
3-19
(2) When using Rexroth system, the layout diagram of the hydraulic device is as followed:
11 12 13 14 15
16
17
10
9
18
5 4
CLG920E922E03006
1. Bucket cylinder 7. Quadruple solenoid valve 13. Breather valve

2. Boom cylinder 8. Center joint 14. Main control valve
3. Right travel motor & speed reducer 9. Right-hand pilot valve 15. Triple solenoid valve
4. Accumulator 10. Arm cylinder 16. Valve block
5. Return oil filter element 11. Slewing motor & speed reducer 17. Left-hand pilot valve
6. Left travel motor & speed reducer 12. Main pump 18. Travel pilot valve
3-20
3.3.2 Hydraulic Elements

3.3.2.1 Main Pump Assembly
1. When the machine using the Kawasaki system, the main pump assembly condition is as follows:
Structure and function of the Kawasaki main pump assembly
Structure of main pump assembly:

1. Drive shaft Pi1-P1 pump pilot-oil port a1, a2, a3, a4 - Pressure ports
2. Minimum flowrate adjusting nut Pi2-P2 pump pilot-oil port B1 - Main-pump suction port B3 - Pilot-
3. Main pump regulator Psv - Main pump servo port pump suction port
4. Electric proportional pressure- Dr - Housing return oil
reducing valve
The main pump assembly is composed of the main pump (pumps P1 and P2) and a pilot pump (pump P3). The
main pump is a double variable plunger pump and provides high-pressure oil for the main circuit so that all
hydraulic parts work. The pilot pump is a constant gear pump and supplies oil for the pilot system and the main
pump control system.
3-21
2. Main pump (pumps P1 and P2)

Specifications of the main pump
Displacement cm³/rev 116.5×2

Pressure Rated 34.3
MPa Max. 37.3
Rotary speed Rated 1950
r/min Max. 2100
Weight kg 127
Category Antiwear hydraulic oil
Temperature range -20~+95°C
Hydraulic oil Viscosity range 10~200cSt (mm²/s)
Nominal dimension of the oil return line: 10μm
Recommended strainer
Suction line 80 ~ 150 mesh filter screen
Structure and working principle of the main pump

The main pump is directly driven by the engine via a coupling, and the pilot gear pump is connected behind the
pump P2 in series, is indirectly driven by the drive shaft and rotates at the same speed to the main pump
during working.
Main pump
1. P2 Pump regulator 3. Shaft 5. P2 pump
2. P1 Pump regulator 4. P1 pump
3-22
The figure below shows the structural diagram of the main pump assembly, and the numbers in () behind
concerned parts in the figure below shall prevail.
Main oil pump structural diagram
530 Auxiliary taper pin 313 Valve cover (R) 719 O-ring
30 Auxiliary swashplate 325 Cover 724 O-ring
13 Auxiliary cylinder (R) 401 Hexagon socket bolt 725 O-ring
111. Drive shaft 406 Hexagon socket bolt 727 O-ring
123 Roller bearing 407 Hexagon socket bolt 728 O-ring
124 Needle bearing 466 VP plug 732 O-ring
127. Bearing washer 468 VP plug 774. Oil seal ring
141. Cylinder block 490 Embedded plug 789 Protective washer
151 Piston 531 Taper pin 792 Protective washer
152. Skid shoe 532. Servo piston 802 Hexagon nut
153. Pressure plate 11 Auxiliary piston 808 Hexagon nut
156 Spherical bushing 3 Gear pump 824. Check ring
157 Cylinder spring 534 Stopper (L) 825. Fixing ring
211. Skid-shoe backing plate 535 Stopper (S) 885. Valve plate pin
212 Swashplate 542 Washer 886. Spring pin
214 Taper bushing 544 Washer 901. Eyebolt
251 Swashplate support platform 548. Feedback pin 953 Hex socket positioning screw
261 Sealing cover (F) 702 O-ring 954 Positioning screw
271. Pump housing 710 O-ring 981 Nameplate
312. Valve cover (R) 717 O-ring 983 Rivet
3-23
The main pump consists of two plunger pumps, block (312), a valve plate (313) and a valve plate pin
namely pump P1 and pump P2, which are con- (885). The valve plate with two melon-shaped holes
nected by the spline joint (114). The engine rotation is installed on the valve block and is used for sup-
is delivered to the drive shaft F (111) at the front to plying and recovering oil to and from the cylinder
simultaneously drive the two pumps. The oil suction block. Oil switched by the valve plate is connected
port and oil discharge port are converged at the to an external pipe via the valve block.
connection (namely valve block (312)) of the two
When the drive shaft is driven by the motor, the cyl-
pumps, and the pump P1 and pump P2 share one
inder block also rotates by means of the spline joint.
suction port.
When the swashplate is tilting, the piston installed in
Because the structure principles and working princi- the cylinder block rotates along with the cylinder
ples of the two pumps P1 and P2 are the same, the block while making reciprocating linkage in relative
pump P1 will be described as an example. to the cylinder. Therefore, for a single piston, when
the cylinder block rotates by one turn, the piston
The pump P1 is roughly composed of a rotating
moves away from the valve plate (oil suction
mechanism for driving the pump to rotate, a swash-
stroke). When the cylinder block rotates by 180°,
plate mechanism for adjusting output capacity and a
the stroke is completed. When the cylinder block
valve cap mechanism for alternately making oil suc-
continues to rotate by another 180°, the piston
tion and output actions.
moves towards the valve plate (oil discharge
The rotating mechanism is composed of a drive stroke). When the tile angle of the swashplate is
shaft F (111), a cylinder block (141), shoes (151, zero, the swashplate neither makes stroke move-
152), a plate (153), a spherical cylinder liner (156), a ment, nor discharges oil.
shim (158) and a cylinder spring (157). Both ends of
the drive shaft are supported by bearings (123,
124). The skid shoe is mounted on the piston, form-
ing a ball joint, while the thrust generated by load
pressure is also reduced, and there is one housing
on the skid shoe (211) to lightly adjust oil pressure
balance. To make auxiliary mechanism of the skid
shoes act smoothly on the support plate, the shoes
are pressed on the support plate by the oil pressure
spring via the pressure plate and the spherical cylin-
der liner. Likewise, the cylinder block is also
pressed on the valve plate (313) by the cylinder
spring.
The swashplate mechanism is composed of a
swashplate (212), a shoe (211), a swashplate sup-
port platform (251), a tilt cylinder liner (214), a tilt pin
(531) and a servo cylinder (532). The cylindrical
section of the swashplate formed at the opposite
side of skid shoe action face is supported on the
swashplate support platform. Oil pressure controlled
by a adjuster makes an auxiliary piston to move
from side to side under the guidance of oil pressure
chambers at both sides of the auxiliary piston. At the
moment, the swashplate slewing on the swashplate
support platform by means of the ball section of the
tilt pin to change the tilt angle (a).
The valve cap mechanism is composed of a valve
3-24
1. Main pump regulator Unnecessary power is not consumed because the

pump only outputs necessary flow when the com-
Overview
mand pilot pressure of necessary correspondent
The main pump adjuster is installed on the main flow during working via this mechanism.
pump and is composed of the following three control
This adjuster has the above three control mecha-
mechanisms.
nism functions. When all controls are combined, pri-
(a) Power control ority is given to the small tilt (small flow) command
through machine calculation described below.
As the own pump output pressure P1 and the oppo-
site pump output pressure P2 rise, the pump tilt
angle (output flow) automatically decreases so as to
limit the input torque below a certain value. (The
input power is constant if the speed is constant.)
For a tandem type double pump, because the total
power type that the load pressures and actions of
pumps P1 and P2 are added, the adjuster of each
pump is controlled to be the same tile angle (output
flow) in the power control state.
Therefore, the overload of a prime motor is auto-
matically prevented in the power control state no
matter how many the loads of the pumps P1 and P2
are.
(b) Power switching control
The power setting value is switched by changing the
power switching command pressure Pf, that is, the
current value of the electric proportional pressure-
reducing valve. The power switching pressure Pf
(secondary pressure of electric proportional pres-
sure-reducing valve) is guided into the power con-
trol section of the adjuster of each pump
respectively via the internal passage of the pump
and is switched into the setting value of respective
same power.
Because the output power of the pump can be
changed freely via this mechanism, the optimal
power can be obtained in the cooperative working
state.
(c) Flow control
The tilt angle (output flow) of the pump can be freely
controlled by changing pilot pressure Pi. Control
ways include the positive flow control (positive con-
trol) way in which the output flow Q increases as the
pilot pressure Pi increases and the negative flow
control (negative control) way in which the output
flow Q decreases as the pilot pressure Pi increases.
This adjuster adopts the negative flow control way.
3-25
Adjuster section diagram VIEW D
VIEW C SECTION B-B
Structure of adjuster
412 Bolt 725 O-ring 755 O-ring
438 Bolt 732 O-ring 801 Nut
496 Screw plug 733 O-ring 802 Nut
708 O-ring 734 O-ring 814 Snap ring
722 O-ring 735 O-ring 858 Snap ring
724 O-ring 753 O-ring 924 Bolt
3-26
Principle of adjuster pin (897) fixed on the feedback rod (611) is protrud-
ing at the major-hole section (section C) of the lever
(2) (613), the pin (897) moves rightwards as the
lever (2) (613) rotates. Moreover, because the U-
shaped slot section (section D) at the top end of the
feedback rod (611) is embedded in a feedback in
(548) fixed on the tilt pin (531) making the pump
swashplate (212) slewing, the feedback rod (611)
rotates around the section D as a fulcrum through
the movement of the pin (897). On the other hand,
the spool (652) on the feedback rod (611) is con-
nected together via the pin (874), the spool (652)
moves rightwards as the feedback rod (611) rotates.
Adjuster circuit diagram If the spool (652) moves, the output pressure P1 is
communicated with the interface Cl via the spool
(652) and is guided into the major-diameter cham-
ber of the servo piston (532). The output pressure
1. Flow control
P1 is usually guided into the minor-diameter section
As shown in the figure below, the output flow of the of the servo piston (532), so the servo piston (532)
pump can be freely controlled according to the pilot moves rightwards through area difference so as to
pressure Pi. decrease the tilt angle.
If the servo piston (532) moves rightwards, section
D also moves rightwards. Because a leftward pull-
ing force usually acts on the spool due to a return
spring (654) installed on the spool (652), the pin
(897) is pushed towards the major-hole section
(section C) of the lever (2) (613). Therefore, the sec-
Output flow Q
tion D moves rightwards, the feedback rod (611)

rotates around the section C as a fulcrum, and the
spool (652) also moves leftwards. The opening sec-
tion between the valve bushing (651) and the spool
(652) is slowly closed through this movement, and
the servo piston (532) stays still in the fully closed
Pilot pressure Pi position.
(2) Flow increase action
When the pilot pressure Pi decreases, the pilot
(1) Flow decrease action
plunger (643) moves leftwards through the pretight-
When the pilot pressure Pi increases, the pilot ening force of the pilot spring (646), and the lever
plunger (643) moves rightwards and stays still in the (2) (613) rotates around the section B as a fulcrum
position where the pretightening force and the through this movement. The pin (897) is pushed
hydraulic force of the pilot spring (646) are bal- towards the major-hole section (section C) of the
anced. Because a pin (875) fixed on a lever (2) lever (2) (613) via the spool (652), pin (874) and
(613) is embedded in the slotted section of the pilot feedback rod (611) through the return spring (654),
plunger (643), the lever (2) (613) rotates around the feedback rod (611) rotates around the section D
section B (fixed via fulcrum bushing (614) and pin as a fulcrum as the lever (2) (613) rotates, and the
(876)) as a fulcrum through the movement of the spool (652) moves leftwards.
pilot plunger (643). On the other hand, because the
When the spool (652) moves, because the interface
3-27
Cl and the oil tank interface are communicated, the (876) (section E) fixed on the housing (601) as a
pressure in the major-diameter chamber of the center. Because the major-hole section (section F)
servo piston is released, the servo piston (532) of the lever (1) (612) is protruding out by the pin
moves leftwards through the output pressure P1 of (897) fixed on the feedback rod (611), the feedback
the minor-diameter section, and the flow increases. rod (611) rotates around the section D as a fulcrum
along with the rotation of the lever (1) (612), and the
The section D also moves leftwards as the servo
spool (652) moves rightwards.
piston (532) moves, the feedback rod (611) rotates
around the section C as a fulcrum, and the spool If the spool (652) moves, the output pressure P1 is
(652) moves rightwards. The opening section guided into the major-diameter section of the servo
between the spool (652) and the valve bushing piston via the interface Cl, the servo piston (532)
(651) continues to move until it is closed, and it moves rightwards, so that the output flow of the
stays still in the fully closed position. pump decreases, and the overload of the prime
motor is prevented.
2. Power control
The movement of the servo piston (532) is transmit-
As shown in the figure below, when the load pres-
ted to the feedback rod (611) via the section D, so
sure increases, the pump tilt angle decreases, and
the feedback rod (611) rotates around the section F
the overload of the prime motor is prevented.
as a fulcrum, and the spool (652) moves leftwards
at the moment. The opening section between the
spool (652) and the valve bushing (651) moves until
it is closed, and the servo piston (532) stays still in
the position where the opening section is fully
closed.
Output flow Q
(2) Flow recovery action

If the own pump output pressure P1 rises or the
opposite pump output pressure P2 decreases, the
compensation rod (623) is pushed back through the
external spring (625) and the internal spring (626),
so the lever (1) (612) rotates around the section E
Output pressure (P1 +P2) as a center. The feedback rod (611) rotates around
the section D as a fulcrum along with the rotation of
the lever (1) (612), so the spool (652) moves left-
wards. Because the interface Cl is communicated
The action of power control is the same to that of
with the oil tank interface, the pressure in the major-
flow control and is briefly described below.
diameter section of the servo piston (532) is
(For detailed actions of each part, refer to flow released, so the servo piston (532) moves left-
control item.) wards, and the pump output flow increases.
(1) Overload prevention action The movement of the servo piston (532) is transmit-
ted to the spool (652) via the feedback mechanism,
If the own pump output pressure P1 rises or the
and the opening section between the spool (652)
opposite pump output pressure P2 rises, because
and the valve bushing (651) continues to move until
P1 and P2 act on the step section of the compensa-
it is closed.
tion plunger (621), the compensation rod (623) is
pushed rightwards and moves to the position where 3. Priority mechanism of small tilt (small flow)
the pretightening forces and hydraulic forces of command
external spring (625) and internal spring (626) are
As previously mentioned, although the tilt com-
balanced. The movement of the compensation rod
mands of flow control and power control are trans-
(623) is transmitted to the lever (1) (612) via the pin
mitted to the feedback rod (611) and the spool (652)
(875), and the lever (1) (612) rotates around the pin
3-28
via the major-hole sections (section C and section (1) Adjustment of maximum flow (pump body side)
F) of the lever (1) (612) and the lever (2) (613),
Loosen the hex nut (808) and then tighten (or
because the section C and section F are structures
loosen) the locating screw (954) for adjustment.
protruding in major hole (φ9) by the pin (φ5), it is
Only the maximum flow is other than other control
only in contact with the pin (897) at the small tilt
characteristics changes.
side, and the holeφ9 of the rod at the large tilt com-
mand state side is free without being in contact with
the pin (897). The command at the small tilt side of
flow control and power control has priority through
this mechanical selection mechanism.
4. Power switching control (power decrease
Output flow Q
control)
As shown in the figure below, the setting power of
the pump can be freely controlled through power
switching pressure Pf.
Pilot pressure Pi
Output flow Q
(2) Adjustment of minimum flow (pump body side)

loosen) the hexagon socket locating screw (953) for
adjustment. The adjustment is the same as that of
the maximum flow. Although other control charac-
teristics will not change, if the locating screw is tight-
ened too much, the power required in the case of
Output pressure (P1 +P2) maximum output pressure (overflow) could rise,
which should thus be noted.
If the power switching pressure Pf increases, the

compensation rod (623) moves rightwards by
means of the pin (898) and the compensation
plunger (621), just like the overload control action
for preventing power control described above, and
Output flow Q
the power setting decreases when the pump tilt

angle decreases. On the contrary, if the power
switching pressure Pf decreases, the power setting
increases.
Adjustment by adjuster
The maximum and minimum flow can be adjusted
through the adjusting screws (953 and 954) at the Pilot pressure Pi
pump body side, power control characteristics can
be adjusted by using the adjusting screw (C) (628)
and adjusting wheel (C) (627) of this adjuster, and
flow control characteristics can be adjusted by using
the hexagon socket locating screw (924).
3-29
(3) Adjustment of input power

As this adjuster is in the concurrent total power
manner, please adjust the adjusting screws (C)
(628) and adjusting wheels (C) (627) of P1 and P2
by the same amount when changing power settings.
Output flow Q
In addition, adjusted pressure changes refer to the
values when both the pumps are pressurized simul-
taneously.
1) Adjustment of outer spring
Loosen the locknut (630) and then tighten (or
loosen) the adjusting screw (C) (628) for adjust-
ment. When the adjusting screw (C) (628) is tight- Output pressure (P1 +P2)
ened, the control curve moves to the right and input
power shows an increase manner as shown in the
figure below. In addition, when the adjusting screw (4) Adjustment of flow control characteristics
(C) (628) is turned by N circles, the internal spring
(626) is also tightened along with the turning, and
loosen) the hexagon socket locating screw (924) for
thus settings will change; therefore, turn the adjust-
adjustment.
ing wheel (C) (627) in the opposite direction by N×A
circles to return the inner spring back. When the hexagon socket locating screw (924) is
tightened, the control curve moves to the right as
(A is the return rate)
shown in the figure below.
Output flow Q
Output flow Q
Output pressure (P1 +P2) Pilot pressure Pi
2) Adjustment of inter spring

loosen) the adjusting wheel (C) (627) for adjust-
ment. When the adjusting wheel (C) (627) is tight-
ened, the flow shows an increase manner as shown
in the figure below, and thus the input power also
increases.
3-30
Cause and handling of adjuster fault

If poor action is caused by the adjuster, refer to section "Disassembly and installation" for disassembly and
inspection.
When prime motor

is overload
Exert the load on monomer of

each pump, and separately check
whether front pump and rear pump
is abnormal
Two pumps are abnormal
Check whether
current value I of
power switch order is
abnormal
No
Single pump is abnormal
Check whether power
switch pressure (pf) is too Replace electro-hydraulic propor-
low, namely check high Yes tional pressure-reducing valve
frequency disturbance
current of amplifier
No
Jamming of compen-
sating plunger (621)
Yes Remove and clean
and compensating
lever (623)
No
Jamming of pin Yes Remove and clean

(898)
LG922E930E03027
3-31
Fall short of
maximum flow
Yes
Confirm whether
pilot pressure is
normal
No
Jamming of pilot
plunger (643) Yes Remove and clean
No
Jamming of spool
Yes Remove and clean
(652)
2) Electric proportional pressure-reducing valve

An electric proportional pressure-reducing valve is used to change the control curve (P-Q curve) of the main
pump (P1and P2) and provide the main pump with the control curve suitable for various working conditions. Its
input pressure is Psv (i.e. pilot pressure), and its output pressure is Pf inversely proportional to the input
current.
Main pump maintenance references
When the abrasion loss of each part exceeds the following references, replacement or re-adjustment is
needed. But a part must be replaced when it has obvious damage in appearance.
Standard Maintenance
Check items Treatments
size (mm) limit (mm)
Space clearance (D-d) inside piston and cylinder 0.039 0.067 Change the piston or cylinder
Looseness (δ) of clearance section between piston Change the piston and skid shoe
0~0.1 0.3
and shoe assembly parts.
Change the piston and skid shoe
Thickness of shoe (t) 4.9 4.7
assembly parts.
Free height (L) of cylinder spring 41.1 40.3 Change the cylinder spring.
Assembly height of plate and spherical bushing Change the plate or spherical
23.0 22.0
(H-h) bushing.
3-32
Looseness of clearance section between plunger

ball head and skid shoe: δ
Thickness of skid shoe: t
Space clearance inside piston and cylinder block:

D-d
Assembly height of plate and spherical bushing: H-h

Maintenance standards of cylinder, valve block
and swashplate (skid shoe plate).
Cylinder block Finish to
(Sliding section) necessary 3-Z (Ra=0.8)
Swashplate roughness
(Shoe plate)
Cylinder block Standard face
Roughness on roughness 0.4-Z (Ra=0.1)
each surface (corrected below (abrading)
(sliding section) value)
Free height of cylinder block spring: L

3-33
(2) Pilot pump

Pilot pump (P3 pump) is a quantitative type gear pump and provides the hydraulic system with pilot oil.
Pilot pump specifications
Model ZX10LGRZ1
Displacement cm³/r 10
+0.2
Set the pressure MPa
3.9 0
Rotation speed r/min 600~2500
Suction side pressure MPa 0.05~-0.01
Rotation direction of shaft (from drive shaft) Clockwise
Weight kg 1.5
Pilot pump construction

3-34
External view of pilot pump
Section view of pilot pump

1. Front casing 8. Spring 15. Angular seal ring
2. Gear housing 9. Ring 16. O-ring
3. Drive gear 10. Adjusting screw 17. O-ring
4. Driven gear 11. Locknut 18. Bolt with washer
5. Strainer 12. Locknut 19. Bolt with washer
6. Valve seat 13. VP oil plug 20. Bolt with washer
7. Cone valve 14. O-ring 21. Lock ring
3-35
Principle of pilot pump (2) When the machine using the Rexroth system,
the main pump assembly condition is as follows:
Specifications of the Rexroth main pump
Displacement 130×2cm³/rev
Rated 38MPa (5510psi)
Max. 42MPa (6090psi)
Rotary Rated 2100r/min
speed Max. 2200r/min
Weight 172.7KG
Category Mineral oil
Hydrauli -25 ~ +90°C
Temperature range
To main pump c oil (-13~+194°F)
Viscosity range 10 ~ 1000cST (mm²/S)
Structure and Working Principle of the Rexroth

Diagram of pilot pump hydraulic circuit Main Pump
The housing comprises a front housing (1) and a The main pump is mainly composed of the main
gear housing (2), with a pair of drive gear (3) and pump (P1, P2) and pilot pump (P3). The main pump
driven gear (4) installed inside as well as a relief is a double variable plunger pump and provides
valve used for setting output pressure. high-pressure oil for the main circuit so that all
The relief valve comprises a strainer (5), a cone hydraulic elements work. The pilot pump is a con-
valve (7), a valve seat (6), a spring (8), a ring (9), an stant gear pump and supplies oil for the pilot system
adjusting screw (10) and a locknut (11). and the main pump control system. The main pump
is directly driven by the engine via a coupling, and
To prevent oil from leaking outside, an angular seal the pilot gear pump is connected behind the pump
(14) and an O-ring (13) are installed on the front P2 in series, is indirectly driven by the drive shaft
housing (1). and rotates at the same speed to the main pump
Working principle during working.
The oil sucked via oil suction port B3 is drained by

the driving and driven gears through the discharge
oil port A3. Discharged oil is kept at setting pressure
through the relief valve. Redundant discharged oil is
discharged from the oil leakage port Dr of the main
pump housing by means of the relief valve.
3-36
1 2
5 4
CLG920E922E03008
CLG920E922E03007
1. Drive shaft
2. Minimum flowrate adjusting nut
3. Main pump regulator
4. Maximum flowrate adjusting nut
Y1, Y2 negative feedback port
X1, X2 pump pilot-oil port
M1, M2, MA1, MA2 - pressure measuring ports
E1, E2 pump swashplate inspection port
A1, A2P1,P2 main pump supply port
S1 main-pump suction port
S3 pilot-pump suction port
A3P3 Pilot-pump supply port
T1 Main pump drain port
T7 pilot-pump drain port
3-37
The figure below shows the structural diagram of the main pump assembly, and the numbers in () behind
concerned parts in the figure below shall prevail.
Structure drawing of main oil pump
4 5 6 7 8
3
15 14 13 12 11 10 9
CLG920E922E03009
1. Drive shaft 6. Spring 11. Thrust plate

2. Swashplate 7. Cylinder block 12. Oil suction port
3. Plunger 8. Inner engaged gear pump 13. Encoder
4. Filler port 9. Bearing 14. Housing
5. Connecting shaft 10. Sensor 15. Flange support
3-38
Parts list of main pump
9 33
15
15
13
8
11 16
6 5
2
3 17 12
12 7 17
1
4 6
10
14 16
CLG920E922E03010
1. Slewing body 7. Housing 13. Shaft seal

2. Slewing body 8. Oil supplement pump 14. Cir-clip
3. Main shaft with bearings 9. Control valve 15. Cylindrical pin
4. Swashplate 10. Flange 16. Hex socket screw
5. Swashplate 11. Flange 17. Angle Sensor
6. Variable unit 12. Gasket 33. O-ring
The main pump consists of two plunger pumps, namely pump P1 and pump P2, which are connected by the
spline joint. The rotation of the motor is delivered to the drive shaft at the front to simultaneously drive the two
pumps. The oil suction port and drain port are converged at the connection of the two pumps, and the pump P1
and P2 share the same suction port. Because the structure principles and working principles of the two pumps
P1 and P2 are the same the pump P1 will be described as an example. The pump P1 is roughly composed of
a rotating mechanism for driving the pump to rotate, a swashplate mechanism for adjusting discharge capacity
and a valve cap mechanism for alternately making oil suction and discharge actions. The rotating mechanism
is composed of a drive shaft, a cylinder block, skid shoes, a plate, a spherical cylinder liner, a shim and a
cylinder spring. Both ends of the drive shaft are supported by bearings. The shoes are installed on the piston to
form a ball joint, the thrust generated by load pressure is also reduced, and there is one housing on the skid
shoe to lightly adjust oil pressure balance. To make auxiliary mechanism of the skid shoes act smoothly on the
support plate, the shoes are pressed on the support plate by the oil pressure spring via the pressure plate and
the spherical cylinder liner. Likewise, the cylinder block is also pressed on the valve plate by the cylinder
spring. The swashplate mechanism is composed of a swashplate, a skid shoe, a swashplate support platform,
a tilt cylinder liner, a tilt pin and a servo cylinder. The cylindrical section of the swashplate formed at the
opposite side of skid shoe action face is supported on the swashplate support platform. Oil pressure controlled
by an adjuster makes an auxiliary piston to move from side to side under the guidance of oil pressure
chambers at both sides of the auxiliary piston. At the moment, the swashplate slewing on the swashplate
support platform using the ball section of the tilt pin to change the tilt angle. The valve cap mechanism is
composed of a valve block, a valve plate, and a valve plate pin. The valve plate with two melon-shaped holes
is installed on the valve block and is used for supplying and recovering oil to and from the cylinder block. Oil
switched by the valve plate is connected to an external pipe via the valve block.
3-39
Rexroth Pilot pump

Pilot pump specification Table
Model R902521593
Displacement 15cm³/r
Setting pressure 4.5MPa (652.5PSi)
Max. rotatory speed 2200r/min
0.05~-0.01MPa (7.25~-
Suction side pressure
1.45PSi)
Rotation direction of shaft (from
Clockwise
drive shaft)
Mass 14.6KG
External view of pilot pump
CLG920E922E03013
Working principle
Oil sucked from the suction port S3 is discharged
from drainage port A3 via the gear. Discharged oil is
kept at setting pressure through the relief valve.
Unwanted discharged oil is discharged from the oil
leakage port T1 of the main pump housing by
means of the relief valve.
CLG920E922E03011
3.3.2.2 Main Control Valve
1. When the machine using the Kawasaki system,
the main control valve condition is as follows
Specifications
Item Specifications
2 Model KMX15RB
1 Standard flow rate 300L/min
+1
Working pressure of main relief valve 34.3 0
MPa
+1
Pressurization pressure of main relief
valve 37.3 0
a MPa
CLG920E922E03012 Boom, arm and
Setting pressure 39.2±0.5MPa
of oil port relief bucket
1. Bolt 3. Housing valve Standby 30.0±0.5MPa
2. O-ring 4. Gear
Working oil temperature -20~90°C
Pilot-pump hydraulic schematic diagram is shown Maximum pressure of leaking oil 0.3MPa
below:
3-40
External view
3-41
3-42
3-43
3-44
3-45
3-46
The ports of the main control valve are shown in following table
Port dimension Symbols Port name

G-1 R2 Oil filler joint
(P0)
G-3/4 (P3)
(P5)
XAtr Right travel (reversing) pilot interface

XBtr Right travel (forwarding) pilot interface
(XAo) (Backup pilot interface)
(XBo) (Backup pilot interface)
XAk Bucket (excavate) pilot interface
XBk Bucket (unloading) pilot interface
XAb1 Boom 1 (rise) pilot interface
XBb1 Boom 1 (lowering) pilot interface
G-3/8 XAa2 Arm 2 (stretch) pilot interface
XBa2 Arm 2 (retraction) pilot interface
XAtL Left travel (reversing) pilot interface
XBtL Left travel (advancing) pilot interface
XAs Slewing (left slewing) pilot interface
XBs Slewing (right slewing) pilot interface
XAa1 Arm 1 (stretch) pilot interface
XBa1 Arm 1 (retraction) pilot interface
Dr1 Oil leakage port
Px Signal interface for work implement
Py Signal interface for travel
Pz Pilot pressure for pressurization of the main relief valve
PG Pilot pressure source interface
N1 Negative control signal pressure interface (boom 1 side)
N2 Negative control signal pressure interface (arm 1 side)
Pns Rotary logic control valve pilot interface
PCk Bucket (excavation) stroke limiting pilot interface
PnA2 Arm 2 logic control valve pilot interface
G-1/4 Dr2 Oil leakage port
PaL Lock valve pilot interface (arm piston rod side)
PbL Lock valve pilot interface (boom piston head side)
(XBp1) Bypass stop spool pilot interface (P1 side)
XBp2 Bypass stop spool pilot interface (P2 side)
XAb2 Boom combining (lifting) pilot interface pressure
Psp Rotation priority pilot port
M12 R1 Oil return port

3-47

Atr Right travel motor interface (reversing)
Btr Right travel motor interface (forward)
(Ao) Backup port
(Bo) Backup port
Ak Interface (excavation) at bucket cylinder piston head side
Bk Interface (unloading) at bucket cylinder piston rod side
Ab Interface (lifting) at boom cylinder piston head side
Bb Interface (lowering) at boom cylinder piston rod side
M10
AtL Left travel motor interface (backward)
BtL Left travel motor interface (forward)
As Slewing motor interface (left rotation)
Bs Slewing motor interface (right rotation)
Aa Interface (extension) at arm cylinder piston rod side
Ba Interface (retraction) at arm cylinder piston head side
P1 Pump port (P1 side)
The ports in () are valve blocks in general.

3-48
Configuration scheme
3-49
3-50
3-51
3-52
3-53
3-54
3-55
3-56
3-57
3-58
Parts list of main control valve

101 Valve body A 258 Plunger 335 Stopper
102 Valve body B 259 Plunger 336 Bolt with gasket
151 Plunger 261 O-ring 337 Stopper
152 Plunger 262 O-ring 339 Stopper
153 Plunger 264 O-ring 372 Spring
154 Plunger 273 Hexagon socket bolt 373 Spring
156 Orifice plug 274 Hexagon socket bolt 511 Cone valve
158 Plug 301 Travel spool 512 Cone valve
159 Plug 302 Arm 1 spool pair 513 Cone valve
161 O-ring 303 Boom 1 spool pair 514 Cone valve
162 O-ring 304 Bucket spool 521 Spring
163 O-ring 305 Slewing spool 522 Spring
164 O-ring 306 Arm 2valve element casing 523 Spring
165 O-ring 307 Boom 2 valve spool 541 Steel ball
166 O-ring 308 Straight travel valve spool pair 542 Spring holder
168 O-ring 309 Standby spool 543 Spring
201 Spring shield 310 Bypass stop spool 550 Plunger
202 Spring shield 311 Slewing priority valve 551 Plunger
203 Spring shield 320 Spring 552 Plunger
204 Spool casing 321 Spring 553 Plunger
205 Spool casing 322 Spring 561 O-ring
206 Spool casing 323 Spring 562 O-ring
209 Flange 326 Spring 601 Main relief valve
210 Plate 327 Spring 602 Interface relief valve
211 Plunger 328 Spring 604 Interface relief valve
251 Logical control valve 329 Spring 610 Negative control relief valve
252 Locking valve selection pair 330 Spring 971 Hexagon socket bolt
254 Revolving logic valve group 331 Spring holder 975 Hexagon socket bolt
256 Arm 2 logic valve group 332 Spring holder 977 Nameplate
257 Arm regeneration stop valve pair 333 Bolt with gasket 978 Rivet
3-59
Main control valve hydraulic circuit
Straight travel
Travel (right)
Travel (left)
Slewing
Slewing priority
Boom 1
Boom 2
Bucket
Spare
Arm 1 Arm 2
Bypass stop
Hydraulic circuit diagram
Figure 4
3-60
Working principle
(1) When the spool is in the neutral position
[Main circuit]
When all spools are in neutral state, the working oil fed from the hydraulic pump (front) flows into the pump
interface P1, is guided to the main passage (1) and returns to the working tank from the return interface (R1)
by the neutral bypass (2) (M-shaped natural slide valve function) of each spool of straight travel (308), left
travel (301), boom 1 (303), bucket (304) and arm 2 (306).
The signals of the negative control relief valve (610) at the boom 1 side are transmitted into the hydraulic pump
adjuster at the P1 side from the interface N1 to control the pump output flow as the minimum flow.
The working oil fed from the hydraulic pump (rear) flows into the pump interface P2, is guided to the main
passage (3), and returns to the working oil tank from the return interface (R1) by the neutral bypass (2) (Neutral
M-shaped slide valve function) of each spool of flowing into the right travel (301), rotation (305), boom flow
merging (boom 2: 307), backup (309) and arm 1 (302).
In addition, the signals of the negative control relief valve (610) at the arm 1 side are transmitted into the
hydraulic pump adjuster at the P2 side from the interface N2 to control the pump output flow as the minimum
flow.
No matter which of the 9 main valve spools is switched, the neutral bypass (2) will be immediately closed. The
signal pressure at the interface N1 or N2 in the negative control circuit is the tank pressure, and controls the
pump output flow as the maximum flow. 4
3-61
Figure 5
3-62
(2) Traveling
[Pilot circuit]
When the left or right travel spool is switched, the side passage is closed, and thus the pressure at the
interface Py (signal interface for travel) rises.
[Main circuit]
When the pilot interface XBtL for the left travel spool (301) is pressurized,
The neutral bypass (2) at the boom 1 side is closed, and the working oil fed from the hydraulic pump (front) is
fed into the left travel motor from the interface BtL.
Similarly, when the pilot interface XBtr for the right travel spool (301) is pressurized, the neutral bypass (2) at
the arm 1 side is closed, and the working oil fed from the hydraulic pump (back) is fed into the right travel motor
from the interface Btr.
On the other hand, the return oil respectively from the left and right travel motors passes through the left (right)
travel spool from the interface AtL (Atr), and then returns to the working oil tank from the return oil interface
(R1).
When the travel on the opposite side (pressurizing the pilot interfaces XAtr and XAtL) is operated, the process
is the same as the above.
Swing motor
Figure 6
3-63
(3) Arm
1) During the arm extending operation
[Pilot circuit]
When the arm 2 spool (306) is switched, the side passage is closed, and thus the pressure at the interface Px
(signal interface for work implements) rises.
[Main circuit]
During the arm extending operation, pilot pressure oil is fed into the ports XAa1 and XAa2. When pilot pressure
oil is applied to both sides of the interfaces XAa1.XAa2, the arm 1.arm 2 spools are respectively switched to
the left of the Figure 6, and thus the working oil flowing into P2 is guided to the neutral bypass (2) through the
main passage (3). By switching the arm 1 spool (302), the neutral bypass is cut off, and thus the working oil
flowing into the parallel passage pushes open the cone valve (511) of the check valve, flows into the arm 1
spool (302) from the U-shaped passage, then flows into the periphery of the arm 1 spool (302) and arm 2 spool
(306), and is fed into the arm cylinder piston rod side from the interface Aa.
On the other hand, the working oil flowing into the interface P1 is fed into the neutral bypass (2) through the
main passage (1). By switching the arm 2 spool (306), the neutral bypass is cut off. Thus the working oil flow-
ing into the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve gp, while the
working oil flowing into the neutral bypass pushes open the cone valve (511) of the check valve. They both
flow into the arm 2 spool (306) from the U-shaped passage, then merge with the interface Aa from the internal
passage of the arm 2 spool (306), and are fed into the arm cylinder piston rod side (R).
The return oil from the arm cylinder piston head side (H) through the interface Ba flows to the respective tank
oil circuit of the arm 1 and arm 2, and returns to the working oil tank from the tank interface (R1).
3-64
Figure 7
2) During the arm retracting operation

3-65
[Pilot circuit]
When the arm 2 spool (306) is switched, the side passage is closed, and thus the pressure at the interface Px
(signal interface for work implements) rises. Meanwhile, pressure oil is fed into the interface PaL, and the
release signal of the lock valve selector pair (252) is sent over.
[Main circuit]
During the arm retracting operation, pilot pressure oil is fed into the ports XBa1 and XBa2. When pilot pressure
oil is applied to both sides of the ports XBa1 and XBa2, the arm 1 and arm 2 spools are respectively switched
to the right of Figure 8. Thus the working oil flowing into P2 is guided to the neutral bypass (2) through the main
passage (3). By switching the arm 1 spool (302), the neutral bypass is cut off. Thus the working oil flowing into
the parallel passage pushes open the cone valve (511) of the check valve, flows into the arm 1 spool (302)
from the U-shaped passage, then flows into the periphery of the arm 1 spool (302), and is fed into the bucket
cylinder piston head side (H) from the interface Ba.
On the one hand, the working oil flowing into the interface P1 is guided to the neutral bypass (2) through the
main passage (1). By switching the arm 2 spool (306), the neutral bypass is cut off, and thus the working oil
flowing into the parallel passage pushes open the logic cone valve (256-101) of the arm 2 logic valve gp, while
the working oil flowing into the neutral bypass pushes open the cone valve (511) of the check valve. They both
flow into the arm 2 spool (306) from the U-shaped passage, then merge with the interface Ba from the internal
passage of the arm 2 spool (306), and are fed into the arm cylinder piston head side (H).
On the other hand, the return oil from the arm cylinder piston rod side (R) makes the working oil with increasing
pressure return to the interface Aa through the self weight of the arms etc. The working oil having returned to
the interface Aa flows into the spool from a hole on the periphery of the arm 1 spool (302); only under low load,
it will push open the cone valve (302-317) inside the spool and merge with the interface Ba from a hole on the
spool. This is called the arm regeneration function.
If the pressure at the arm cylinder piston head side and in the U-shaped passage rises, the arm regeneration
stop spool (257-211) is switched to the left of Figure 9, and is closed through the back pressure of the cone
valve (302-317) inside the spool simultaneously. Thus the arm regeneration function is released. The return oil
from the arm cylinder piston rod side (R) flows into the spool from the hole (a) on the periphery of the arm 1
spool (302), then flows to the arm regeneration stop valve pair (257) from the hole (c) on the periphery of the
arm 1 spool (302), and returns to the working oil tank through the tank interface (R1).
3-66
Small load
Arm dead-weight
LG922E930E03056
Figure 8
3-67
When the pressure on the side of arm cylinder piston head (H) rises
Figure 9
3-68
(4) Boom
1) When the boom is operated to lift
[Pilot circuit]
When the boom 1 spool (303) is switched, the side passage is closed, and thus the pressure at the interface
Px (signal interface for work implements) rises.
[Main circuit]
During the boom lifting operation, pilot pressure oil is fed into the interface XAb1, and the boom 1 spool (303)
moves to the left of Figure 10. The working oil flowing into the interface P1 is guided to the neutral bypass (2)
by means of the main passage (1). By switching the boom 1 spool (303), the neutral bypass is cut off, and thus
the working oil flowing into the parallel passage pushes open the cone valve (511) of the check valve, flows
into the boom 1 spool (303) from the U-shaped passage, then flows into the periphery of the boom 1 spool
(303), and is fed into the boom cylinder piston head side (H) from the interface Ab.
Meanwhile, pilot pressure oil is also fed into the interface XAb2, and the boom 2 spool (307) moves to the right
of Figure 10. As the neutral bypass is cut off by switching the boom 2 spool (307), thus the working oil from P2
flowing into the parallel passage flows into the boom 2 spool (307) by means of the U-shaped passage, then
pushes open the cone valve (511) of the check valve, and is fed into the boom cylinder piston head side (H)
after merging with the interface Ab. This is called the boom flow merging function.
On the other hand, the return oil from the boom cylinder piston rod side (R) flows into the periphery of the
boom 1 spool (303) from the interface Bb, and returns to the working oil tank from the tank interface (R1).
3-69
Figure 10
3-70
2) During boom lowering operation

[Pilot circuit]
When the boom 1 spool (303) is switched, the side passage is closed, and thus the pressure at the interface
Px (signal interface for work implements) rises. Meanwhile, pressure oil is fed into the interface PbL, and the
release signal of the lock valve selector pair (252) is sent over.
[Main circuit]
During the boom lowering operation, pilot pressure oil is fed into the interface XBb1, and the boom 1 spool
(303) moves to the right of Figure 10. The working oil flowing into the interface P1 is guided to the neutral
bypass (2) by means of the main passage (1). By switching the boom 1 spool (303), the neutral bypass is cut
off. Thus the working oil flowing into the parallel passage pushes open the cone valve (511) of the check valve,
flows into the boom 1 spool (303) from the U-shaped passage, then flows into the periphery of the boom 1
spool (303), and is fed into the boom cylinder piston rod side (R) from the interface Bb.
On the other hand, the return oil from the boom cylinder piston head side (H) passes through the hole (a) and
periphery of the boom 1 spool (303).
The return oil makes pressure rise through the self weight of the booms. To maintain sufficient pressure, the
cone valve (303-317) inside the spool is pushed towards the right of Figure 11 by means of the internal spool
passage, and the return oil flows out of the spool. This pressure oil acts as the working oil for the boom lower-
ing operation and is again fed into the boom cylinder piston rod side (R), which is called the boom regeneration
function. Part of the return oil flowing into the internal spool passage from the hole (a) returns to the working oil
tank by means of the hole (b).
3-71
Figure 11
(5) Bucket
1) During bucket excavation operation
[Pilot circuit]
When the bucket spool (304) is switched, the side passage is closed, and thus the pressure at the interface Px
(signal interface for work implements) rises. Meanwhile, pressure oil is also fed into the interface XBp2.
[Main circuit]
During the bucket excavation operation, pilot pressure oil is supplied into the interface XAk, and the bucket
spool (304) moves to the right of Figure 11. The working oil flowing into the interface P1 is guided to the neutral
bypass (2) by means of the main passage (1). By switching the bucket spool (304), the neutral bypass is cut
off. Thus the working oil flowing into the parallel passage pushes open the cone valve (511) of the check valve,
flows into the bucket spool (304) from the U-shaped passage, then flows into the periphery of the bucket spool
(304), and is fed into the bucket cylinder piston head side (H) from the interface Ak.
On the other hand, the return oil from the bucket cylinder piston rod side (R) flows into the interface Bk, and
then flows to the tank interface (R1) from the periphery of the spool to return to the working oil tank.
During the simultaneous boom lifting and bucket excavation operation, pilot pressure oil is fed into the interface
Pck, and thus the stroke of the bucket spool is not only be limited within the full stroke but in a halfway position.
3-72
Thus the passage of the bucket cylinder is throttled, and working oil also flows into the boom 1 spool (303)
from the bucket spool (304). Therefore, the boom lifting operation takes priority
.
Figure 12
3-73
2) During bucket unloading operation

[Pilot circuit]
When the bucket spool (304) is switched, the side passage is closed, and thus the pressure at the interface Px
(signal interface for work implements) rises. Meanwhile, pilot pressure oil is also fed into the interface XBp2.
[Main circuit]
During the boom lifting operation, pilot pressure oil is fed into the interface XAb1, and the bucket spool (304)
moves to the left of Figure 12. The working oil flowing into the interface P1 is guided to the neutral bypass (2)
by means of the main passage (1). By switching the bucket spool (304), the neutral bypass is cut off. Thus the
working oil flowing into the parallel passage pushes open the cone valve (511) of the check valve, flows into
the bucket spool (304) from the U-shaped passage, then flows into the periphery of the bucket spool (304), and
is fed into the bucket cylinder piston rod side (R) from the interface Bk.
On the other hand, the return oil from the bucket cylinder piston head side (H) flows into the interface Ak, and
then flows to the tank interface (R1) from the periphery of the spool to return to the working oil tank.
Figure 13
3-74
3) Bucket flow merging

During the bucket excavation operation, pilot pressure oil is also supplied into the interface XBp2, and the neu-
tral bypass stop spool (310) is switched. Working oil supplied via the interface P2 is guided into the neutral
bypass (2) via the main passage (3). The neutral bypass is cut off by switching the neutral bypass spool (310).
So working oil pushes open the check valve (514) and merges with flow in the bucket spool (304) via the inter-
nal passage and the U-shaped passage.
(6) Slewing
1) During individual rotation
[Pilot circuit]
When the slewing spool (305) is switched, the side passage is closed, and thus the pressure at the interface
Px (signal interface for work implements) rises.
[Main circuit]
During individual rotation, pilot pressure oil is supplied into the interface XAs (or interface XBs) to switch the
rotary spool (305). The working oil flowing into the interface P2 is guided to the neutral bypass (2) by means of
the main passage (3). The neutral bypass is cut off by switching the slewing spool (305). So working oil flowing
in the parallel passage pushes open the logic cone valve (254-101) of the rotary logic valve group, flows in the
rotary spool (305) via the U-shaped passage, then flows into the periphery of the rotary spool (305) and is sup-
plied to the slewing motor via the interface As (or interface Bs).
On the other hand, return oil from the slewing motor flows in from the interface Bs (or interface As), flows into
the oil tank interface (R1) via the periphery of the spool and then returns to the working oil tank.
Swing motor
Figure 14
3-75
2) Rotation priority function

[Pilot circuit]
Pilot pressure oil is supplied into the interface Psp to switch the rotary priority spool (311).
[Main circuit]
Because the opening area of the rotary priority spool decreases by switching the rotary priority spool (311),
working oil from the spool (302) of the arm 1 also flows back the rotary spool (305) so that rotation takes prior-
ity.
Figure 15
3-76
(7) Standby
The standby spool is used for controlling various additional devices.
1) Optional operation
[Pilot circuit]
When the standby spool (309) is switched, the bypass is closed, so the pressure of the interface Px (signal
interface for working device) rises.
[Main circuit]
When the standby spool is operated, pilot pressure oil is supplied into the interface Px (or interface XBo) to
switch the standby spool (309). The working oil flowing into the interface P2 is guided to the neutral bypass (2)
by means of the main passage (3). The neutral bypass is cut off by switching the standby spool (309). Thus the
working oil flowing in the parallel passage pushes open the cone valve (511) of the check valve, flows in the
standby spool (309) via the U-shaped passage, then flows into the periphery of the standby spool (309) and is
supplied to the additional devices via the interface As (or interface Bo).
On the other hand, return oil from the additional devices flows in from the interface Bo (or interface Ao), flows
into the oil tank interface (R1) via the periphery of the spool and then returns to the working oil tank.
Figure 16
3-77
2) Backup flow merging

To merge standby flow, pilot pressure oil is also supplied to the interface XBp1 to switch the bypass stop spool
(310). The working oil flowing into the interface P1 is guided to the neutral bypass (2) by means of the main
passage (1). The neutral bypass is cut off by switching the bypass stop spool (310), so that working oil pushes
open the cone valve (514) of the check valve and merges with the flow in the standby spool (309) via the inter-
nal passage and the U-shaped passage.
(8) Straight travel
When the travel spool (301) is operated together with other spools.
The condition where the travel spool (301) and the rotary spool (305) are simultaneously operated is described
below. (When pilot pressure oil is supplied to the interfaces XAtL, XAtr and XAs)
[Pilot circuit]
The side passage of right travel and left travel spools (301) and the side passage of the rotary spool at the
downstream side are closed, pilot pressure oil from the interface PG is supplied to the interface PTa, and the
straight travel spool (308) is switched.
[Main circuit]
When the straight travel spool (308) is switched, the right travel and left travel spool (301) is preferentially com-
municated with the interface P2, the parallel passage of the rotary, boom 2 standby, arm 1 oil passage/boom 1
bucket and arm 2 oil passage is preferentially communicated with the interface P1, so that working oil supplied
from the interface P2 mainly flows into the interface AtL and the interface Atr and is evenly supplied to two
travel motors.
On the other hand, working oil supplied from the interface P1 is also supplied to the slewing motor via the inter-
face As.
When the pressure oil in the interface P2 is lower than that of the interface P1, one part of working oil supplied
from the interface P1 is supplied to the P2 side. So the rapid decrease of travel speed can be prevented.
3-78
Figure 17
3-79
(9) Function of lock valve

The lock valve selector pair (252) is installed among the arm cylinder piston rod side (R), the arm 1 spool (302)
and the arm 2 spool (306) to reduce the internal leakage of the spool caused by cylinder pressure.
Likewise, a lock valve selector pair (252) is also installed between the boom cylinder piston head side (H) and
the boom 1 spool (303) to reduce the internal leakage of the spool caused by cylinder pressure.
1) Spool neutral state
The condition where the boom 1 spool (303) is selected is shown below. (The condition of arm 2 spool (306) is
also the same.)
When the boom 1 spool (303) is neutral, the spool (252-511) inside the lock valve selector pair is kept in the
position as shown in Figure 18 by the pretightening force of the spring (252-321) and is pressed in the valve
seat of the valve bushing (252-541) inside the lock valve selector pair.
In this position, working oil at the boom cylinder piston head side (H) flows in from hole (a), flows across the
periphery of the spool (252-511) of the lock valve selector pair and presses the valve seat of valve body of the
cone valve (513) at hole (b) so as to reduce internal leakage.
Figure 18
3-80

When the boom is operated to lower, pilot pressure oil is supplied into the interface PbL and the interface
XBb1. The spool (252-511) inside the lock valve selector pair moves to the upper side of Figure 18 through
pilot pressure oil. The hole (a) is first cut off through the movement of the spool (252-511) inside the lock valve
selector pair, and working oil from the boom cylinder piston head side (H) does not flow into the spring cham-
ber (RH). In addition, oil in the cavity of spring chamber (RH) flows into the leakage oil circuit via the hole (b).
Therefore, the cone valve (513) is jacked through the pressure at the boom cylinder piston head side (H), and
the function of the lock valve selector pair (252) is released.
Figure 19
3-81

During the boom lifting operation, pilot pressure oil is fed into the interface XAb1. The cone valve (513) is
pushed open through oil flowing in via the boom 1 spool (303), so working oil flows into the interface Ab.
(10)Function of the main relief valve
The main relief valve is installed on the valve body A (101) and has the following functions:
1) Working oil fills the cavity of chamber (a) using the holes in the valve seat (541) and small holes in the
valve plunger (512) through the passage (P), and the valve plunger (512) is pressed against the valve seat
(541) to form a reliable seal.
2) When the pressure inside the passage (P) exceeds the pretightening force of the spring (621), the cone
valve (611) is opened, so working oil flows into the low pressure passage (R) from the periphery of the
cone valve (611) and across the holes in the valve bushing (103).
3) The pressure inside the cavity (a) drops due to the opening of the cone valve (611), and the valve plunger
(512) is opened. Therefore, working oil in the passage (P) directly flows into the low pressure passage (R).
4) When pressure oil above 3MPa is supplied into the interface Pz, the pressure oil pushes the plunger (614)
to move leftwards to change the setting load of the spring (621), and the pressure starts to rise.
Figure 20
3-82
(11)Function of the port relief valve

The interface relief valve is installed between the cylinder interface and the low-pressure passage. Besides the
function as a relief valve, the interface relief valve also has the function as a check valve for preventing cavita-
tion and replenishing oil.
1) Function as a relief valve
a. Working oil fills the cavity of chamber (B) via hole (A) of the plunger (301) and presses the valve plunger
(511) against the valve seat (541), and the valve seat (541) is pressed against the valve seat of the valve
body to form reliable seal.
Figure 21
3-83
Figure 22
3-84
b. When the pressure inside the passage (P) exceeds the elastic force of the spring (621), the cone valve is
opened, so working oil flows into the low pressure passage (R) from the periphery of the cone valve
(611) and across the hole (C).
Figure 23
3-85
Figure 24
3-86
c. The pressure inside the cavity of chamber (B) drops due to the opening of the cone valve (611), and the
valve plunger (511) is opened. Therefore, working oil in the passage (P) directly flows into the low
pressure passage (R).
Figure 25
3-87
Figure 26
3-88
2) Function as a check valve for preventing cavitation and replenishing oil

When the passage (P) generates negative pressure, working oil is supplied from the passage (R). When the
pressure of the passage (R) is higher than the pressure of the passage (P), the valve seat (541) moves right-
wards. Therefore, working oil is guided into the passage (P) from the passage (R) through the periphery of the
valve seat (541) so as to prevent cavitation.
Figure 27
3-89
Figure 28
3-90
(12)Function of negative control relief valve

The negative control relief valve is installed between
the most downstream of the neutral by-pass and the
low-pressure passage. The function of the negative
control relief valve is shown below.
1) If the pressure of the interface P is smaller than
the setting pressure of the spring (321), the
cone valve (511) is in the state shown in Figure
29. The pressure bearing section φB of the
cone valve (511) is canceled by the section φA
of damping rod (512), and the pressure bearing
area is φB-φA at the moment. Working oil in the
interface P flows to (R) through the orifice (c).
Figure 30
Through the above change, the relationship

between the flow Q of working oil flowing from the
interface P to the low pressure passage (R) and the
pressure change is shown in Figure 31.
Pressure
Figure 29
2) When the pressure of the interface P is greater

than the setting pressure of the spring (321) as
shown in Figure 30, the cone valve (511) is
opened, and working oil in the interface P flows
to the low pressure passage (R) through the Flow
periphery of the cone valve (511).
Figure 31
Structural Function and Maintenance
3-91
CLG920E922E03014
-20 ~ +90°C (-4~194°F)
M9-G1118-00/7M9-25
Specifications
0.3MPa (43.5PSi)
34MPa (4930psi)
37MPa (5365psi)
38MPa (5510psi)
30MPa (4350psi)
Relief-valve
2. When the machine using the Rexroth system, the main control valve condition is as follows?
backup port
Relief valve of the
bucket small cavity
Relief valve of the
boom small cavity
Main-valve Main-valve oil inlet P1 Main-valve
oil inlet P2 drainage
port S
Oil shutoff
valve PC2
Main-valve drainage port T
POPT port
Main-valve drainage port K
Port P?(connecting with Port POPT)

Relief valve of the
Boom, arm and bucket arm small cavity
Pilot drainage port
Standby
Pressurization pressure of main relief valve
Working pressure of main relief valve
Maximum pressure of the leaking oil

Relief-valve
backup port
Backup port (blocked) Relief valve of the
Working oil temperature

Backup port
bucket big cavity
(blocked)
Relief valve of the
Bucket small cavity
Bucket big cavity boom big cavity
Model
Item
Pilot drainage port
Boom small cavity
Boom big cavity
Setting pressure of main relief valve

Main-valve
Left travel forward Left travel backup drainage port Y Oil shutoff valve PC1
Right travel forward Right travel backup
CLG920E/922E/923E
Left slewing Right slewing
September 15, 2020

Relief valve of the
arm big cavity
Arm small cavity
Arm big cavity
Specifications
External view
3-92
Table of Ports of the Main Control Valve

M14×19
B1 Interface (extension) at arm cylinder piston rod side
B5 Port at boom cylinder piston rod side (stretching)
POPT Outside oil port (at the POPT side)
P' Outside oil port (at the P’ side)
A1 Interface (retraction) at arm cylinder piston head side
A2 Slewing motor interface (left rotation)
A3 Right travel motor interface (reversing)
A4 Left travel motor interface (backward)
A5 Port at boom cylinder piston head side (retracted)
M12×19
A6 Port at bucket cylinder piston head side (retracted)
A7 Backup port
B2 Slewing motor interface (right rotation)
B3 Right travel motor interface (forward)
B4 Left travel motor interface (forward)
B6 Port at bucket cylinder piston rod side (stretching)
B7 Backup port
T Oil port T (at the T side)
M10×15.5
K Oil radiator (at the K side)
3-93

L1 Drain port
L2 Drain port
L3 Drain port
PC1 Pilot of the bypass stop spool
PC2 Pilot of the bypass stop spool
Y Pilot port of the transient power-boosting
Y' Standby port and secondary pressure pilot port
AB Arm combining (retracting) pilot port
BB Boom combining (lifting) pilot port
a1 Arm (stretching) pilot port
a2 Slewing (right) pilot port
a3 Right travel (backup) pilot port
G-1/4 a4 Left travel (forward) pilot port
a5 Boom (lowering) pilot port
a6 Bucket (unloading) pilot port
a7 Backup port pilot
b1 Arm (retracting) pilot port
b2 Slewing (left) pilot port
b3 Right travel (forward) pilot port
b4 Left travel (backup) pilot port
b5 Boom (lifting) pilot port
b6 Bucket (digging) pilot port
b7 Backup port pilot
Pi Straight-travel pilot port
po Straight-travel pilot port
M33×2 S Drainage port of the main valve
3-94
Configuration scheme
CLG920E922E03015
3-95
CLG920E922E03016
Parts list of main control valve

112. Plug 152. Compression spring 200. Plug
113. Cover plate 158. Screw 202. Relief valve
114. Washer 173. Compression spring 204. Relief valve
140. Check valve 180. O-ring 210. Relief valve
141. Check valve 184. Compression spring 240. Shut-off valve
150. O-ring 186. Cover plate 243 Sling
151. Spring washer 187. Screw
3-96
Main control valve hydraulic circuit
Standby Bucket Boom Arm

动臂油缸
BOOM CYLINDER
B B
A A
Travel (left) Travel (right) Slewing
Straight travel (pi, po)

CLG920E922E03017
3-97
Working principle
1. When the spool is in the neutral position
[Main circuit]
When all spools are in neutral state, the working oil fed from the hydraulic pump (rear) flows into the pump
interface P1, is guided to the main passage and returns to the working tank from the return interface (T) by the
neutral bypass of each spool of straight travel, right travel, slewing and arm.
The working oil fed from hydraulic pump (front), via the pump port P2, is guided into the main passage and
returns to the working tank from the return interface (T) by the neutral bypass of each spool of straight travel,
left travel, boom, bucket, arm and standby.
Also, when the electrical sensor does not detect any action of the pilot pressure, the electrical program controls
the output flow of P1 and P2 pumps to the minimum flow by controlling the electric proportional control valves
of P1 and P2 pumps.
No matter which of the 8 main valve spools is switched, the neutral bypass will be immediately closed. After the
pressure sensor of the electric appliance detects the pilot pressure, it will control the flow output from the pump
to the maximum flow.
CLG920E922E03018
3-98
CLG920E922E03019
3-99
(1) Traveling
[Pilot circuit]
When switching the right travel or left travel valve
spools, the side bypass is closed, the electrical
pressure sensor detects the pilot pressure, and the
signal is uploaded to the system, so the output flow
of the pump becomes larger.
[Main circuit]
When the pilot port b3 for the right travel spool is
pressurized, the neutral bypass at the right travel is
closed, and the working oil fed from the hydraulic
pump (rear) is fed into right travel motor from the
port B3.
Similarly, when the pilot port b4 for the left travel
spool is pressurized, the neutral bypass at the left
travel closed, and the working oil fed from the
hydraulic pump (front) is fed into the left travel motor
from the port B4.
On the other hand, the return oil respectively from
the left and right travel motors passes through the
right (left) travel spool from the ports A3 (A4) and
then returns to the working oil tank from the oil
return port (T).
When the travel on the opposite side (pressurizing
the pilot ports a3 and a4) is operated, the process is
the same as the above.
CLG920E922E03020
3-100
(2) Arm
During the arm extending operation
[Pilot circuit]
When switching the arm spool, the bypass is
closed, the electrical pressure sensor detects the
pilot pressure, and the signal is uploaded to the sys-
tem, so the output flow of the pump becomes larger.
[Main circuit]
When the arm is extending, the pilot pressure oil is
fed into the port a1. When pilot pressure oil is
applied to the port a1, the arm spools are switched
to the upper part as shown in the figure above, and
thus the working oil flowing into P1 is guided to the
neutral bypass through the main oil circuit. By
switching the arm spool, the neutral bypass is cut
off, and thus the working oil flowing into the parallel
passage opens the cone valve of the check valve,
then flows into the periphery of the arm spool, and is
fed into the arm cylinder piston rod side (B) from the
port A1.
The return oil from the arm cylinder piston head side
(A) through the port B1 flows to the tank circuit of
the arm, and returns to the working tank from the
tank port (T).
At the same time, the pilot oil is supplied to port AB
as well as to port a1. The bypass switching valve CLG920E922E03021
spool is reversed so that the working oil from the P2
pump is led into the main circuit at the arm side
through the main circuit to form a combined flow.
On the other hand, the oil return circuit from the pis-
ton rod side of the arm cylinder flows into the arm
spool and the outer circumference from the B1 inter-
face, and returns to the working tank from the inter-
face (T).
3-101
2. During the arm retracting

[Pilot circuit]
When switching the arm spool, the side bypass is
pilot pressure, and the signal is uploaded to the sys-
tem and change the output flow of the pump.
[Main oil circuit]
During the arm retracting operation, pilot pressure
oil is fed into the Port b1. When the pilot pressure oil
is applied at the side of the b1 interface, the arm
valve spool switches to the lower part as shown in
the figure below. Thus the working oil flowing into
P1 is guided to the neutral bypass through the main
oil circuit. By switching the arm spool, the neutral
bypass is cut off. Thus the working oil flowing into
the parallel passage opens the cone valve of the
check valve, flows into the arm spool, then flows
into the periphery of the arm spool, and is fed into
the arm cylinder piston head side (B) from the port
B1.
At the same time, the pilot oil is supplied to port AB
as well as to port b1. The bypass switching valve
spool is reversed so that the working oil from the P2
pump is led into the main circuit at the arm side
through the main circuit to form a combined flow.
ton rod side of the arm cylinder flows into the arm CLG920E922E03022
spool and the outer circumference from the A1 inter-
face, and returns to the working tank from the inter-
face (T).
3-102
(1) Boom
1) When lifting the boom
[Pilot circuit]
When switching the boom spool, the side bypass is
pilot pressure of the boom actuating, and the signal
is uploaded to the system to change the pump out-
put flow.
[Main circuit]
During the boom lifting operation, pilot pressure oil
is fed into the interface b5, and the boom spool
moves to the lower part as shown in the figure. The
working oil flowing from the P2 interface is led into
the neutral bypass through the main channel. By
switching the middle bypass of the boom spool, the
working oil flowing to the parallel channel is cut off,
and the cone valve of the check valve is opened to
flow into the boom spool. Then, it flows into the
outer circumference of the boom spool and is fed
into the boom cylinder piston head side (A) from the
B5 interface.
At the same time, the pilot oil is also supplied to port
BB. The bypass shut-off valve moves to the upper
part as shown in the figure, and the working oil flow-
ing into the P1 pump is led into the main circuit at
the boom side through the main circuit to form a
combined flow.
ton rod side of the boom cylinder flows into the
boom spool and the outer circumference from the
A5 interface, and returns to the working tank from
CLG920E922E03023
the interface (T).
3-103

[Pilot circuit]
When switching the boom spool, the side bypass is
pilot pressure, signal is uploaded to the system and
change the output flow of the pump.
[Main circuit]
When operating the boom lowering, the A5 port is
supplied with pilot pressure oil, and the boom spool
moves to the top as shown in the figure below. The
working oil flowing into the interface P2 is guided to
the neutral bypass by means of the main oil circuit.
By switching the boom spool, the neutral bypass is
cut off. Thus, the working oil flowing into the parallel
passage pushes open the cone valve of the check
valve, then flows into the boom spool and the outer
circumference, and supplies the oil from the A5
interface to the piston rod side (B) of the boom cylin-
der.
On the other hand, the oil returned from the piston
head side (A) of the boom cylinder flows through the
boom spool and the outer circumference.
The return oil makes pressure rise through the
boom self-weight. To maintain sufficient pressure,
the cone valve inside the spool is pushed towards
the right of the figure below using the internal spool
passage, and the return oil flows out of the spool.
The pressure oil is supplied to the rod side (B) of the
boom cylinder again as the working oil for the boom
lowering operation, which is called the boom regen-
eration function. Part of the return oil flowing into the
internal spool passage returns to the working oil CLG920E922E03024
tank.
3-104
(2) Bucket
1) During bucket excavation operation
[Pilot circuit]
When switching the bucket spool, the side bypass is closed. At the same time, the electrical pressure sensor
detects the pilot pressure, signal is uploaded to the system, and change the output flow of the pump.
[Main circuit]
During the bucket is digging, the pilot pressure oil is supplied into the port b6, and the bucket spool then moves
to the lower part as shown in the figure below. The working oil flowing into the interface P2 is guided to the
neutral bypass by means of the main passage. By switching the bucket spool, the neutral bypass is cut off.
Thus the working oil flowing into the parallel passage opens the cone valve of the check valve, flows into the
bucket spool, then flows into the periphery of the bucket spool, and is fed into the bucket cylinder piston head
side (A) from the port B6.
At the same time, the built-in program of the electric appliance will switch the straight travel valve spool to
Position 2 to lead the working oil supplied by P1 and P2 pumps into the main circuit on the side of the bucket,
so that the bucket will form confluence when it is digging.
On the other hand, the return oil from the bucket cylinder piston rod side (B) flows into the port A6, and then
flows to the tank port (T) from the periphery of the spool to return to the working oil tank.
During the simultaneous boom lifting and bucket excavation operation, pilot pressure oil is supplied at the B6
port because there is an orifice in the boom spool to the bucket spool. Thus the passage of the bucket cylinder
is throttled, and working oil also flows into the boom spool from the bucket spool. Therefore, the boom lifting
operation takes priority.
2) During bucket unloading operation

[Pilot circuit]
When switching the bucket spool, the side bypass is closed. At the same time, the electrical pressure sensor
detects the pilot pressure, signal is uploaded to the system, and change the output flow of the pump.
[Main circuit]
During the bucket is unloading, the pilot pressure oil is supplied into the port a6, and the bucket spool then
moves to the upper part as shown in the figure below. The working oil flowing into the interface P2 is guided to
the neutral bypass by means of the main passage. By switching the bucket spool, the neutral bypass is cut off.
Thus the working oil flowing into the parallel passage opens the cone valve of the check valve, flows into the
bucket spool, then flows into the periphery of the bucket spool, and is fed into the bucket cylinder piston rod
side (B) from the port A6.
On the other hand, the return oil from the bucket cylinder piston head side (A) flows into the port B6, and then
flows to the tank port (T) from the periphery of the spool to return to the working oil tank.
3-105
CLG920E922E03025
3-106
CLG920E922E03026
3-107
(3) Slewing
1) During individual rotation
[Pilot circuit]
When switching the revolving valve spool, the side
bypass is closed. At the same time, the electrical
pressure sensor detects the pilot pressure, signal is
uploaded to the system, and change the output flow
of the pump.
[Main circuit]
During individual slewing, pilot pressure oil is sup-
plied into the port b2 (or port a2) to switch the slew-
ing spool. The working oil flowing into the interface
P1 is guided to the neutral bypass by means of the
main passage. The neutral bypass is cut off by
switching the slewing valve spool. Thus the working
oil flowing in the parallel passage opens the cone
valve of check valve, flows into the slewing spool,
then flows into the periphery of the slewing spool
and is supplied to the slewing motor via the inter-
face B2 (or interface A2).
On the other hand, return oil from the slewing motor
flows into the port A2 (or port B2), flows into the tank
port (T) via the periphery of the spool and then
returns to the working oil tank.
When revolving and arm are operated at the same
time, there is an orifice on the revolving valve spool
leading to the arm spool, so that the passage of arm
cylinder is throttled, and the working oil also flows
into the revolving valve spool from the arm spool.
Therefore, the revolving operation takes priority.
CLG920E922E03027
3-108
(4) Standby
The standby spool is used for controlling various
additional devices.
1) Optional operation
[Pilot circuit]
When switching the standby valve spool, the side
bypass is closed. At the same time, the electrical
pressure sensor detects the pilot pressure, signal is
uploaded to the system, and change the output flow
of the pump.
[Main circuit]
When the standby spool is operated, pilot pressure
oil is supplied into the port b7 (or port a7) to switch
the standby spool. The working oil flowing into the
interface P1, P2 is guided to the neutral bypass by
means of the main passage. The neutral bypass is
cut off by switching the standby valve spool. Thus
the working oil flowing in the parallel passage opens
the cone valve of the check valve, flows in the
standby spool, then flows into the periphery of the
standby spool and is supplied to the additional
devices via the interface B7 (or interface A7).
On the other hand, return oil from the additional
devices flows into the port A7 (or port B7), flows into
the tank port (T) via the periphery of the spool and
then returns to the working oil tank.
At the same time, if it is necessary to increase the
overflow limit of option block pressure from 18Mpa
to 30MPa, Y' can be connected with pilot oil, and
then the overflow pressure can be increased to
30MPa.
CLG920E922E03028
3-109
2) Backup flow merging

To combine the standby flow, pilot pressure oil is also supplied to the interface PO, AB, BB to switch the
straight travel spool. The working oil flowing into the interface P1 is guided to the neutral bypass by means of
the main passage. The neutral bypass is cut off by switching the bypass stop valve spool, so that working oil
pushes open the cone valve of the check valve and merges with the flow in the standby spool via the internal
passage.
(5) Straight travel
When the travel spool is operated together with other s.
The condition where the travel spool and the rotary spool are simultaneously operated is described below.
(Port b3, b4, and pi are fed with pilot pressure oil)
[Pilot circuit]
The side passage of the right travel and left travel valve spool and the side passage of the slewing spool are
closed, and the pilot pressure oil from the PI interface makes the straight travel spool is switched.
[Main circuit]
When the straight travel spool is switched, the right travel and left travel spool is preferentially communicated
with the interface P1, and the parallel passage of the slewing, boom, standby, arm circuit is preferentially
communicated with the interface P2, so that working oil supplied from the interface P1 mainly flows into the
interface B3(A3) B4(A4) and is evenly supplied to two the travel motors.
On the other hand, working oil supplied from the interface B2 (A2) is also supplied to the slewing motor via the
interface As.
3-110
CLG920E922E03029
(6) Function of lock valve

The lock valve selector pair (252) is installed among the arm cylinder piston rod side (B) and the arm spool to
reduce the internal leakage of the spool caused by cylinder pressure.
Likewise, a lock valve selector pair is also installed between the boom cylinder piston head side (A) and the
boom spool to reduce the internal leakage of the spool caused by cylinder pressure.
1) Spool neutral state
The condition where the boom spool is selected is shown below. (The condition of arm spool is also the same.)
When the boom spool is neutral, the spool (252-511) inside the lock valve selector pair is kept in the position
as shown in the following figure by the pretightening force of the spring (252-321) and is pressed in the valve
seat of the valve bushing (252-541) inside the lock valve selector pair. In this position, working oil at the boom
cylinder piston head side (A) flows in from hole (a), flows across the periphery of the spool (252-511) of the
lock valve selector pair and presses the valve seat of the valve body of the cone valve (513) at the hole (b) so
as to reduce internal leakage.
3-111

When the boom is operated to lower down, the pilot pressure oil is supplied into the interface a5. The spool
(252-511) inside the lock valve selector pair moves to the upper side of Figure 15 through pilot pressure oil.
The hole (a) is first cut off through the movement of the spool (252-511) inside the lock valve selector pair, and
working oil from the boom cylinder piston head side (A) does not flow into the spring chamber (RH). In addition,
oil in the cavity of spring chamber (RH) flows into the leakage oil circuit via the hole (b). Therefore, the cone
valve (513) is jacked through the pressure at the boom cylinder piston head side (H), and the function of the
lock valve selector pair (252) is released.
CLG920E922E03030

During the boom lifting operation, pilot pressure oil is fed into the interface b5. The cone valve (513) is pushed
open through oil flowing in via the boom spool, so working oil flows into the interface B5.
(7) Function of the main relief valve
The main relief valve is installed on the valve body with the following functions:
3-112
Maintenance references
Part name Inspection item Judgment references Treatments

1) Valve holes in the valve body and spool slide
section, especially spool shoulder related to
pressure maintenance is damaged
2) The O-ring contact face between the spool
Check for scratches or cover and the spring cover is damaged.
Valve body grinding cracks, rusting and 3) The interface seal in contact with O-ring is Replace
corrosion damaged.
4) The seal of each relief valve of main interfaces
is damaged.
5) The seals of plunger and plug are damaged.
6) Other damages affecting normal function
Check for scratches or Replace (especially
When there are bruises caused by jamming of
grinding cracks, rusting and the section in contact
sliding on the periphery
corrosion with the seal)
O-rings and seals at both
Sliding section is damaged Replace
ends
Spool
Insert the spool into the valve
hole, and observe the
condition where the spool O-ring is damaged or the spool acts unsmoothly Repair or replace
rotates while moves to make
travel.
Each spring is damaged The spring is damaged. Replace
The cone valve is damaged and cannot be fully
Each cone valve is damaged Repair or replace
sealed
Cone valve
Install the spool of each check
valve into the valve hole of the Normally, no need for
It isn’t jammed and can act easily and freely
valve body, and observe its treatment
action condition
Check the spring, spring seat,
plunger, and cover are not
Around the spring Part has significant damages Replace
rusted, deformed, or
fractured.
Oil leakage outward Oil leakage Repair or replace
Around the
sealing section of Whether the seal plate is
the spool rusted, corroded, and The seal plate is rusted, corroded, and deformed. Repair or replace
deformed.
Whether there is rust and
There is rust and fracture on appearance Replace
fracture on appearance.
1) Main Relief
Valves Contact face of the valve seat The contact face of the valve seat is damaged. Replace
2) Interface relief The contact face of each
valve The contact face of the spool is damaged Replace
spool
3) Negative
control relief valve Abnormal spring Abnormal spring Replace
O-rings, snap rings and seals Replace all of them in principle Replace
3-113
3.3.2.3 Center Connector

Center revolving joint is mainly used for connection to short-distance hydraulic access, and for connecting
fixed and rotating parts which have the high-pressure resistance, wear resistance, multi-channel, mutual
noninterference by 360°, simple connection, safety, reliability and other features.
Structure
The structure of the center joint is shown in the figure below.
LG922E930E03080
3
Parts List
1. Bolt M10×25 6. Spindle 11. Plug
2. Washer 10 7. Retainer 12. Seal ring
3. End cover 8. Center joint body 13. O-ring 17.8×2.4
4. O-ring 98.02×3.53 9. Bushing 14. O-ring 89.6X5.7
5. Retainer 60 10. Dust ring
3-114
Working principle
The center revolving joint is composed of the revolv-
ing body, revolving shaft, end cover and other parts.
The revolving body (or revolving shaft) is fixed on
the upper (or lower) part of the vehicle body while
the revolving shaft (or revolving body) is installed on
the lower (or upper) part of the vehicle body and can
rotate 360° freely. The annular groove equaled to
the number of oil lines will be slotted on the revolv-
ing shaft. The hydraulic oil will be supplied to the
travel motor by entering the inlet of the revolving
body that connects with a radial hole on the revolv-
ing shaft through the oil groove on the revolving
body. Because the annular grooves on the revolving
body and revolving shaft are closed, no matter
whether the revolving body or revolving shaft
rotates along with the vehicle body, the oil ports cor-
responding to each other are always independent
and smooth, so as to guarantee the normal flowing
of hydraulic oil. See the figure below
Working Schematic Diagram

of Central Swivel Joint
Body port
X1: left travel motor high-speed/low-speed switch-

ing port P
X2: right travel motor high-speed/low-speed switch- Shaft port
ing port P
A1: left travel motor port A
B1: right travel motor port B
A2: right travel motor port A
B2: right travel motor port B
L: left and right travel motor oil drain port
3-115
Fault Analysis
No. Fault Symptom Fault cause Countermeasures

1. Dust impurities enter the neck to damage 1. Take dust-prevention measures for base
neck seal; machine
Oil leaks at neck 2. The connection is subject to external 2. The products must meet installation
1
part force during installation, causing single requirements when being connected and
side abrasion of the seal to lead to oil installed;
leakage. 3. Replace the seals.
Oil leakage at the Loosening of fastening bolt or damage and
2 Re-tighten the bolt, and replace the seal.
end cover aged sealing parts at the end cover.
Hydraulic pipe fitting that connected with oil
3 Leaks at oil port Replace with new hydraulic pipe fitting.
port is damaged
3.3.2.4 Explosion-Proof Valve

The hose explosion-proof valve is an optional part and its schematic is as follows:
1. Adjustable throttle valve 3. Relief valve 5. Check valve

2. Throttle valve 4. Spool 6. Strainer
3-116
If the explosion-proof valve is selected, it is directly installed on the cylinder (boom cylinder big cavity and arm
cylinder small cavity) to prevent the control cylinder from suddenly dropping without the action of gravity after
hose bursting to cause accidents.
During normal working, oil enters the cylinder through the check valve (5). During reverse action, oil needs to
cooperate with the pilot signal to enter the control port of the balanced valve (4) through the check valve (5) at
the lower right corner so as to open the balanced valve. Oil flows out of explosion relief valve through balanced
valve (4).
After the hose bursts suddenly, hydraulic oil in the hydraulic cylinder cannot pass through the valve due to the
blocking of the spool of the balanced valve (4). When the system uses two identical cylinders, one small
balance line is used to balance the pressure between the cylinders.
The relief valve (3) is used for protecting cylinders from being damaged under the action of external force.
When external force impacts the cylinder, impact pressure passes through the (6) strainer and outputs
pressure signals to the balanced valve (4) through the relief valve (3) to open the balanced valve. The pressure
of the cylinder is released. The check valve at the lower right corner ensures enough pressure to open the
balanced valve (4) can be created after the impact pressure passes through the relief valve (3).
The setting pressure of the relief valve (3) is the maximum pressure that the cylinder cannot be damaged.
When the impact pressure does not reach the relief pressure of the relief valve (3), the relief valve (3) cannot
overflow, and the bursting-proof valve cannot be opened in the reverse direction.
After the hose bursts, the cylinder can be slowly lowered by adjusting the relief valve (3). However, after the
cylinder is lowered to the safety position, the safety pressure of the relief valve (3) needs to be reset. The
safety pressure of the relief valve (3) for protecting the cylinder from being damaged has been set while
leaving the factory. After adjustment, the relief valve needs to be reloaded to the test bench to set the safety
opening pressure.
The safety pressure of the relief valve (3) is used for protecting the cylinder from being damaged. Do
not adjust without permission. After adjustment for specific reasons, please restore to the factory
setting pressure.
3-117
3.3.2.5 Hand Pilot Valve Working principle
Specifications
Primary side
Maximum pressure of 6.9 MPa
pressure
Secondary
0 ~ 4.4 (maximum control pressure) MPa
side pressure
Allowable
Maximum 0.3 MPa
backpressure
Rated flow 20L/min
Operating
±19°
angle
Mass 1.9kg
In order to obtain well responsiveness,
appropriate pipeline is the one with inner
diameter of φ8 and length of about 3m. In
Pipeline
addition, return oil shall not be affected by Schematic diagram of hand pilot valve
other backpressures and directly enter
into the tank. 1. 2. 3. 4. oil inlet & outlet P - pilot pressure-oil port
port T- Pilot oil-return port
Structure
Structural schematic diagram of hand pilot valve

Overall structure of hand pilot valve
1. Pressure plate 10. Oil inlet passage
1. Control lever 2. Pilot valve 2. Push rod 12. valve rod
3. Spring 13. Oil port
The hand pilot control valve is composed of a con- 4. Dowel bar 14.Oil inlet cavity
trol lever (1) and a pilot valve (2). It can control two 5. Spring seat 15.Return passage
6. Pressure spring
working devices, the left pilot controlling rotation 7. Restoring spring
16.Oil inlet passage
and the arm, and the right pilot controlling bucket 17. Oil port
8. Oil return cavity
and boom. 9. Oil return passage
3-118
When the control lever pulled rightwards, the presser plate (1) tilts rightwards. The pressure plate (1) pushes
the push rod (2) downwards, it brings the spring seat (5) to overcome the pre-tightening forces of the pressure
adjusting spring (6) and restoring spring (7) to move downwards. The valve stem (11) also moves downwards
under the action of force of the spring (6). The oil inlet passage (10) is opened. Pilot oil flows from the oil inlet
cavity (13) to the port of the main valve control valve rod through the passage (10) and via the oil port (12).
Pilot pressure oil makes the main control spool to move, and corresponding actuating mechanism under
control acts to operate or rotate.
Pilot oil at the another port of the main valve control valve rod returns to the oil port (17), and the return
passage (14) is opened and the oil inlet passage (15) is closed because the push rod is not pressed by the
presser plate. Pilot oil returned to the oil port (17) enters the return cavity through the return passage (14) and
returns to the system oil tank via the hand pilot valve.
Therefore, the control lever generates one angle, the pressure adjusting spring (6) is compressed and
pretightened, the pressure adjusting spring (6) will also make the valve stem (11) move downwards, the oil
inlet passage (10) is opened, pilot pressure oil reaches one end of the main valve control valve stem through
the oil inlet passage (10), and thus, the angle of the main control valve stem corresponding to the control lever
generates a certain displacement.
When the pilot lever slightly swinging at a small angle under non-operative state, the pressure adjusting spring
(6) will also force the valve stem (11) moving downwards slightly, and the main valve control valve stem also
generates one small displacement. At the moment, the main valve will output small-flow pressure oil, and this
pressure oil will make the working cylinder or motor act slowly. However, when the pilot lever suddenly slewing
by a large angle, the pressure adjusting spring (6) will also make the valve rod (11) move downwards quickly,
the main control valve rod will quickly generate one large displacement to output large-flow pressure oil, so
that the working cylinder or motor quickly acts. Therefore, the action speed of the cylinder or motor is related to
the control angle of the pilot control lever.
The controllability depends on the action sensitivity of the cylinder and motor. The timely action of the cylinder
and motor needs pilot pressure oil to timely reach the main control valve rod end and timely make the main
control valve rod act timely. The pilot lever swings in the non-operative state, and only the pressure adjusting
spring (6) can force the valve stem (11) moving downwards. Actually, the downward movement of the valve
stem (11) firstly makes the push rod (2), the spring (3) and the dowel bar (4) move downwards, and then, the
spring (3) and the pressure adjusting spring (6) act together to make the valve stem (11) move downwards.
Therefore, the conduction speed of pilot pressure oil is closely related to these two springs, i.e. the
controllability is closely related to these two springs.
When the lever is released, the restoring spring (7) makes the control lever return to the natural non-operative
state.
3-119
Maintenance References
Check items Maintenance limit Treatments Remarks

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

Push rod Replace
than 1 mm.
The amount of clearance

Abrasion of the
between the disk (302) of When shaking (clearance) is generated due to the
operating section
operating section and the joint Replace looseness of the tightening section, etc.,
(amount of
section (301) is more than 2 adjustment is needed.
clearance)
mm.
Abnormal sounds, irregular
vibrations, too low primary Replace the pilot
Stability of action pressure, etc. are generated valve with a new
during working and cannot be one
restored after treatment
Note 1) Although seals such as O-rings are expected to be replaced after removal, it is OK to reuse them after
being confirmed to be undamaged.
3-120
3.3.2.6 Travel Pilot Valve control the left and right travel motors and share the
oil return port T and oil inlet port P.
Specifications
Working principle
Primary side Maximum pressure 6.9 MPa (70 kgf/
pressure cm²) The schematic diagram of the travel pilot valve is as
Secondary side Maximum control pressure 0~4.4 MPa follows:
pressure (0~44.8 kgf/m²)
Allowable
Maximum 0.3 MPa (3kgf/m²)
backpressure
Rated flow 10L/min
Operating angle ±12.4°
Mass 6.3kg
For obtaining good responsibility, a
pipeline with about φ8 inner diameter
and 3 m length shall be selected.
Pipeline
Return oil shall not be affected by other
backpressures and directly enter into
the tank.
Please set an oil filter with more than 40
meshes at the inlet of Port P to prevent
Oil filter
the slide valve from sticking due to
uncleanness.
1. Pedal T- oil interface
Structure 2. Pilot valve P- oil interface
The overall structure of the travel pilot valve is
shown in the figure below
Internal structure of travel pilot valve

1. Push rod 10. Oil port
External structure of travel pilot valve 2. Spring 11. Cam adjusting group
3. Spring 12. Push rod
1. Pedal T- Oil return port 4. Spring cavity 13. Pedal
2. Pilot valve P- Oil inlet port 5. Steel ball 14. Pressure spring
6. Damping piston 15. Oil port
The travel pilot valve is composed of a pedal (1) and 7. Spring seat T- oil interface
a pilot valve (2). Two control pedals respectively 8. Restoring spring P- oil interface
9. Spool
3-121
A hydraulic damping device is arranged inside this valve. When the machine is moving forwards or backwards
on a bumpy road, machine is easily causing vibration, which will affect the driver’s operation, and if the driver
failed to operate well, the machine will vibrate more severely to form a vicious circle. Maneuverability of travel
pilot valve is poor due to no such a device, and the driver always has no choice but to stop the machine to
eliminate machine vibration.
The hydraulic damper is composed of a spring (2), a spring (3), a spring cavity (4), a steel ball (5) and a
damping piston (6); and the pressure-reducing valve is composed of a spring seat (7), a spring (14) and a
spool (9).
When the travel pedal presses leftwards as shown in the figure, the cam adjusting gp (11) tilts to press the
push rod (12) downwards, the push rod (12) moves downwards to drive the damping piston (6) and the spring
valve seat (7) to overcome the resistance applied by the hydraulic damper and the elastic forces of the springs
(8) and (14) to move downwards, and the pressure adjusting spring (14) forces the spool (9) to move
downwards so the oil port (10) is communicated with the oil inlet joint P. When the oil port (10) is
communicated with the oil inlet joint P, pilot pressure oil enters along the oil inlet joint P, reaches the travel
control valve stem control port through the oil port (10), and pushes the travel control valve stem so that high-
pressure oil from the main pump flows across the travel control valve stem to the travel motor. The travel motor
rotates to drive the mechanical travel to move.
The travel control valve rod makes the low-pressure oil at the other end flow back the oil port of the travel pilot
valve (15), the pressure adjusting spring is not stressed due to the action of the return spring, the spool is also
in the upper position, and the oil port (15) is communicated with the return interface T at the moment. Low-
pressure oil that entered the oil port (15) will enter the return cavity along the oil port (15) and returns to the
system oil tank from the return interface T.
To ensure the stability of the mechanical movement, it is required that the pilot oil pressure at the control port
of travel control valve stem shall be stable, that is, the pressure of oil that coming out of the port (10) shall be
stable. This is the function realized by the pressure-reducing valve composed of spring seat (7), spring (14)
and spool (9).
When the oil pressure of the oil inlet joint P rises, the pressure of oil port (10) will also rise within a short period
of time. Because the oil pressure of the oil port (10) rises, the force making the spool (9) move upwards
increases, so the pressure adjusting spring pushes the spool (9) upwards to reduce the communication
amount between the port P and the oil port (10). Because the communication amount between the port P and
the oil port (10) is reduced, damping increases, i.e. the pressure drop from the port P to the oil port (10)
increases, and the pressure of the oil port (10) is ensured to be unchanged, even when the pressure of the oil
inlet joint P has risen. When the pressure of the oil inlet interface P decreases, the pressure of the oil port (10)
will also decrease within a short period of time. Because the oil pressure of the oil port (10) decreases, the
force making the spool (9) move upwards decreases, so the pressure adjusting spring pushes the spool (9)
downwards to increase the communication amount between the port P and the oil port (10), i.e. damping of
communication between the port P and the oil port (10) decreases, the pressure drop from the port P to the oil
port (10) decreases, and the pressure of the oil port (10) is ensured to be unchanged, even when the pressure
of the oil inlet joint P has decreased.
3-122
Fault causes and countermeasures

It is not easy to locate the fault. Several problem points to be considered are listed in the table below. Because
this valve is difficult to repair, please refer to the cause and countermeasure columns in the table.
Symptom Reason Treatments

Insufficient primary pressure Ensure primary pressure
The elastic force of the spring (324) for setting
Replace with the new one
Low secondary secondary pressure has been weakened.
pressure The clearance between the slide valve and the
Replace the slide valve and valve body group
valve body has been abnormally enlarged.
Operating parts are loose Remove, assemble and replace operating parts
Sliding parts are jammed Repair jammed parts
Unstable secondary Oil pressure changes in the tank circuit Oil directly return to the tank
pressure
Operate repeatedly for several times to empty
Air in the pipeline
the air
High secondary Excessive high tank oil circuit pressure Filling oil directly return to the oil tank
pressure Sliding parts are jammed Repair jammed section
Operate repeatedly for several times to empty
Air remained in the plunger chamber
the air
Sliding parts are jammed Repair jammed section
The elastic force of the buffer springs (336 and 337)
Replace with the new one
has been weakened.
Ineffective buffering The clearance between the buffering plunger (224)
Replace the buffering plunger and hosing
and the buffering housing has been abnormally
group;
enlarged.
Check the check valve section after
Poor action of the check valve
disassembly.
The damping hole of the buffering plunger has been
Replace the buffering plunger
abnormally enlarged.
Sliding parts are jammed Repair jammed parts
Heavy buffering torque The damping hole of the buffering plunger has been
Replace or repair the buffering plunger
blocked
3-123
3.3.2.7 Cushion Valve

Outline drawing
Valve
Part No.
Mfr code
Factory S/N
Ex-factory date
3-124
Structure
1. Plug 6. Throttle valve 11. Spring

2. O-ring 7. Plug 12. Joint
3. Steel ball 8. Check valve 13. Orifice
4. Plug 9. Valve body 14. Fitting
5. O-ring 10. Spool 15. Spring
3-125
Schematic diagram
1. Strainer 4. Check valve and throttle valve 7. Throttle valve

2. Orifice 5. Spool
3. Check valve 6. Check valve
3-126
Working principle Therefore, the action of the external cylinder

represents quick starting. When the operation of the
The buffering valve has two functions, and its work-
hand pilot valve is suddenly stopped, the ports A
ing principle will be respectively described below.
and B are communicated with return oil through the
Oil replacement hand pilot valve. Hydraulic oil in the pilot hose
assembly is subject to the action of the return spring
When the outside working temperature is relatively
of the main valve rod. It flows back to the oil tank
low, the viscosity of hydraulic oil greatly increases,
through port E to A and flows across the small
so that the flowing property of the hydraulic medium
orifice of the check throttle valve (4). Therefore, this
becomes poor, and the property for transmitting
pressure signal will lag for a certain period of time,
pressure energy greatly decreases. Therefore, the
which is represented by the stop of the cylinder after
action of the whole machine lags. To improve the
buffering.
flowing property, low temperature hydraulic medium
in the pilot hose needs to be replaced.
The specific working process is as follows:
High temperature hydraulic oil (system return oil) of
the whole machine enters the buffering valve
through the port P, and the strainer (1) preliminarily
filters oil entering the buffering valve. The purpose
of preventing large-particle impurities in oil from
entering the buffering valve is achieved. Filter high
temperature oil flows to check throttle valves (4),
(7), etc. through check valves (3), (6), etc., flows out
of the pilot oil ports A, B, etc. through small damping
holes of the check throttle valves, and flows back
the oil tank through the hand pilot valve. Therefore,
the purpose of replacing low temperature hydraulic
medium in the pilot hose is achieved.
Buffering function
When the hand pilot valve is operated, the port A of
the buffering valve receives pilot pressure signal,
and the port B is communicated with return oil
through the hand pilot valve. Pilot oil flows out from
the port F of the buffering valve through the port A
and the check valve of the single-way throttle valve
4. It enters the valve rod control port of the main
control valve. Drive the main valve rod to act. Mean-
while, this pressure signal drives the spool 5 of the
buffering valve to move rightwards. The port F is
communicated with the port T.
3-127
3.3.2.8 Solenoid Valve

Different solenoid valves are selected depending on the machine configuration. Please refer to the parts atlas
or machine model to determine the corresponding solenoid valve.
1. Octuple proportional solenoid valve
Specifications
1. Maximum working pressure 7.0MPa 12. Electrical specification
2. Allowable back pressure Below 1.0MPa 1. Solenoid valve type Oil immersed type
2. Coil insulation category JIS C 3214 Class-H (180°C)
3. Maximum flow (Equivalent Reversing valve 16L/min
to 1 spool) Proportional valve -10L/min 3. Connector type Tyok Electronics Japan
Econoseal J series
Control valve -70cm³/min
4. Leakage volume 12-1 Solenoid directional
Proportional valve -125cm³/ Specifications
(Equivalent to 1 spool) valve
min
5. Waterproofness Equivalent to JIS D 0203 S2 1. Rated voltage DC 24V
JIS D 1601-1995 Category 3 2. Allowable voltage
6. Vibration resistance variation range 20.4 ~ 30V
Class B Grade 70
3. Rated power Less than 17W (at 24V and
7. Working oil Equivalent to ISO VG32~68 consumption 20°C)
8. Oil temperature applicable 4. Over voltage limiter Diode (equivalent to Hitachi
-20 ~ 90°C
range U05E)
5. Continuous running
10. Allowable pollution degree Below NAS level 10 Below 29V
rated values
12-2 Electro-hydraulic
JIS B 2351 G1/4 proportional pressure- Specifications
reducing valve
11. Interface specifications
1. Rated power 700mA
JIS B 2351 G3/8
2. Coil resistance values 17.5 Ω (at 20°C)
3-128
Overall structure
Structure of octuple solenoid valve
1. Valve body 4. Oil inlet port P1

2. Solenoid valve 5. Oil outlet port A
3. Oil return port T1
Schematic diagram
Schematic diagram of octuple solenoid valve
3-129
This valve is composed of eight solenoid valves, including six switch type solenoid valves and two proportional
type solenoid valves. Solenoid valves A1-A8 share one return port T1, solenoid valves A1-A7 share one oil
inlet port P1, and the solenoid valve A8 independently uses oil inlet port P2. A1-A8 output pressure oil is
connected with return oil T1 according to electronic control signals. In addition, proportional solenoid valves
A5, A6 can proportionally output 0 ~ 3.9MPa pressure oil according to signals of electronic control system.
2. Quadruple proportional solenoid valve
Specifications
Working pressure 10MPa Electrical connector model DT04-2P
Work flow 20L/min Oil temperature range -20 ~ 100°C
Allowable ambient working
Electromagnet voltage DC27V±15% -20 ~ 90°C
temperature
Allowable pollution degree ISO 4406 CLASS21/18/15 Oil viscosity range ISO 20~400mm²/S
Electrical protection grade IP67
Overall structure
Figure of Quadruple Solenoid Valve Structure
4
5
CLG920E922E03031
1. Valve body 4. Oil return port T

2. Solenoid valve 5. Oil outlet port A
3. Oil inlet port P
3-130
Schematic diagram
Four combined electromagnetic valve structure
CLG920E922E03032
3. Triple proportional solenoid valve

Specifications
The specifications and parameters of the triple proportional solenoid valve are listed as follows.
Parameters Value Parameters Value

Working pressure 5MPa Electrical connector model DT04-2P
Proportional pressure-reducing valve A 3MPa Working voltage DC24V
Maximum working flow of the proportional
Maximum pressure of oil return circuit T 3MPa 7.5L/min
pressure-reducing valve
Maximum solenoid working flow 20L/min
Overall structure
Figure of Triple proportional solenoid valve structure
3
4 5
CLG920E922E03033
1. Valve body 4. Oil inlet port P
2. Solenoid valve 5. Oil return port T
3. Pressure reducing valve 6. Oil outlet port A
3-131
Schematic diagram
Four combined electromagnetic valve structure
CLG920E922E03034
3.3.2.9 Travel Motor & Speed Reducer

The running motor and speed reducer is a hydraulically-driven rotary drive device, which consists of a
hydraulic motor, a speed reducer, a brake and brake control valve.
Specifications
Model
GM38VL2
Item
Rated output torque N.m (kgf.m) 37300 (3800)
Maximum operating speed (r.p.m) 60
Reduction ratio 1/max 1/66
Max. Displacement ml/rev 140.5
Hydraulic motor Maximum speed r.p.m 2800
Maximum pressure MPa (kgf/cm²) 34.81 (350)
Brake torque N.m (kgf.m) 398 (40.6)
Parking brake
Release pressure MPa (kgf/cm²) 0.59 (6)
3-132
Basic Structure and Schematic Diagram

1. The basic structure of the motor
Hydraulic circuit
High-speed range Low-speed range
Reduction gear
Hydraulic motor
Brake valve
Stop braking
2-speed switching mechanism
Control valve
Hydraulic pump
3-133
3-134
3-135
Details of Parts
A. Speed reducer assembly 27. O-ring 115. Friction plate 381. Plunger
A. Shaft group 29. O-ring 116. Matching plate 324. Screw plug
A. Shaft assembly 30. O-ring 132. Oil seal 325. Spring seat
2. Shaft 33. Screw plug 135. O-ring 326. Screw plug
3. Fixed flange 35. Hex socket screw 139. O-ring 327. Valve
19. Hex socket screw 36. Steel ball 149. Deep groove ball bearing 328. Spring
34. Mounting pin 42. Positioning pin 150. Deep groove ball bearing 330. Spring
37. Washer 43. O-ring 167. Hinge 336. O-ring
B. RV - Gear assembly B. Motor assembly 171.Positioning pin 337. O-ring
A. RV - Gear group A. Part drawings of the 193. Spring 346. Hex socket screw plug
4. RV gear A cylinder & plunger C. Relief valve 352. Hex socket screw plug
5. RV gear B A. Plunger drawing A. Drawing of valve 354. Hex socket screw
9. Crankshaft A. Plunger assembly 201. Valve 355. O-ring
12. Gasket 105. Plunger 202. Valve bushing 357. Hex socket screw plug
22. Cone bearing 106. Skid shoe 203. Spring stopper 358. O-ring
23. Needle bearing 104. Cylinder block 204. Screw plug 359. O-ring
C. Support gear group 107. Thrust plate 205. Snap Ring 363. valve rod
7. Supporting gear 108. Thrust steel ball 206. Spring 366. Spring
D. Floating seal group 110. Washer 208. O-ring 368. Steel ball
31. Floating seal ring 111. Bushing 209. O-ring 379. Filter
1. Hub 114. Spring 210. O-ring 380. Screw plug
6. Axle gear 145. Elastic snap ring for 211. Support ring 382. Screw plug
8. End cover holes 217. Support ring 383. O-ring
13. Washer 151. Needle 219. O-ring 384. O-ring
15. Sleeve B. Plunger assembly 220. Plunger seal 385. Steel ball
17. Pin 161. Plunger D. Control valve assembly 397. Strainer
20. Elastic snap ring for holes 162. Skid shoe A. Rear cover flange assembly 398. Hex socket screw plug
21. Angle bearing 102. Drive shaft A. Rear cover flange group 399. Nameplate
25. Elastic snap ring for rods 103. Swashplate 301. Rear cover flange 341. Plain pin
109. Thrust plate 323. valve rod 343. Bolt
112. Plunger
113. Spring
3-136
[Note]
Spur gear
1. The assembly in the Component Column should Crank shaft
be an integral assembly in principle, and treated
as one component.
2. KIT and ASS'Y in the Component Column can
be dismantled into single components, but, in
principle, it should be treated as one
component, just like a set of components and Shaft
assemblies.
3. The distinction is to show the available range of
complementary components.
A: Available components (JIS components or Input geer
exchangeable components from the manufacturers)
B: Available components (Single components sup- Description of Speed Reducer Motion
plied by our company)
1. First speed reducers
C: Available components (If any component needs
The rotary movement of the hydraulic motor is
to be replaced, our company will provide the assem-
bly or KIT.) transferred to the input sun gear splined to the shaft
[102]. Then, the 3 planetary spur gears engage the
E: Assembly offered conditionally (When any com- input sun gear, resulting in a decelerated rotation.
ponent needs to be replaced, a single component
can be supplied with a precondition that the speci- In this case, the reduction ratio of the first speed
reducers is shown below;
fied clearance needs to be adjusted.)
i1=
F: Assembly offered conditionally (When any com-
ponent needs to be replaced, an assembly or KIT i1 = Reduction ratio of the first speed reducers Zi =
can be supplied with a precondition that the speci- Number of teeth of the input sun gear
fied clearance needs to be adjusted.)
Zs= Number of teeth of the planetary spur gears
X: Unavailable components (Any single component
cannot be provided but assembly or KIT)
Spur gear
? The number in the Adjustment Symbol Column Needie beanng
means that a component whose clearance needs to Rolation
be adjusted when replaced. Ecconlric
Speed reducer
Ralation
Working principle
The speed reducer consists of a spur gearing (here-
inafter referred to as the first speed reducers) and a
differential gearing with epicycloid tooth profile
(hereinafter referred to as the second speed reduc-
ers). The purpose of the speed reducer is to convert Ecconlric motion RV gear B
the hydraulic motor’s high-speed rotary movement RV gear A
into a low-speed and high torque one to rotate the
hub [1] (housing).
3-137
2. Second speed reducers

Hub
1) The 3 planetary spur gears are respectively
Pin
splined to the crankshaft [9] to transfer the
torque from the first speed reducers to the Rv gear A or B
second speed reducers. When the crankshaft
[9] is rotated, its eccentric A and eccentric B Grank shaft
perform eccentric motion (orbital motion) while
rotating.
Affect by the eccentric A and B and needle roller
bearing installed on the eccentric A and B Only
transfer the eccentric motion of eccentric A and B
into the RV cycloidal gear A and B.
Crank shaft one rev Crank shaft one rev
Then, the RV cycloid gears A and B move eccentri-
cally, together with the planetary gears and the
crankshaft, in the same direction and at the same Hydraulic motor (brake valve)
speed.
Function
2) The eccentric movement of RV cycloid gears A
1. Function of hydraulic motor
and B makes the tooth surfaces of RV cycloid
gears A and B of ZR and their engaging pin The hydraulic motor is called swashplate axial pis-
teeth of ZP to change their engaging positions ton motor. Act on changing the oil pressure from the
while rolling. pump into rotary motion.
When RV cycloid gears A and B make a return of 2. Function of hydraulic brake valve
eccentric rotary movement, the needle-sharp teeth
(1) The hydraulic brake valve can overcome the
will move the difference of number of teeth [(ZP-ZR)
inertial force due to the inertia of the vehicle
/ ZP] between ZR (number of revolution teeth) and
body when the running motor is stopped,
ZP (number of needle-sharp teeth) in the same
resulting in smooth braking, so that the motor
direction. Therefore, then the reduction ratio of the
can be stopped smoothly.
second speed reducers is shown below;
(2) It can avoid cavitation on the hydraulic motor,
i2 just like a check valve.
(3) It can control the volatility of the hydraulic motor
i2 = Reduction ratio of the second speed reducers brake pressure, just like a release valve, and
ZR = Number of teeth of the RV gears A and BZP = avoid cavitation.
Number of needle-sharp teeth 3. Function of parking brake
Therefore, when the shaft of the hydraulic motor The parking brake is integrated into the hydraulic
makes a turn. The rotational speed of the input shaft motor. The parking brake can prevent the excavator
is as follows; from slipping or sliding through the friction brake
i=i1*i2 mechanism when the excavator is parked on a
slope.
i1 = Reduction ratio of the first speed reducers
i2 = Reduction ratio of the second speed reducers
i
3-138
Principle and Instructions of Operation 2. Brake valve

1. Hydraulic motor 2-1) When operating (with brake released)
The pressure oil from the hydraulic pump enters into The pressure oil provided by Port A pushes the
the rear flange [301] of the hydraulic motor, and valve [327] open and flows into Port C on the suc-
then flows into the cylinder [104] from the plate [109] tion side of the hydraulic motor to rotate the hydrau-
through the brake valve mechanism. The oil pres- lic motor. Meanwhile, the pressure oil flows through
sure is only injected into the side which connects the pipe (a) through the orifice of the spool [323]
the top dead center and the bottom dead center and flows into the chamber (b), and then acts on the
(Y1-Y2) of the stroke of the plunger [105]. The pres- end face of the spool, producing a force which can
sure oil into one side of the cylinder [104] will push push the spool (in the neutral state due to the spring
the plunger (4 or 5), respectively, resulting in F (Fkg [328] force ) left.
= Pkg/cm²×Acm²). This force is applied to the
Once moved, the spool will pass the slot, resulting
swashplate [103]. Since there is an α angle of the
in a clearance (passageway) between the spool and
swashplate with the axis of the motor rotating shaft,
the rear flange. Through this passageway and, Port
the force can be divided into the component forces
D of the return oil line of the hydraulic motor will be
F2 and F3. The radial component (F3) of the two
linked to Port B in the other direction. Return oil
component forces applies a different torque (T = F3
flows into the tank, so that the hydraulic motor can
× ri) to Y1-Y2. The resultant torque of these torques
be rotated.
[T = Σ (F3 × ri), as a running torque, allows the cylin-
der to rotate through the plunger. The cylinder is Also, due to the sliding movement of the spool of
splined to the motor shaft, so that the moment of the valve [323], the pressure oil flows into Port P
rotation can be transferred to the motor shaft. and Port S. The oil into Port P allows the plunger
[112] of the parking brake to move, thereby releas-
ing the parking brake force (for more information,
see the Parking Brake section.).
If the oil pressure is provided by Port B, the valve
element [323] and the valve [327] move left and
right reversely, so that the hydraulic motor is rotated
reversely.
2-2) When stopping, stalling (with brake activated)
When traveling, if the pressure oil from Port A is
stopped, the oil pressure disappears. As a result,
3-139
the spool [323] moved left will return right (neutral 3. Parking brake
state) through the stopper [325] due to the spring
[128] force. Meanwhile, the pressure oil from Port A
is stopped, but the hydraulic motor will continue to
rotate due to inertia. However, the oil discharged
from the hydraulic motor allows the oil pressure in
Pipe D to rise. The pressurized oil flows into the
chamber (g) from the chamber (f) through the hole
of the valve [201] on the left side. The oil into the
chamber (g) will allow the plunger [308] to move to
the right shown in the figure, so that the pressure
will not rise. During this period, the valve [201] on
the left side is pushed open by the pressure oil in
Chamber D.
As a result, the pressure oil in Chamber D flows to
the chamber (c) with a lower pressure. Therefore,
the pressure in Chamber D can be controlled, thus
3-1) When traveling
avoiding cavitation of the chamber (c). When the
plunger [381] reaching the end of the stroke, the When the brake valve providing pressure oil, the
pressures in the chamber (g) and the chamber (f) spool [323] of the brake valve of the hydraulic motor
rise. As a result, the valve [201] on the left side will will move, so that the passageway to the parking
be closed again, resulting in pressure rise of Port D. brake will be opened. The hydraulic oil flows into the
As a result, the valve [201] on the right side will be cylinder chamber (a) which is composed of the main
pushed open. The oil in Port D will flow into Port c at shaft [2] and the plunger [112] of the speed reducer.
a pressure higher than the set overflow pressure of
When the oil pressure reaches more than 0.6 MPa
the excavator. Thus, the pressure of Port D can be
(6kgf/cm²), the pressure is greater than the spring
controlled through two stages, so that the hydraulic
[113] force. The plunger [112] will move to the side
motor can be stopped smoothly.
of the rear flange [101] accordingly. Due to move-
2-3) When self-propelled ment of the plunger [112] toward the engagement
piece [116], the thrust to friction plate [115] will dis-
When the excavator traveling down along a slope,
appear. As a result, the friction plate in the cylinder
its traveling speed will be higher than that corre-
[104] of the hydraulic motor can move freely and the
sponding to the oil volume supplied by the oil
braking force applied to the cylinder [104] can be
hydraulic pump, and this is called a self-propelled
released.
speed (overspeed).
3-2) When stopped
When self-propelled, the oil pressure will disappear,
just like when stopped. As a result, the brake valve With the pressure oil from the brake valve cut off,
operates in the same way when stopped to pressur- when the pressure in the cylinder chamber (a) is
ize the return circuit of the hydraulic motor, resulting reduced to 0.6MPa (6kgf/cm²) or less, due to the
in a backpressure which decelerates the hydraulic spring [113] force, the plunger [112] will be restored,
motor rotating due to inertia to fit the oil supply of thus pushing the engagement piece [116] in the free
the pump to control the motor speed. state to engage the friction plate [115] on the main
shaft [2] of the speed reducer, resulting in a fric-
tional force which stops the rotating cylinder [114]
and keeps the brake torque of the main shaft of the
hydraulic motor of 397.9N·m (40.6kgf·m). Further,
the anti-inversion oil-circuit design is used to ensure
smooth operation of the whole process above.
3-140
4. Description of 2-speed switch when braking

At low speed
When Port D has no control pressure provided, the spool [363] will be moved upward by the spring [366] force
and the hydraulic pressures of Port A and Port B, and the hydraulic oil of Port C will be blocked, so that the oil
in Chamber P will pass through the spool [363] and flow out through the discharge outlet. Thus, the inclination
angle of the swashplate [103] maximizes, so that the motor will be rotated at low speed.
3-141
At high speed
The control pressure provided by Pipe D reaches 3.4MPa, which is greater than the spring [366] force, so that
the spool will be pushed downward. The pressure oil of Port C flows into Chamber P through the spool [363],
and the piston [161] will push the swashplate until the upper of the swashplate clings to the Y surface. Then,
the inclination angle (θ2) of the swashplate [103] becomes small, so that the volume displacement of the
hydraulic motor minimizes. As a result, the hydraulic motor will be rotated at high speed.
3-142
Faults and Actions:
Without The set adjustment pressure

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

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

has failed normally and repair it if
necessary.
With pressure Brake valve fault Replace the corresponding

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

Check the hydraulic oil and
has failed
replace with new hydraulic
oil or motor of reduction
gear if the oil deteriorates.
Replace the motor with

Reduction gear is damaged
reduction gear
Overloading appears Lighten the load
At the joint The joint surface Correct with oil stone,

Oil leakage
surface is damaged abrasive cloth, etc.
Perform the inspection

The bolts are loose.
after tightening
At the housing If the pipe is loose. Tighten
Damage resulting from Replace the motor with

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

At the floating seal
surface reduction gear
The O-ring is not in Replace the motor with

place reduction gear
From the The bolts are loose. Tighten

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

Damage on seal surface
abrasive cloth, etc.
LG922E930E03216
3-143
Poor volume efficiency Replace the motor

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

valve increases Replace the brake valve
(replace the rear placed flange)
Parking brake valve is out of work
The spring is damaged Replace the spring

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

The bearing is worn reduction gear
Hydraulic oil leaks into the Replace the oil seal

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

pressure status
Different oil inlet volume at the Repair the hydraulic pump
left and right sides and the control valve
Different motor displacement Replace the motor with
at the left and right sides reduction gear
Different brake valve actions Replace the brake valve and
at the left and right sides the rear placed flange
The set adjustment pressure Set correct pressure or
of the left or the right control replace the relief valve
valve is excessively low
Hydraulic motor or reduction Replace the motor with

Abnormal sound gear is damaged reduction gear
The oil supply pipe vibrates Perform tightening

3-144
3.3.2.10 Slewing Motor & Speed Reducer

The slewing motor & speed reducer includes a rotary hydraulic motor (hereinafter referred to as slewing motor)
and a speed reducer.
1. Slewing motor
Specifications of slewing motor
Theoretical capacity cm³ 129.2

Relief valve pressure MPa 25.5
Maximum speed (r/min) 1850
Theoretical output torque N-m 666
Brake torque N-m 843
Brake release pressure (MPa) 3.4
Weight kg 48
Structure of slewing motor
Hydraulic motor section diagram
LG922E930E03116
3-145
Parts list of slewing motor

10. Piston 131. Valve fixing plate 401. Hex socket screw
20. H2 valve body assembly 151. Screw plug 443. Roller bearing
31 Time-delay valve 161. O-ring 444. Roller bearing
33. Hexagon socket head cap bolt 162. O-ring 452. Pin
51. Relief valve 163. O-ring 469. Screw plug
80. Seal package 171. Hexagon socket head cap bolt 712. Brake spring
100. Valve body 301 H2 housing 742 Brake lining
101. Drive shaft 351 H2 piston 743. Isolation panel
111. Cylinder 355 H2 spring 983. Plug
114. Spring pressure plate 390. Nameplate 984. Plug
123. Fixing plate 391. Pin 985. Plug
124. Swashplate 400. Anti-swing valve
Working principle of slewing motor

Schematic diagram of hydraulic motor
1. Thrust plate 3. Skid shoe 5. Cylinder block

2. Plunger 4. Swashplate
3-146
When high-pressure oil enters the cylinder block pressure of the slewing circuit is held at a constant
cavity through the oil port (a) (the inlet of the oil dis- value. A small buffering piston is arranged in the
tribution plate 1), hydraulic pressure acting on the relief valve, and acts within a short time after the
plunger generates axial force F. Pressure F acts on relief valve starts to work and holds the pressure of
the shoe (3) through the plunger (2), and the shoe the slewing circuit at a relatively small value. There-
(3) acts on the swashplate (4) through hydrostatic fore, a relatively mild acceleration and braking pro-
support. Force F1 vertically acts on the swashplate cess can be obtained.
(4), and force F2 vertically acts on the cylinder cen-
ter. Force F2 is transmitted to the cylinder block (5)
through the plunger and causes rotation movement
around the cylinder block. Because there are (9)
equally arranged plungers inside the cylinder block,
the rotating moment will be successively transmitted
to the cylinder drive shaft through several plungers
connected to the high-pressure oil port. When the
direction of oil flow is opposite, the direction of the
cylinder is also the opposite.
(1) Control valve
Air suction preventing check valve
Working principle of air suction preventing check
valve
1. Control valve 2. Oil filler pipe 3. Refilling check

valve
In order to prevent insufficient oil supply when the

motor works, hydraulic oil in the oil tank can directly
enter the slewing motor through the oil replenishing
line (2) and the oil replenishing check valve.
(2) Relief valve
During the acceleration or braking process of the
slewing motor, the relief valve is opened and the
3-147
(3) Braking of slewing motor

Braking process of slewing motor
1. Hydraulic oil cavity 111. Cylinder block 742. Friction plate

2. Hydraulic oil acting force 301. Housing 743. Release plate
3. Spring action force 702. Brake plunger
101. Drive shaft 712. Brake spring
The cylinder block (111) is connected with the drive shaft (101) through one gear, and the friction plate (742) is
connected with the outer side of the cylinder block through one gear. When the brake spring (712) acts on the
friction plate 742 through the release plate (743) and brake plunger (702), the friction force is generated
between every two of the friction plate, housing, release plate and brake piston. This friction force acts on the
drive shaft to exert braking action on it.
On the other hand, when the unlock pressure enters the cavity formed between the brake plunger and the
housing, the hydraulic oil pressure overcomes the spring force to make the brake plunger move; the friction
plate and the housing are separated to release the brake.
Maintenance references of slewing motor
3-148
Replacement standards of friction parts

When the abrasion degree of each friction part exceeds the following standard, it shall be replaced or
readjusted. However, if there is obvious damage on the appearance, it shall be replaced in advance instead of
being restricted by the standard.
Part replacement reference
Standard size Replacement

Item Handling method
(mm) recommended value (mm)
Clearance between plunger and cylinder Replace the plunger or
0.027 0.052
bore (D-d) cylinder.
Looseness (δ) between the plunger and Replace the plunger and
0 0.3
shoe riveting section skid shoe group.
Replace the plunger and
Thickness of shoe (t) 5.5 5.3
skid shoe group.
Thickness of friction plate 2.0 1.8 Replace it.
Looseness (δ) between plunger and shoe
Clearance (D-d)
Thickness of shoe (t)
3-149
Maintenance standards of rotation meshing surfaces

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

Skid shoe 0.8-Z (Ra=0.2)(abrading) 3-Z (Ra=0.8)
Skid shoe plate 0.4-Z (Ra=0.1)(abrading) 3-Z (Ra=0.8)
Cylinder 1.6-Z (Ra=0.4)(abrading) 12.5-Z (Ra=3.2)
Valve plate 0.8-Z (Ra=0.2)(abrading) 6.3-Z (Ra=1.6)
Remarks)
1. The roughness of each rotation meshing surface is controlled to be lower than the standard roughness
through abrading.
2. When the spherical meshing section between the leaf spring and cylinder is rough, the complete set of
group shall be replaced.
1. Reducer
Structure of speed reducer
The speed reducer is composed of double planetary gears.
The tooth number of each gear is shown in the table below, and the total drive ratio is 20.01. I.e. the rotating
speed of the hydraulic motor is transmitted to the output shaft in 1/20.01. The output shaft is consistent with the
rotating direction of the output shaft.
Sun gear Planetary gear Inner gear Transmission ratio

First level 17 23 64 i1=4.765
Second level 20 21 64 i2=4.2
Total
transmission i1×i2=20.01
ratio
3-150
Reduction gear section diagram
102. Valve body D2 283. No. 1 pin B 904. Hexagon socket head cap bolt
104. Rear axle cover E 284. Push plate E 905. O-ring
201. Drive shaft B 390. Nameplate 909. Pin
202. Gear ring E 391. Pin 910. Pin
203. No. 2 planetary gear D 402. Self-aligning roller bearing 912. Snap ring
204. No. 2 sun gear D 403. Positioning pin plug 913. Snap ring
210. No. 1 planetary gear D 601. hexagon head bolt 915 Bearing seal ring
211. No. 1 sun gear D 602. Hexagon socket head cap bolt 922. Screw plug
230. No. 2 carrier D 801. Oil seal 925. Exhaust valves
231. No. 1 carrier D 802. O-ring 926. Grease fitting
282. No. 2 pin B 903. Screw plug 930. Hex socket screw
3-151
Maintenance references of speed reducer
Maintenance
Part Inspection Treatments
References
When the size of single pitting
Sun gear
corrosion and dent is above
Planetary gear Pitting corrosion and dents on tooth surface Replace
φ1mm or occupied 5% of the
Internal gear ring
total area
Replace
(Caution: It is
recommended to replace
Oil seal Lip surface is damaged or abraded Damaged or abraded
them when disassembling
the speed reducer for
inspection, etc.)
• Notice: Do not extract it from the drive
shaft
1. Check whether the race surface and
roller of the bearing have pitting
corrosion, abrasion, etc. within the Replace
Support bearing visible range.
(Notice: Do not reuse
(front side) of drive 2. Check whether dust caused by Abnormal condition
excessive abrasion exists in gear oil. bearing extracted from the
shaft
3. Check whether excessive abrasion dust shaft.)
is adhered between the roller and the
cage.
4. Check whether it can smoothly rotate by
hand.
Drive shaft bearing Check whether the race surface and roller of
Having pitting corrosion Replace
(rear side) the bearing have pitting corrosion
Slide bearing
Check whether planetary gear No.2 and pin
section of
No.2 of carrier group No.2 are loose in the Looseness is above 0.5 Replace
planetary gear
peripheral direction.
No.2
Check whether the sliding face zone with the
Side plate type If yes: Replace
sun gear No.2 has obvious bruises.
Needle bearing set
and No.1 pin for Check whether the rotation face has pitting Having pitting corrosion and
Replace
supporting No.1 corrosion and abrasion abrasion
planetary gear
This speed reducer has few parts and adopts the design method that the life of each section is balanced, i.e.
although all parts can be supplied individually, it is necessary to replace all of them due to structural or
functional causes during replacement. These are shown in the table below. Please pay special attention to
them.
3-152
List of parts to be replaced simultaneously

Parts to be replaced simultaneously
Part number 201 401 402 203 230 282 286 910 210 231 283 284 285 287 403 909
Braking Braking
Part No2 No.1
self- self- No.2
number Drive Plane No.2 Thrust Sprin Plane Carrie Pin Thrus Side Thrus Pin Spring
Part name aligning aligning Carri
shaft tary Pin washer g pin tary r No.1 No.1 t plate plate t plate gauge pin
roller roller er
gear gear
bearing bearing
201 Drive shaft - ○ ○
Braking self-
aligning
401
roller △ - △
bearing
Braking self-
aligning
402
roller △ △ -
bearing
Parts to be replaced simultaneously
No2
203 Planetary - △ ○ △ ○
gear
230 No.2 Carrier △ - ○ △ ○
282 No.2 Pin △ △ - △ ○
Thrust
286
washer △ △ ○ - ○
910 Spring pin △ △ ○ △ -
No1
210 Planetary - △ ○ △ △ △ △ ○
gear
231 Carrier No.1 △ - ○ △ △ △ △ ○
283 Pin No.1 △ △ - △ △ △ △ ○
284 Thrust plate △ △ ○ - △ △ △ ○
285 Side plate △ △ ○ △ - △ △ ○
287 Thrust plate △ △ ○ △ △ - △ ○
403 Pin gauge △ △ ○ △ △ △ - ○
909 Spring pin △ △ ○ △ △ △ △ -
The part marked by ○ indicates that it needs to be replaced simultaneously.

Parts marked by △ indicate parts to be replaced simultaneously at best.
Note: Inner and outer races in the roller bearing must be replaced simultaneously.
3-153
Cause and treatment of speed reducer fault

Fault state Reason Treatment
Overload Lighten the load
Inlet pressure Damage of

of swing motor Replace
reduction gear
rises reduction gear
Parking brake of Confirm pressure

swing motor is not relief and check the
released brake part
Confirm relief of
command pressure
3-154
No rise of inlet pressure of swing motor
Swing motor has Motor axle damage

whirling motor Replace swing motor
Damage of Replace reduction gear

reduction gear
Abnormalities of Confirm abnormal

Swing motor has no whirling. pump, valve, etc. parts and dispose
3-155
Forget to apply liquid seal filling Remove and apply again

material
Junction surface is loosened

Oil leak from Remove, apply again and
because the bolt is not screwed
junction surface assemble as specified
with looseness, etc.
There is bruise on Replace parts and

junction surface components
Leakage from Oil seal has been Replace oil seal when
shaft damaged removing reduction gear
3-156
Confirm the oil level

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

etc. have been Replace reduction
damaged gear
3-157
3.3.2.11 Cylinder Structural diagram of arm cylinder
Basic functions
Hydraulic cylinder is a kind of hydraulic actuator that
converts hydraulic energy supplied by hydraulic
pump into huge linear motion force and changes the
direction of oil pressure through valve operation, to
realize stretching of movement direction.
Its basic function is to convert the directions of huge
linear motion and movement.
The structural diagram of the cylinder is shown
below:
Structure diagram of bucket cylinder

1. Cavity oil port 6. Punching sleeve
2. Cavity oil port 7. Plug
3. Boom cylinder 8. Arm cylinder
4. Cartridge 9. Punching sleeve
5. Plunger rod 10. Bucket cylinder
Working principle
Working principle of cylinder
Structure figure of boom cylinder
3. Boom cylinder 10. Bucket cylinder

8. Arm cylinder
3-158
Cylinder extension: pressure oil enters the big cav- Arm cylinder cushion:
ity, return oil enters the small cavity, pressure oil
Cushion device of boom and bucket cylinder
acts on the big end of the piston, and the piston
moves towards the rod cavity so that the piston rod
extends out.
Cylinder retraction: pressure oil enters the small
cavity, return oil enters the small cavity, pressure oil
acts on the rod end of the piston, and the piston
moves towards the no-rod cavity so that the piston
rod retracts.
Cushioning process:
Cushioning of boom and bucket cylinder
Cushion device of boom and bucket cylinder
2. The oil port of big cavity 12. Passage

9. Cushion collar
The extension of the arm cylinder is same to the

boom and bucket cylinder, as described above.
When the arm cylinder retracts and the cushion col-
lar (9) approaches to the end of the extension
stroke, the flow area of the passage (12) decreases,
so that the displacement of the cylinder decreases,
and the movement speed of the piston slows down
and reaches the stroke end slowly. The arm cylinder
is cushioned during extension and retraction.
Precautions on loading,transport
1. Small cavity oil port 11 Passage
6 Cushion collar 1) Hydraulic cylinder must be transported
horizontally, and placed on wood block, and it is
When the boom and bucket cylinder stretches out
better to use original packaging if possible.
and the cushion collar (6) approaches to the end of
the extension stroke, the flow area of the passage 2) Impact, collision, etc. are not allowed during the
(11) decreases, so that the displacement of the cyl- process of storage and transportation. The
inder decreases, and the movement speed of the surface of exposed piston rod and other
piston slows down and reaches the stroke end assembly must be protected properly.
slowly. The boom and bucket cylinder is only cush-
3) Using soft strap to avoid damaging surface
ioned during extension.
coating.
4) Strap distribution shall make lifting stable. Use
balance device if necessary. The center of
gravity of cylinder can be confirmed by test.
3-159
Precautions for use 5) Periodically check and fasten the screws of

important parts (such as flange and oil pipe).
1) In order to guarantee hydraulic cylinder
The dynamic seals in the hydraulic cylinder are
operates normally, working medium in hydraulic
vulnerable parts. When internal leakage and
cylinder must be fully filled. The cleanliness of
external leakage exceeds allowable values,
the medium must meet NAS level 8 as the
please contact your LiuGong Service Agency.
minimum limit requirement. If anti-rust oil needs
to be mixed in working oil, its oxidation or
acidification degree must be detected.
2) Because air is highly compressible, the residual
air in hydraulic cylinder can affect its operating.
If the hydraulic cylinder with air not emptied

needs to be quickly operated or pressurized,
because high heat generated by adiabatic
compression of air will cause seal burn-out,
leakage generated inside the hydraulic cylinder
cannot maintain the load, etc., and there is a
possibility of major accidents.
For air exhaust of hydraulic cylinder, please refer to
"Air exhaust of various devices" in "Test and adjust-
ment" chapter.
Regular maintenance
Lubricant shall be applied on hydraulic cylinder,
such as swing shaft, articulated point, pin, etc. peri-
odically to prevent rust and stagnant operation.
After a new system is put into operation, it must be
checked regularly t
When checking, please note the following points:
1) Check the oil port does not leaking.
2) Check the piston rod is not damaged.
3) Frequently clear the dirt, water, dust, grease,
etc. on piston rod. However, please wipe the
dust ring and sealing parts with waste cotton or
rags instead of cleaning with water. If the
storage time is more than one week, please
apply anti-rust oil on the piston rod surface.
4) Periodically check sealing performance of
hydraulic cylinder, especially the joint between
piston rod and cylinder head for leakage.
3-160
3.3.2.12 Hydraulic Tank Assembly

Structure
Exterior drawing of hydraulic oil tank

1. Hydraulic tank 7. Washer 12. O-ring
2. Return oil filter element 8. Bolt 13. Plate
3. Magnet 9. Respirator 14. Plug
4. Cover 10. Tank cover 15. O-ring
5. Spring 11. Suction element 16. Level gauge
6. O-ring
3-161
Distribution diagram of oil ports in tank body
I- Oil filler VI-Leakage oil return port in slewing X-Pilot oil return port
II - Leakage oil return port in pump motor X-Back pressure oil return port
III - Oil drain port VI-Leakage oil return port in travel motor XI - Oil cooler oil return port
IV - Oil suction port VIII-Auxiliary line oil return port
V-Dipstick position
3-162
(1) Return oil filter

Return oil filter is composed of a return oil filter ele-
ment 7 and a bypass valve 6, the return oil filter ele-
ment 7 can filter out particles with overall size
greater than 10 μ? in oil so the oil keeps certain
cleanliness. The bypass valve (6) plays the action of
protecting the return oil filter element (7). When the
filter element works for some time and there are too Safe oil level: above red line
may oil pollutants on its surface, the liquid resis-
tance passing through the return oil filter element
(7) will increase, the bypass valve (6) will be opened
during liquid resistance pressure setting, oil directly
returns to the oil tank (8) without filtering, so that the
damage of the strainer of the return oil filter element
(7) by flushing can be avoided, and it can be used
after many times of cleaning. The system works
under this state, then the back pressure of the sys-
tem is too high, and unsuccessful oil return will
cause slow and powerless working. To avoid this
problem, the return-oil filter element shall be fre-
quently cleaned or replaced.
(2) Magnet
The functions of a magnet are as follows: (1) mag-
netizing the tank; (2) absorbing magnetizable solid
particles in oil together with the tank, which are
mainly some metal particles, such as the metal
powder particles formed due to the abrasion
between actuating mechanisms.
(3) Air Filter
The respiratory system of the hydraulic system is
mainly composed of a tank and an air filter, wherein
the air filter is the respiratory passage of the system,
and its function is mainly to prevent the air pressure
in the hydraulic oil tank from rising or dropping in the
following case:
An air pressure change in the hydraulic oil tank due
to oil cylinder movement,
An air pressure change in the hydraulic oil tank due
to a temperature change.
(4) Level gauge
Its function is mainly to reflect the oil level in the
tank and the oil range for the system. As shown in
the figure, a safety oil level refers to the system oil
level that is above the red line, and the following
indicates there is insufficient oil for the system.
3-163
Working principle
Schematic diagram
1. Suction element 7. Return oil filter element Dr1-Dr2-Dr3-Dr6-Dr7 Main valve return oil
2. Pump 8. Tank DrT-Leakage return oil in travel motor
3. Relief valve 9. Air Filter DrS-Leakage return oil in slewing motor
4. Actuator Ch2-Check valve Drp-Leakage return oil inside pump
5. Radiator Ch1-Back pressure valve
6. Bypass valve T-Pilot oil return
Oil suction process: the oil is drawn from the oil tank (8) oil suction port through the suction filter element (1) to
the pump (2).
Oil return process: The oil flows through pump (2) for pressure-up and is transferred to the actuator; then flows
from the actuator through and cooled by the radiator (5) to the oil port XI or through back pressure valve Ch1 to
oil return filter element (7) and return to oil tank (8); if the system oil pressure is excessively high, some fluids
flow through relief valve (3) through and cooled by radiator (5) or back pressure valve Ch1 to oil return filter
element (7) for filtering and then return to the tank (8). Oil passing across the back pressure valve Ch1 indi-
cates the return oil pressure is too high, which is caused by excessive high liquid resistance flowing across the
radiator 5.
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3.3.3 Hydraulic Principle

3.3.3.1 Main Hydraulic Circuit
The main hydraulic circuit is the passage transmitting the hydraulic energy from the tank to the actuators. The
complete main hydraulic circuit includes: suction passage, drain passage, return passage and leakage pas-
sage.
Suction passage
Oil Suction Passage of the Kawasaki System
As the solid arrow shown in the following figure, the oil enters the hydraulic pump from the suction port of the
tank passing through the suction filter.
Figure of Oil Suction Passage of the Kawasaki System
LG922E9330E03135
1. Tank 3. Suction steel tube

2. Oil suction hose 4. Main pump
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Oil Return Circuit of the Rexroth System

As the solid arrow shown in the following figure, the oil enters the hydraulic pump from the suction port of the
tank passing through the suction filter.
Figure of Oil Suction Passage of the Rexroth System
2
3
CLG920E922E03035
1. Tank 3. Suction steel tube

2. Oil suction hose 4. Main pump
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Drain passage
Figure of Oil Drainage Passage of the Kawasaki System
o
3-167
Figure of Oil Drainage Passage of the Rexroth System
6 8
9
1
2
3
5
4
CLG920E922E03036
1. P1 hose assembly 4. Left travel motor hose assembly 7. Arm cylinder hose assembly
2. P2 hose assembly 5. Boom cylinder hose assembly 8. Slewing motor hose assembly
3. Main control valve 6. Bucket cylinder hose assembly 9. Right Travel motor hose assembly
As shown at the arrow, the oil pumped from the P1 pump enters the P1 port of the main control valve, and the
oil pumped from the P2 pump enters the P2 port of the main control valve. After being distributed by the main
control valve, the oil enters the actuators. The diagram only presents one of the oil flow directions.
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Return passage
Figure of Oil Return Passage the Kawasaki System
3-169
Figure of Oil Return Passage the Rexroth System
6
5
1
3
4
CLG920E922E03037
1. Return passage 3. Check valve 5. Hydraulic tank

2. Return passage 4. Oil Radiator 6. Check valve
All return oil of the actuators will return to the hydraulic tank through the return passage. As shown in the figure
above, under normal conditions, a large amount of 2 return oil flows to the hydraulic tank (5) after passing
through the check valve (3) and the oil cooler (4).
When a large amount of return oil passes through the oil cooler (4), as the return oil amount increases, such as
arm opening action. the return back pressure will increase rapidly, to prevent the oil cooler from being dam-
aged by the increased pressure. The check valve (6) on the return passage 1 is opened. Return passage 1
helps to shunt and prevent the oil cooler from damage.
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Leakage passage
1. Right travel motor 2. Left travel motor 3. Center joint
The drained oil at the lower part, which is absorbed to the upper part through the center joint (3), is mainly from
the two travel motors.
3-171
Figure of Oil Drainage Passage the Kawasaki System
1. Center joint 2. Slewing motor 3. Main pump
The leaking oil at the upper part is mainly composed of three parts:
I. Leaking oil from the two travel motors is back to the tank through the center connector (1);
II. Leaking oil from the slewing motor (2);
III. Oil drained from the main pump (3).
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Figure of Oil Drainage Passage the Rexroth System
1 2 CLG920E922E03038
1. Center joint 2. Slewing motor 3. Main pump
The leaking oil at the upper part is mainly composed of three parts:
I. Leaking oil from the two travel motors is back to the tank through the center connector (1);
II. Leaking oil from the slewing motor (2);
III. Oil drained from the main pump (3).
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1. Kawasaki System
3.3.3.2 Pilot Circuit
Block
Structural Function and Maintenance

Forward Main control valve
Travel-rh
Reverse
Travel pilot valve
Forward
Travel-lh
Reverse Swing motor PG
Figure of Pilot Circuit of the Kawasaki System

Close to
the right
Bucket cocurrent flow
Bucket
Retracting
Right to the left
After rise
Boom
Before
Hand pilot valve dropping
Before
stretching
Arm
After
Pump
retracting
FR Adjuster (rear)
Left Adjuster (front)
Slewing
FL
Travel variable speed

Transient
Pilot pump
power Arm 2nd gear
boosting
Pilot unlocking
LG922E9330E03140
CLG920E/922E/923E
September 15, 2020
3-175
1. Pilot pump 5. Left-hand pilot valve

2. Hydraulic tank 6. Right-hand pilot valve
3. Pilot valve group 7. Travel pilot valve
4. Four-step solenoid valve group 8. Main control valve
The pressure of the pilot loop is from the pilot pump 1, which sets the system pressure as 3.9MPa using the
build-in filter screen and relief valve.
The pilot oil flows out from the A3 port of the pilot pump (1), and enters the electronic proportional pressure-
reducing valve to carry out electronic control to the main pump power; at the same time, it enters the
accumulator passing through the filter of the pilot valve group (3) and the check valve. The check valve can
keep the pressure. The accumulator can place the work implement on a safe ground in case of failure of the
machine, stabilize the pilot system pressure and absorb the pulsation when the machine is working, and
supplement the system pressure drop timely when several actions act at the same time;
The pilot oil which flows out from the pilot valve group (3) enters the P1 port of the four-step solenoid group (4).
The return oil of all the solenoids in the four-step solenoid group (4) flows back to the tank through the T1 port.
A1 controls the pilot shutoff; A2 controls the travel shift; A3 controls the pressurizing; A4 controls the grader
mode.
The pilot oil which flows out from the four-step solenoid A1 enters the left-hand pilot valve (5), right-hand pilot
valve (6), travel pilot valve (7) at the same time, and controls the valve rod of the main control valve (8) by
operating the pilot valves.
Left-hand pilot valve (5) controls the machine arm and the revolving action. Right-hand pilot valve (6) controls
the actions of boom and bucket of the machine. Travel pilot valve (7) controls the travel action of the machine.
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2. Rexroth System
Figure of Pilot Circuit of the Rexroth System
CLG920E922E03039
3-177
1. Pilot pump 5. Left-hand pilot valve

2. Hydraulic tank 6. Right-hand pilot valve
3. Pilot valve group 7. Travel pilot valve
4. Quadruple Solenoid Valve + Triple Proportional Solenoid Valve 8. Main control valve
The pressure of the pilot loop is from the pilot pump 1, which sets the system pressure as 3.9MPa using the
build-in filter screen and relief valve.
The pilot oil flows out from the A3 port of the pilot pump 1, and enters the electronic proportional pressure-
reducing valve to carry out electronic control to the main pump power; at the same time, it enters the
accumulator passing through the filter of the pilot valve group 3 and the check valve. The check valve can keep
the pressure. The accumulator can place the work implement on a safe ground in case of failure of the
machine, stabilize the pilot system pressure and absorb the pulsation when the machine is working, and
supplement the system pressure drop timely when several actions act at the same time;
The pilot oil which flows out from the pilot valve group 3 enters the P1 port of the four-step solenoid valve
group 4. The return oil of all the solenoids in the four-step solenoid valve group 4 flows back to the tank
through the T1 port. A1 pressure control pilot valve cut-off; A2 traveling control transmission; A3 control flat
ground mode; A7 control pressurization.
The pilot oil that flows out from the quadruple solenoid valve and the triple proportional solenoid valve A1
enters the left-hand pilot valve 5, right-hand pilot valve 6, travel pilot valve 7 at the same time, and controls the
valve rod of the main control valve 8 by operating the pilot valves.
Left-hand pilot valve 5 controls the complete machine arm and the revolving action. Right-hand pilot valve 6
controls the actions of boom and bucket of the machine. Travel pilot valve 7 controls the travel action of the
complete machine.
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3.3.3.3 Neutral Flow Control Circuit (With Control Spool in the Neutral)
Flow control system (neutral)
1. Kawasaki System
Figure of Kawasaki Flow control system (Neutral)
LG922E930E03141
3-179
1. Center position passage 7. Negative flow control oil

2. Oil return passage 8. Oil return passage
3. Negative flow control oil 9. Center position passage
4. Relief valve 10. Hydraulic tank
5. Orifice 11. Right pump
6. Relief valve 12. Left pump
The negative flow control system is an energy saving system. When the system does not work, the pressure oil
output from the left pump (12) and the right pump (11) of the main pump enters into return passage (2) and (8)
and returns to the hydraulic tank (10) through the orifice (5) respectively after passing through the neutral
passage (1) and (9) of main valve, and at the same time, the feedback pressure generated before flowing
through the orifice (5) enters the negative flow control port of the main pump respectively after passing through
the line (3) and (7), which minimizes the swashplate slewing angle of the main pump to reduce the output flow
of the main pump and then save the energy.
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2. Rexroth System
Figure of Rexroth Flow control system (Neutral)
CLG920E922E03040
3-181
1. Left pump 6. Oil return passage

2. Hydraulic tank 7. Center position passage
3. Right pump 8. Flow control oil
4. Center position passage 9. Relief valve
5. Oil return passage
The neutral flow control system is an energy-saving system. When the system is not working, the pressure oil
from the left pump (1) and the right pump (3) of the main pump flows through the neutral oil passages (4) and
(7) of the main valve to the return oil passages (5) and (6) and back to the hydraulic tank (2). At the same time,
the electrical pressure sensor detects that the system is not working, and the swashplate angle of the main
pump is minimized through the flow control oil (8) to reduce the output flow of the main pump for energy
saving.
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3.3.3.4 Negative Flow Control Circuit (With Control of Spool Moving)

Negative flow control system (operation)
1. Kawasaki System
Figure of Kawasaki negative flow control system (operation)
LG922E930E03142
3-183
1. Center position passage 8. Oil return passage

2. Oil return passage 9. Center position passage
3. Negative flow control oil 10. Hydraulic tank
4. Relief valve 11. Right pump
5. Orifice 12. Left pump
6. Relief valve 13. Slewing valve spool
7. Negative flow control oil 14. Check valve
In case of any action, such as revolving, as shown in the figure above, the revolving spool (13) moves toward
the left with the action of the pilot pressure, the right pump output pressure of the main pump flows through the
check valve (14), the right position of the revolving spool (13) moves to the slewing motor, the original neutral
passage (9) is closed by the revolving spool, the negative flow control line (7) is minimized, and the right pump
swashplate slewing angle of the main pump increases to supply oil to the slewing motor; the left pump of the
main pump keeps in the smallest slewing angle with the action of the negative feedback control pressure (3).
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2. Rexroth System
Figure of Rexroth positive flow control system (operation)
CLG920E922E03041
3-185
1. Left pump 7. Center position passage

2. Hydraulic tank 8. Flow control oil
3. Right pump 9. Relief valve
4. Center position passage 10. Check valve
5. Oil return passage 11. Slewing valve spool
6. Oil return passage
If there is any action such as slewing as shown in the figure above, the swing spool (11) moves to the left
under the pilot pressure, and the pressure oil output by the right pump of the main pump flows to the swing
motor through the check valve (10) and the right position of the swing spool (11). The original center passage
(7) is closed by the swing spool. The electrical pressure sensor detects the pilot pressure and increases the
swing angle of the right swashplate of the main pump through the flow control oil (8) to supply oil to the swing
motor. The left pump of the main pump still uses flow control oil (8) to minimize the swashplate angle of the
main pump.
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3.3.3.5 Boom Lifting Working Circuit

Lifting of the boom
1. Kawasaki System
Figure of Boom Lifting of the Kawasaki System
LG922E930E03143
3-187
1. Boom cylinder 10. Hand pilot valve

2. Boom cylinder big cavity pipe 11. Solenoid valve
3. Oil pipe of boom cylinder small cavity 12. Pilot valve group
4. Boom lock valve 13. Tank
5. Pressure passage 14. Left pump
6. Pilot control oil line 15. Right pump
7. Boom spool 1 16. Pilot pump
8. Check valve 17. Boom spool 2
9. Pilot control oil line 18. Check valve
Operate the hand pilot valve (10) handle to make it rotate backward, the pilot pressure from the pilot pump (16)
through the solenoid valve (11) of the pilot valve block (12) to Port 4 of the hand pilot valve (10), through the
pilot lines (6) and (9) to the control port of the boom spool 1 (7) and boom spool 2 (17), respectively. At the
same time, the control oil in the right control cavity of boom spool 1 (7) flows back to the tank (13) through the
oil pipe at the other end of the valve spool (7) and through the oil port 2 of the hand pilot valve (10). Under the
action of the pilot control pressure, boom spool 1 (7) and boom spool 2 (17) change direction to the
corresponding position. The pressure oil from the left pump (14) of the main pump flows through the check
valve (8) boom spool 1 (7), pressure passage (5), and boom locking valve (4) to the large cavity of boom
cylinder (1). At the same time, the pressure oil of the right pump (15) joins the pressure oil of the boom spool 1
(7) through the boom spool 2 (17) and the check valve (18) to the big cavity of the boom cylinder (1). The oil in
the small cavity of boom cylinder (1) flows through oil circuit (3), boom spool 1 (7), and return the oil to the tank
(13). In this way, the boom cylinder, under the action of pressure oil, extends the piston rod and pushes the
boom up.
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2. Rexroth System
Figure of Boom Lifting of the Rexroth System
B
A
BOOM CYLINDER
动臂油缸
A
B
CLG920E922E03042
3-189
1. Boom cylinder big cavity pipe 10. Pilot pump

2. Boom cylinder 11. Right pump
3. Oil pipe of boom cylinder small cavity 12. Hydraulic tank
4. lockout valve 13. Left pump
5. Check valve 14. Solenoid valve
6. Pressure passage 15. Pilot valve group
7. Boom spool 16. Pilot control oil line
8. Check valve 17. Hand pilot valve
9. Pressure passage
Operate the hand pilot valve (17) handle to make it rotate backward, the pilot pressure flows from the pilot
pump (10) through the pilot valve block (15) to the solenoid valve (14) to Port 4 of the hand pilot valve (17), and
through the pilot line (16) to the control port of the boom spool (7). At the same time, the control oil in the right
control cavity of the boom spool (7) flows back to the tank (12) through the oil pipe at the other end of the valve
spool (7), and the boom spool (7) changes direction to the corresponding position under the action of the pilot
control pressure. The pressure oil from the left pump (13) of the main pump flows through the check valve (8),
boom spool (7), pressure passage (9) and boom lockout spool (4) to the big cavity (1) of the boom cylinder (2);
meanwhile, the pressure oil from the right pump (11) joins the pressure oil from boom spool (7) through the
dynamic pressure passage (6) and check valve (5) to the big cavity (1) of boom cylinder (2). The oil in the small
cavity (3) of the boom cylinder (2) flows through the oil pipe line (3), the boom spool (7) and the oil returns to
the tank (12). In this way, the boom cylinder, under the action of pressure oil, extends the piston rod and
pushes the boom up.
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3.3.3.6 Boom Lowering Working Circuit

Lowering of the boom
1. Kawasaki System
Figure of Boom Lowering Circuit of the Kawasaki System
LG922E930E03144
3-191
1. Boom cylinder 10. Hand pilot valve

2. Boom cylinder big cavity pipe 11. Solenoid valve
3. Oil pipe of boom cylinder small cavity 12. Pilot valve group
4. Boom lock valve 13. Tank
5. Pressure passage 14. Left pump
7. Boom spool 1 16. Pilot pump
8. Check valve 17. Boom spool 2
When the hand pilot valve (10) handle is rotated forward, the pilot pressure reaches the port 2 of the right-hand
pilot valve (10) after passing through the pilot valve group (12) and the solenoid valve (11) from the pilot pump
(16), and reaches the control ports of the boom spool 1 (7) and boom lockout valve (4) respectively after
passing through the pilot line (9); at the same time, the control oil in the left control chamber of the boom spool
1 (7) flows back to the tank (13) after passing through the hand pilot valve (10) oil port 4, and the boom spool 1
(6) towards to right with the action of the pilot control pressure;
The pressure oil in the left pump of the main pump (14) flows through the check valve (8), the boom spool 1
(7), and the small chamber oil pipe (3) of the boom cylinder to the small chamber of the boom cylinder (1); the
oil in the big cavity of the boom cylinder (1) flows through the boom cylinder big cavity oil pipeline (2), boom
lockout valve (4), and the part return tank (13) of the boom spool 1 (7) to the small chamber of the boom
cylinder (1), and another part of the hydraulic oil joints in the small chamber of the boom cylinder (1) after
passing the check valve in the boom spool 1 (7). Thus, with the action of the pressure oil, the boom cylinder
makes the piston rod withdraw, pull the boom downward and realize the function of return oil regeneration.
During the declining process, the boom spool 1 (7) has a certain amount of return oil, a certain pressure still
exists in the negative flow of the left pump (14), which minimizes the discharge capacity of the left pump (14),
and then the energy is saved.
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2. Rexroth System
Figure of Boom Lowering Circuit of the Rexroth System
B
A
BOOM CYLINDER
动臂油缸
A
B
CLG920E922E03043
3-193
1. Boom cylinder 9. Upper pump

2. Boom cylinder big cavity 10. Hydraulic tank
3. Boom cylinder small cavity 11. Lower pump
4. lockout valve 12. Solenoid valve
5. Boom spool 13. Pilot valve group
6. Check valve 14. Pilot control oil line
7. Pressure passage 15. Hand pilot valve
8. Pilot pump
When the hand pilot valve (15) handle is rotated forward, the pilot pressure reaches the port 2 of the right-hand
pilot valve (10) after passing through the pilot valve group (13) and the solenoid valve (12) from the pilot pump
(8), and reaches the control ports of the boom spool 1 (5) and boom lockout valve (4) respectively after
passing through the pilot line (14); at the same time, the control oil in the left control cavity of the boom spool 1
(5) flows back to the tank (10) after passing through the hand pilot valve (15) oil port 4, and the boom spool 4
(5) towards to right with the action of the pilot control pressure;
The pressure oil in the lower pump (11) of the main pump flows through the check valve (6), the boom spool
(5), and the small cavity pipe (3) of the boom cylinder to the small cavity of the boom cylinder (1). The oil in the
big cavity of the boom cylinder (1) flows through the oil pipeline (2) in the boom cylinder big cavity, boom
lockout valve (4), boom spool (5), and part of oil returns to the tank (10); and the other part of the hydraulic oil
flows through the check valve in the boom spool (5) to the small cavity of the boom cylinder. Thus, with the
action of the pressure oil, the boom cylinder makes the piston rod withdraw, pull the boom downward and
realize the function of return oil regeneration.
During the process of boom lowering, there is a certain amount of return oil in the neutral position of boom
spool (5), and the upper pump (9) reduces the angle of its (9) regulator swashplate under the feedback of
electrical pressure sensor to reduce the displacement, achieving the energy-saving effect.
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3.3.3.7 Arm Stretching Working Circuit

1. Kawasaki System
Figure of arm stretching working circuit of the Kawasaki system
3-195
1. Arm cylinder 11. Solenoid valve

2. Arm cylinder big cavity pipe 12. Pilot valve group
3. Oil pipe of arm cylinder small cavity 13. Tank
4. Arm lock valve 14. Left pump
5. Pressure passage 15. Right pump
6. Arm spool 2 16. Pilot pump
7. Check valve 17. Regeneration control valve
8. Pilot control oil line 18. Arm spool 1
9. Switching valve 19. Pressure passage
10. Left-hand pilot valve
When the left-hand pilot valve handle is rotated forward, the pilot pressure reaches the port 2 of the hand pilot
valve (10) after passing through the solenoid valve (11) of pilot valve group (12) and from the pilot valve (16),
and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (6) respectively after passing through
the switching valve (9) and pilot piping (8); at the same time, the control oil in the right control chamber of the
arm spool 1 (18) and arm spool 2 (6) flows back to the tank (13) after passing through the piping, switching
valve (9), and the port 4 of the left-hand pilot valve (10); the arm spool 1 (18) and arm spool 2 (6) reverse to
corresponding positions with the action of the pilot control pressure;
The pressure oil output from the left pump (14) of the main pump reaches the small chamber of the arm
cylinder (1) after passing through the check valve (7), arm spool 2 (6), arm locking valve (4), and arm cylinder
small chamber oil pipe (3); at the same time, the pressure oil of the right pump (15) reaches the arm spool 1
(18) and pressure passage (19) to joint after passing through the check valve; the pressure oil of the arm spool
2 (6) reaches the small chamber of the arm spool (1) after passing through the arm locking valve (4) and the
arm cylinder small chamber oil pipe (1); the oil in the arm cylinder (1) big cavity flows back to the tank (13) after
passing through the arm cylinder big cavity oil piping (2), arm spool 1 (18) and the arm spool 2 (6), thus, with
the action of the pressure oil, the piston rod of the arm cylinder withdraws to make the arm stretch out.
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2. Rexroth System
Figure of arm stretching working circuit of the Rexroth system
A
B
ARM CYLINDER
斗杆油缸
CLG920E922E03044
3-197
1. Check valve 10. Hydraulic tank

2. Pressure passage 11. Lower pump
3. Arm cylinder big cavity 12. Solenoid valve
4. Arm cylinder 13. Pilot valve group
5. Arm cylinder small cavity 14. Pilot control oil line
6. Arm spool 15. Hand pilot valve
7. lockout valve 16. Pressure passage
8. Pilot pump 17. Neutral switching spool
9. Upper pump
When the left-hand pilot valve (15) handle is rotated forward, the pilot pressure from the pilot pump (8) through
the pilot valve block (13) and the solenoid valve (12) to Port 2 of the hand pilot valve (15), and through the pilot
line (14), to the arm spool (6), respectively. At the same time, the control oil in the left control cavity of the arm
spool (6) flows back to the tank (10) through the pipeline to the oil port 4 of the left pilot valve (15), the control
oil in the control cavity of the neutral switching spool (17) flows back to the tank (10) through the internal oil
channel, and the arm spool (6) reverses to the corresponding position under the action of the pilot control
pressure.
The pressure oil from the upper pump (9) of the main pump flows through the pressure passage (2) to the
check valve (1), the arm spool (6), the arm lockout valve (7), and the arm cylinder small cavity pipe to the arm
cylinder small cavity (5). At the same time, the pressure oil of the lower pump (11) joins the pressure oil of the
arm spool (6) through the check valve, the pressure oil passage (16) and the arm lockout valve (7), and the
small cavity pipe of the arm cylinder to the small cavity of the arm cylinder (5). The oil in the big cavity (3) of the
arm cylinder returns to the tank (10) through the oil pipe of the big cavity of the arm cylinder and the return
passage of the arm spool (6). In this way, the arm cylinder retracts the piston rod under the action of pressure
oil and pulls the stick out.
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3.3.3.8 Arm Retraction Working Circuit (With Regeneration)

Arm retraction (with regeneration)
1. Kawasaki System
Figure of arm retraction working circuit (without regeneration) of the Kawasaki system
LG922E930E03146
3-199

When the left-hand pilot valve handle is rotated backward, the pilot pressure reaches the port 4 of the hand
pilot valve (10) after passing through the pilot valve group (12) and solenoid valve (11) from the pilot valve (16),
and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (5) and the control port of the arm
locking valve (4) respectively after passing through the switching valve (9) and pilot piping (8); at the same
time, the control oil in the arm spool 2 (6) and arm spool 1 (18) flows back to the tank (13) after passing
through the piping, switching valve (9), and the port 2 of the left-hand pilot valve (10); the arm spool 1 (18) and
arm spool 2 (6) reverse to corresponding positions with the action of the pilot control pressure; the pilot
pressure oil opens the reverse control valve of the arm locking valve (4) at the same time to connect the control
pressure of the arm locking valve and that of the tank, and unlock the arm small chamber return oil. The
pressure oil output from the left pump (14) of the main pump reaches the big cavity of the arm cylinder (1) after
passing through the pressure passage, check valve (7), arm spool 2 (6), and the arm cylinder big cavity oil pipe
(2); at the same time, the pressure oil of the right pump (15) reaches the arm cylinder (1) big cavity jointing the
pressure oil of the arm spool 2 (6) after passing through the arm spool 1 (18) and the arm cylinder big cavity oil
pipe (2); with the light load, the regeneration control valve (17) does not switch, and at this moment, the oil in
the small chamber of the arm cylinder (1) flows back to the arm spool 1 (18) after passing through the arm
cylinder small chamber oil piping (3) and the arm locking valve (4); a part of oil reaches the big cavity of the
arm cylinder (1) after passing through the internal check valve of the arm 1 (18), another part of the oil flows
back to the tank after passing through the regeneration control valve orifice, this circuit can accelerate the
moving speed, and the function is called "regeneration". Thus, with the action of the pressure oil, the piston rod
of the arm cylinder stretches out to make the arm withdraw.
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2. Rexroth System
Figure Arm retraction working circuit of the Rexroth system (without regeneration)
A
B
ARM CYLINDER
斗杆油缸
CLG920E922E03045
3-201

3. Arm cylinder small cavity 12. Hand pilot valve
4. lockout valve 13. Pilot control oil line
5. Arm spool 14. Pressure passage
6. Pilot pump 15. Pressure passage
7. Upper pump 16. Check valve
8. Hydraulic tank 17. Check valve
9. Lower pump
When the left-hand pilot valve handle is rotated backward, the pilot pressure flows from the pilot pump (6)
through the pilot valve block (11) and the solenoid valve (10) to Port 4 of the hand pilot valve (12), through the
pilot line (13) to the control port of the arm spool (5) and the control port of the arm lockout valve (4). At the
same time, the control oil of the right side of the arm spool (5) flows back to the tank (8) through the line, port 2
of the left-hand pilot valve (12). The arm spool (5) and the pilot control pressure change direction to the
corresponding position, and the pilot pressure oil simultaneously opens the change direction control valve of
the arm lockout valve (4), communicates the control pressure of the arm lockout valve with the tank, and
unlocks the return oil of the arm small cavity.
The pressure oil from the upper pump (7) of the main pump flows through the pressure passage (14), the
check valve (16), the arm spool (5), and the big cavity pipe of the arm cylinder to the big cavity (1) of the arm
cylinder. At the same time, the pressure oil of the lower pump (9) flows through the pressure passage (15) and
the pressure oil converging with the arm spool (5) to the big cavity (1) of the arm cylinder through the big cavity
pipe of the arm cylinder. Under the light load condition, the regeneration control valve does not switch. At this
time, the oil in the small cavity (3) of the arm cylinder returns to the arm spool (5) through the oil line in the
small cavity of the arm cylinder and the arm lockout valve (4). One part of the oil enters the pressure oil
passage through the check valve inside the arm spool to the big cavity (1) of the arm cylinder and the other
part flows back to the oil tank through the throttle of the regeneration control valve. This circuit can accelerate
the moving speed of the cylinder. This is the function of“Regeneration”. In this way, the arm cylinder extends
the piston rod under the action of pressure oil and retracts the arm.
3-202
3.3.3.9 Arm Retraction Working Circuit (Without Regeneration)

Arm retraction (without regeneration)
1. Kawasaki System
Figure of Arm retraction working circuit (without regeneration) of the Kawasaki system
LG922E930E03147
3-203

With the heavy load, when the oil inlet pressure of the arm cylinder big cavity exceeds the set pressure of the
regeneration control valve (17) spring, the regeneration control valve (17) will reverse, at this moment, the arm
cylinder small chamber return oil can flow to the tank directly, and then the "regeneration" function is
unavailable.
When the left-hand pilot valve handle is rotated backward, the pilot pressure reaches the port 4 of the hand
pilot valve (10) after passing through the pilot valve group (12) and solenoid valve (11) from the pilot valve (16),
and reaches the control ports of the arm spool 1 (18) and the arm spool 2 (6) and the control port of the arm
locking valve (4) respectively after passing through the switching valve (9) and pilot piping (8); at the same
time, the control oil in left control chamber of the arm spool 1 (18) and arm spool 2 (6) flows back to the tank
(13) after passing through the switching valve (9), and the port 2 of the left-hand pilot valve (10); the arm spool
1 (18) and arm spool 2 (6) reverse to corresponding positions with the action of the pilot control pressure; the
pilot pressure oil opens the reverse control valve of the arm locking valve (4) at the same time to connect the
control pressure of the arm locking valve and that of the tank, and unlock the arm small chamber return oil;
The pressure oil output from the left pump of the main pump (14) reaches the big cavity of the arm cylinder (1)
after passing through the check valve (7), arm spool 2 (6) and the arm cylinder big cavity oil pipe (2); at the
same time, the pressure oil of the right pump (15) reaches the big cavity of the arm cylinder (1) jointing the
pressure oil of the arm spool 2 (6) after passing through the arm spool 1 (18) and the arm cylinder big cavity oil
pipe (2); the oil in the arm cylinder (1) small chamber connects and flows back to the tank after passing through
the arm cylinder small chamber oil piping (3), arm locking valve (4) and the arm spool 1 (18), thus, with the
action of the pressure oil, the piston rod of the arm cylinder stretches out to make the arm withdraw.
3-204
2. Rexroth System
Figure Arm retraction working circuit of the Rexroth system (with regeneration)
A
B
ARM CYLINDER
斗杆油缸
CLG920E922E03046
3-205

3. Arm cylinder small cavity 12. Hand pilot valve
4. lockout valve 13. Pilot control oil line
5. Arm spool 14. Pressure passage
6. Pilot pump 15. Pressure passage
7. Upper pump 16. Check valve
8. Hydraulic tank 17. Check valve
9. Lower pump
With the heavy load, when the oil inlet pressure of the arm cylinder big cavity exceeds the set pressure of the
regeneration control valve spring, the regeneration control valve will reverse, at this moment, the arm cylinder
small cavity return oil can flow to the tank directly, and then the "regeneration" function is unavailable.
When the left-hand pilot valve handle is rotated backward, the pilot pressure flows from the pilot pump (6)
through the pilot valve block (11) and the solenoid valve (10) to Port 4 of the hand pilot valve (12), through the
pilot line (13) to the control port of the arm spool (5) and the control port of the arm lockout valve (4),
respectively. At the same time, the control oil of the right control cavity of the arm spool (5) flows back to the
tank (8) through the pilot line, Port 2 of the left-hand pilot valve (12). The arm spool (5) and the pilot control
pressure change direction to the corresponding position, and the pilot pressure oil simultaneously opens the
change direction control valve of the arm lockout valve (4), communicates the control pressure of the arm
lockout valve with the tank, and unlocks the return oil of the arm small cavity.
The pressure oil output from the upper pump (7) of the main pump reaches the big cavity of the arm cylinder
after passing through the check valve (16), the arm spool (5), and the big cavity pipe (1) of arm cylinder. At the
same time, the pressure oil of the lower pump (9) joins the pressure oil of the arm spool (5) passing through
the pressure-oil passage (15) to the big cavity of arm cylinder through the big cavity pipe (1) of the arm
cylinder. The oil in the small cavity of arm cylinder is connected with the oil return passage through the oil line
(3), arm lockout valve (4), arm spool (5) of the small cavity of the arm cylinder and then returns to the tank. In
this way, the arm cylinder extends the piston rod under the action of pressure oil and retract the arm.
3-206
3.3.3.10 Bucket Retraction Working Circuit

Bucket Retraction
1. Kawasaki System
Figure of bucket retraction working circuit of the Kawasaki system
LG922E930E03148
3-207
1. Bucket cylinder 11. Solenoid valve

2. Bucket cylinder big cavity pipe 12. Pilot valve group
3. Small cavity pipe of the bucket cylinder 13. Tank
4. Pilot control oil line 14. Left pump
6. Bucket spool 16. Pilot pump
7. Check valve 17. Center position passage
9. Shuttle valve 19. Shut-off valve
10. Right-hand pilot valve
Operate the handle of the right-hand pilot valve (10) to make it rotate toward left, and the pilot pressure
reaches the port 1 of the hand pilot valve (10) passing through the pilot valve group (12) and solenoid valve
(11) from the pilot pump (16); reaches the control port of the bucket spool (6) after passing through the pilot
control oil line (8); at the same time, the pressure oil output from the hand pilot valve (10) makes the shut-off
valve (19) switch to left after passing through the shuttle valve (9) and the pilot control line (4) to shut off the
return oil of the right pump (15); the control oil in the right control cavity of the bucket spool (6) flows back to the
tank (13) after passing through the piping and the port 1 of the right-hand pilot valve (10). The bucket spool (6)
switches to the corresponding position under the action of the pilot control pressure.
The pressure oil of the left pump (14) reaches the big cavity of bucket cylinder (1) after passing through the
check valve (7), bucket spool (6) and the bucket big cavity pipe (2); the oil in the small cavity of the bucket
cylinder (1) flows back to the tank after passing through the bucket cylinder small cavity oil piping (3) and the
bucket spool (6), thus, with the action of the pressure oil, the piston rod of the bucket cylinder stretches out to
make the bucket withdraw.
The pressure oil output from the right pump (15), together with the oil from the left pump (14), enters the bucket
spool (6) after passing through the neutral passage (17), check valve (18) and the pressure passage (5) to
realize the jointing inside the valve.
3-208
2. Rexroth System
Figure of bucket retraction working circuit of the Rexroth system
铲斗油缸
CLG920E922E03047
3-209
1. Bucket cylinder big cavity 10. Lower pump

3. Bucket cylinder small cavity 12. Pilot valve group
4. Bucket spool 13. Switching valve
5. Check valve 14. Pressure passage
6. Pressure passage 15. Check valve
7. Pilot pump 16. Pilot control oil line
8. Upper pump 17. Hand pilot valve
9. Hydraulic tank
When the handle of the right-hand pilot valve (17) is rotated to left, pilot pressure from pilot pump (7) reaches
Port 1 of the right-hand pilot valve (17) after passing through pilot valve group (12) and solenoid valve (11) and
reaches bucket spool (16) control port through pilot control oil pipeline (4). At the same time, control oil of
control cavity at the right bucket spool (4) flows back to the tank (9) after passing through pipeline, oil port 3 of
the right pilot valve (17), then bucket spool (4) and switching valve (13) reverses to the corresponding position
with the action of the pilot control pressure.
switching valve (13), pressure oil passage (6), check valve (5), bucket spool (4) and the bucket big cavity pipe;
the oil in the small cavity of the bucket cylinder (3) flows back to the tank after passing through the bucket
cylinder small cavity oil piping and the bucket spool (4), thus, with the action of the pressure oil, the piston rod
of the bucket cylinder stretches out to make the bucket retracts.
At the same time, the pressure oil output from the lower pump (10) flows into the pressure oil passage (6) of
the upper pump (8) through the switching valve (13), pressure oil passage (14) and check valve (5), and then
enters the big cavity from the bucket spool (4) to the oil pipe of the bucket big cavity to the bucket cylinder (1)
together to realize the confluence in the valve.
3-210
3.3.3.11 Bucket Stretching Working Circuit

Stretching of bucket
1. Kawasaki System
Figure of bucket stretching working circuit of the Kawasaki system
LG922E930E03149
3-211

2. Bucket cylinder big cavity pipe 12. Pilot valve group
3. Small cavity pipe of the bucket cylinder 13. Tank
6. Bucket spool 16. Pilot pump
7. Check valve 17. Center position passage
9. Shuttle valve 19. Shut-off valve
10. Right-hand pilot valve
Operate the handle of the right-hand pilot valve (10) to make it rotate toward left, and the pilot pressure
reaches the port 1 of the hand pilot valve (10) passing through the pilot valve group (12) and solenoid valve
(11) from the pilot pump (16); reaches the control port of the bucket spool (6) after passing through the pilot
control oil line (8); at the same time, the pressure oil output from the hand pilot valve (10) makes the shut-off
valve (19) switch to left after passing through the shuttle valve (9) and the pilot control line (4) to shut off the
return oil of the right pump (15); the control oil in the right control cavity of the bucket spool (6) flows back to the
tank (13) after passing through the piping and the port 1 of the right-hand pilot valve (10). The bucket spool (6)
switches to the corresponding position under the action of the pilot control pressure.
check valve (7), bucket spool (6) and the bucket big cavity pipe (2); the oil in the small cavity of the bucket
cylinder (1) flows back to the tank after passing through the bucket cylinder small cavity oil piping (3) and the
bucket spool (6), thus, with the action of the pressure oil, the piston rod of the bucket cylinder stretches out to
make the bucket withdraw.
The pressure oil output from the right pump (15), together with the oil from the left pump (14), enters the bucket
spool (6) after passing through the neutral passage (17), check valve (18) and the pressure passage (5) to
realize the jointing inside the valve.
3-212
2. Rexroth System
Figure of bucket stretching working circuit of the Rexroth system
铲斗油缸
CLG920E922E03048
3-213
1. Bucket cylinder big cavity 8. Upper pump

2. Bucket cylinder 9. Hydraulic tank
3. Bucket cylinder small cavity 10. Lower pump
4. Bucket spool 11. Solenoid valve
5. Check valve 12. Pilot valve group
6. Pressure passage 13. Pilot control oil line
7. Pilot pump 14. Hand pilot valve
When the handle of right-hand pilot valve (14) is rotated to right, the pilot pressure from pilot pump (7) reaches
the Port 3 of the right hand pilot valve (14) after passing through pilot valve group (12) and solenoid valve (11),
and reaches bucket spool (13) control port through pilot control oil pipeline (4). At the same time, the control oil
of control cavity at left bucket spool (6) flows back to oil tank (9) after passing through pipeline, oil port 1 of right
pilot valve (17), and the bucket spool (4) reverses to corresponding position with the action of the pilot control
pressure;
The pressure oil of the lower pump (10) reaches the small cavity bucket cylinder (1) after passing through the
pressure oil passage (6), check valve (5), bucket spool (4) and the bucket small cavity pipe; the oil in the big
cavity of the bucket cylinder (3) flows back to the tank after passing through the bucket cylinder big cavity oil
pipeline and the bucket spool (4), thus, with the action of the pressure oil, the piston rod of the bucket cylinder
retracts to make the bucket stretches out.
Meanwhile, the hydraulic oil output by the upper pump (8) returns to the tank passing through the central oil
passage, and the regulator of the upper pump (8) adjusts its swashplate angle to the minimum to achieve the
effect of energy-saving.
3-214
3.3.3.12 Left Slewing Working Circuit

Left slewing
1. Kawasaki System
Figure of Left Slewing Working Circuit in the Kawasaki System
LG922E930E03150
3-215
1. Left-hand pilot valve 14. Pilot pump

2. Switching valve 15. Return oil check valve
3. Pilot control oil line 16. Slewing motor oil supplement piping
4. Pilot control oil line 17. Slewing logic valve
5. Motor unlock control line 18. Slewing valve spool
6. Orifice 19. Port A pipeline of slewing motor
7. Solenoid valve 20. Port B pipeline of slewing motor
8. Pilot control pressure piping 21. Slewing motor & speed reducer
9. Negative flow feedback pressure piping 22. Motor unlock piping
10. Pilot valve group 23. Time-delay valve
11. Tank 24. Motor unlock control line
13. Right pump 26. Shut-off valve
When the left-hand pilot valve (1) handle is rotated to left, the pilot pressure reaches the port 1 of the hand pilot
valve after passing through the pilot valve group (10) and solenoid valve (7) from the pilot pump (14), and
reaches the control port of the slewing spool (18) after passing through the pilot line (4); at the same time, the
control oil in the control chamber-rh of the slewing spool (18) flows back to the tank (10) after passing through
the piping (3) and the oil port 3 of the left-hand pilot valve (1). With the action of the pilot control pressure, the
slewing spool (18) switches to the corresponding position; at this moment, the pilot pressure oil generates the
pressure after passing through the piping (8), throttle valve (6) and the slewing spool (18) stops after reversing;
the control pressure provided by the pilot valve group (10) reaches the time delay valve (23) unlocked by the
slewing motor after passing through the pilot control pressure piping (8), throttle port (6) and the motor unlock
control piping (5) and (24), and pushes the reverse valve of the time delay valve to reverse; the control
pressure oil output from the pilot valve group (10) enters the locking cylinder of the motor after passing through
the motor unlock piping (22) to realize the unlocking;
The pressure oil of the right pump (13) reaches the slewing motor and & speed reducer (21) after passing
through the slewing logic valve (17), slewing spool (15), and the slewing motor B port line (20); the oil of the
slewing motor & speed reducer (21) A port flows back to the tank after passing through the slewing motor A
port line (19) and the slewing spool (18), thus, with the action of the pressure oil, the slewing motor & speed
reducer drive the platform to rotate toward the left.
The pressure oil output from the left pump (12) of the main pump flows back to the tank after passing through
the neutral passage (25) and the shut-off valve (26); the front feedback pressure at the throttle port acts on the
variable mechanism of the left pump (12) through the negative flow feedback pressure line (9), which
minimizes the discharge capacity of the left pump (12).
3-216
2. Rexroth System
Figure of Left Slewing Working Circuit in the Rexroth System
CLG920E922E03049
3-217
1. Hand pilot valve 10. Pilot pump

2. Pilot control oil line 11. Upper pump
3. Motor unlocking control oil-line 12. Hydraulic tank
6. Slewing valve spool 15. Solenoid valve
7. Port A pipeline of slewing motor 16. Solenoid valve
8. Time-delay valve 17. Slewing motor & speed reducer
9. Port B pipeline of slewing motor
When the left-hand pilot valve (1) handle is rotated to left, the pilot pressure flows from the pilot pump (10)
through the pilot valve group (14) and the solenoid valve (15) to the Port 1 of the hand pilot valve (1), and
through the pilot line (2) to the control port of the swing spool (6). At the same time, the control oil in the right
control cavity of slewing spool (6) flows back to the tank (13) through the pipeline (2) and the oil port 3 of the
left-hand pilot valve (1), and the slewing spool (6) reverses to the corresponding position under the pilot control
pressure. At this time, the pilot pressure oil supplied from the pilot valve group (14) passes through the
solenoid valve (16) and the motor unlocking control oil circuit (3) to the delay valve (8) of slewing motor
unlocking, pushing its reversing valve to reverse, and the control pressure oil output from the pilot valve group
(14) enters the locking cylinder of the motor after passing through the motor unlocking pipeline (3) to realize
the unlocking.
The pressure oil of the upper pump (11) flows through the pressure passage (4), check valve (5), slewing spool
(6), and swing motor Port A pipeline (7) to the swing motor and speed reducer (17). The oil from B port of
slewing motor and speed reducer (17) returns to the tank through Port B pipeline (9) of slewing motor and
slewing spool (6). In this way, the rotary motor and reducer drive the platform to rotate to the left under the
action of pressure oil.
The pressure oil output from the lower pump (13) of the main pump flows through the neutral channel and the
oil-return tank (12). At the same time, the regulator of the upper pump adjusts the angle of the swashplate to
the minimum to minimize the displacement of the lower pump (13).
3-218
3.3.3.13 Rotating Priority Pipeline (Rotating Opposite Bucket Rod Priority Function)
Arm retraction (with regeneration)
1. Kawasaki System
Figure of Arm retraction (regeneration) of the Kawasaki system
LG922E930E03151
3-219

2. Arm spool 2 11. Tank
3. Slewing pilot control oil passage 12. Left pump
4. Slewing shuttle valve pilot control oil passage 13. Right pump
5. Arm pilot control oil passage 14. Pilot pump
6. Shuttle valve 15. Slewing valve spool
7. Switching valve 16. Rotary priority valve
8. Hand pilot valve 17. Slewing motor & speed reducer
9. Solenoid valve 18. Arm spool 1
The main function of the priority valve (16) is to distribute the pressure oil output to the slewing spool (15) and
the arm spool 1 (18) by the right pump (13). As shown in the circuit diagram, the throttle passage is in the right
position.
When the left handle of the hand pilot valve (8) is operated at about 45° toward rear right, the pilot pressure
reaches the port 3 and port 4 of the left-hand pilot valve from the pilot pump (14) after passing through the pilot
valve group (10) and the solenoid valve (9), and reaches the slewing spool (15) and the corresponding control
ports of the arm spool 1 (18) and the arm spool 2 (2) after passing through the switching valve (7) and the pilot
piping (3) and (5) respectively. At this moment, the control oil of the slewing pilot control oil passage (3)
reaches the pilot control port PSP of the slewing priority valve (16) after passing through the shuttle valve (6),
which makes the valve move to the right throttle position.
The pressure oil output from the left pump (12) of the main pump reaches the big cavity of the arm cylinder (1)
after passing through the arm spool 2 (2).
At the same time, a part of the pressure oil of the right pump (13) reaches the slewing motor (17) after passing
through the slewing spool (15), and another part enters the arm cylinder (1) big cavity after passing through the
throttle passage-rh of the slewing priority valve (16) and the arm spool 1 (18); as the throttling action of the
slewing priority valve (16), the flow entering the arm spool 1 (18) is restricted, and then the slewing priority to
the arm is achieved.
3-220
2. Rexroth System
Figure of Arm retraction (regeneration) of the Rexroth system
A
B
ARM CYLINDER
斗杆油缸
CLG920E922E03050
3-221
1. Hand pilot valve 12. Port B pipeline of slewing motor

2. Pilot control oil line 13. Arm spool
3. Pilot control oil line 14. Pilot pump
4. Pressure passage 15. Upper pump
5. Check valve 16. Hydraulic tank
6. Slewing valve spool 17. Lower pump
7. Slewing-spool priority orifice 18. Pilot valve group
9. Time-delay valve 20. Solenoid valve
10. Slewing motor & speed reducer 21. Pilot control oil circuit
11. Arm cylinder
The main function of the slewing-spool priority orifice (7) is to distribute the pressure oil output to the slewing
spool (6) and the arm spool (13) by the upper pump (14). As shown in the circuit diagram, the throttle passage
is in the right position (7).
When the left handle of the hand pilot valve (1) is operated at about 45 degrees toward rear right, the pilot
pressure reaches the port 3 & port 4 of the left-hand pilot valve from the pilot pump (14) through the pilot valve
group (18) & the solenoid valve (19), and reaches spool the corresponding control ports of the slewing spool
(6) & the arm spool (13) through the pilot line (2) and (21). Move the slewing spool (6) and arm spool (13) to
the corresponding positions in the pilot control circuit (2) and (21).
The pressure oil output from the lower pump (17) of the main pump reaches the big cavity of the arm cylinder
(11) after passing through the arm spool (13).
At the same time, a part of the pressure oil of the upper pump (15) enters the slewing motor (10) through the
slewing spool (6), and another part enters the big cavity of the arm cylinder (11) after passing through the
throttle passage of the slewing spool priority orifice (7) and the arm spool (13); as the throttle action of the
slewing spool priority orifice (7), the flow entering the arm spool (13) is restricted, and then the slewing priority
to the arm is achieved.
3-222
3.3.3.14 Right Slewing Working Circuit

Right slewing
1. Kawasaki System
Figure of Right Slewing Working Circuit in the Kawasaki System
LG922E930E03152
3-223
1. Left-hand pilot valve 14. Pilot pump

2. Switching valve 15. Return oil check valve
3. Pilot control oil line 16. Slewing motor oil supplement piping
4. Pilot control oil line 17. Slewing logic valve
5. Motor unlock control line 18. Slewing valve spool
6. Orifice 19. Port B pipeline of slewing motor
7. Solenoid valve 20. Port A pipeline of slewing motor
8. Pilot control pressure piping 21. Slewing motor & speed reducer
9. Negative flow feedback pressure piping 22. Motor unlock piping
10. Pilot valve group 23. Time-delay valve
11. Tank 24. Motor unlock control line
13. Right pump 26. Shut-off valve
Operate the left-hand pilot valve (1) handle to make it rotate to the right, the pilot pressure flows from the pilot
pump (14) through the pilot valve group (10) and the solenoid valve (7) to the Port 3 of the hand pilot valve (1),
and through the pilot line (3) to the control port of the slewing spool (18). At the same time, the control oil in the
left control cavity of the slewing spool (18) flows through the line (20), and Port 1 of the left-hand pilot valve
(13) then flows back to the tank (10). The slewing spool (18) is reversed to the corresponding position under
the action of the pilot control pressure. At this time, the pilot pressure oil is cut off through the pipeline (8), the
throttle valve (6), and the slewing spool (18), and then the pressure is built up. The control pressure supplied
from the pilot valve group (10) is passed through the pilot control pressure pipeline (8), the throttle port (6), and
the motor unlocking control pipeline (5), (24) to the delay valve (23) of swing motor unlocking, push the
reversing valve to reverse, and the control pressure oil output from the pilot valve group (10) enters the locking
cylinder of the motor through the motor unlocking pipeline (22) to realize unlocking. The pressure oil from the
right pump (13) flows through the slewing logic valve (17), slewing spool (18), and slewing motor Port-A line
(19) to the slewing motor and speed reducer (21). The oil at Port A of slewing motor and reducer (21) returns to
the tank through Port B pipeline (20) of slewing motor and slewing spool (18). In this way, the rotary motor and
speed reducer drive the platform to rotate to the right under the action of pressure oil.
The pressure oil output from the left pump (12) of the main pump flows back to the tank after passing through
the neutral passage (25) and the shut-off valve (26); the front feedback pressure at the throttle port acts on the
variable mechanism of the left pump (12) through the negative flow feedback pressure line (9), which
minimizes the discharge capacity of the left pump (12).
3-224
2. Rexroth System
Figure of Right Slewing Working Circuit in the Rexroth System
CLG920E922E03051
3-225
1. Hand pilot valve 10. Pilot pump

2. Pilot control oil line 11. Upper pump
3. Motor unlocking control oil-line 12. Hydraulic tank
6. Slewing valve spool 15. Solenoid valve
8. Time-delay valve 17. Slewing motor & speed reducer
9. Port B pipeline of slewing motor
When the left-hand pilot valve (1) handle is rotated to right, the pilot pressure flows from the pilot pump (10)
through the pilot valve group (14) and the solenoid valve (15) to the Port 3 of the hand pilot valve (1), and
through the pilot line (2) to the control port of the swing spool (6). At the same time, the control oil in the left
control cavity of slewing spool (6) flows back to the tank (13) through the pipeline (2) and the oil port 1 of the
left-hand pilot valve (1), and the slewing spool (6) reverses to the corresponding position under the pilot control
pressure. At this time, the pilot pressure oil supplied from the pilot valve group (14) passes through the
solenoid valve (16) and the motor unlocking control oil circuit (3) to the delay valve (8) of slewing motor
unlocking, pushing its reversing valve to reverse, and the control pressure oil output from the pilot valve group
(14) enters the locking cylinder of the motor after passing through the motor unlocking pipeline (3) to realize
the unlocking.
The pressure oil of the upper pump (11) reaches the slewing motor and speed reducer (17) after passing
through the pressure oil passage (4), check valve (5), slewing spool (6), and slewing motor Port B pipeline (7).
Oil from the slewing motor & speed reducer (17) Port A flows back to the tank after passing through the
slewing motor Port A pipeline (9) and slewing spool (6). Thus, with the action of the pressure oil, the slewing
motor & speed reducer drive the platform to rotate leftward.
The pressure oil output from the lower pump (13) of the main pump flows through the neutral channel and the
oil-return tank (12). At the same time, the regulator of the upper pump adjusts the angle of the swashplate to
the minimum to minimize the displacement of the lower pump (13).
3-226
3.3.3.15 Travel Forward (Fast)

Travel forward (fast)
1. Kawasaki System
Figure of Kawasaki System Travel Forward (Fast)
LG922E930E03153
3-227
1. Left travel motor & speed reducer 25. Motor brake

2. Right travel motor & speed reducer 26. Control passage
3. Motor brake 27. Check valve
4. Unlock pressure oil passage 28. Transmission reversing valve
5. Port A oil passage of motor 29. Variable displacement cylinder
6. Balanced valve 30. Center revolving joint
7. Port A pipeline of left travel motor 31. Pilot control oil line
8. Port B pipeline of left travel motor 32. Pilot control oil line
9. Control passage 33. Solenoid valve
10. Port B port passage of motor 34.
11. Pilot control oil line 35. Left travel spool
12. Pilot control oil line 36. Pressure passage
13. Travel pilot valve 37. Solenoid valve
14. Travel fast and slow gear control line 38. Pilot return lines
15. Port B pipeline of right travel motor 39. Four-step solenoid valve group
16. Port A pipeline of right travel motor 40. Hydraulic tank
17. Port A oil passage of motor 41. Pilot pump
18. Control passage 42. Left pump
19. Balanced valve 43. Right pump
20. Oil return passage 44. Pressure switch
22. Transmission reversing valve 46. Right travel spool
23. Control passage 47. Control passage
24. Variable displacement cylinder 48. Control passage
When the travel fast-slow gear control switch is in the "Rabbit" state and the travel pilot valve (13) is operated
toward forward, the pilot pressure reaches the port 1 and port 3 of the travel pilot valve (13) after passing
through the pilot valve group (45) and the solenoid valve (33) from the pilot pump (41), and reaches the control
ports of the travel -lh spool (35) and the travel -rh spool (46) after passing through the pilot lines (31) and (11)
respectively; at the same time, the control oil in the control cavity-lh of the travel -lh spool (35) and the travel -
rh spool (46) flows back to tank (40) after passing through the piping (32) and (12), oil port 2 and 4 of the travel
pilot valve (13) and the pilot return line (38); with the action of the respective pilot control pressure, the travel -
lh spool (35) and the travel -rh spool (46) reverse to corresponding position respectively, at this moment, the
travel fast-slow gear control switch is in the "Rabbit" state of the fast gear, namely, energizing the solenoid
valve (37) of the four-step solenoid valve group (39) to make it reverse; the pilot control pressure reaches the
transmission reverse valve (28) and (22) of the travel motor-lh and the reducer (1) as well as the travel motor-
rh and reducer (2) after passing through the piping, center slewing joint (30) and the travel fast-slow gear
control line (14) to push the reverse valve to reverse; at this moment, the oil inlet pressure of the motor-rh
enters the variable cylinder (24) of the travel motor-rh after passing through the check valve (21), transmission
reverse valve (22) and the control passage (23), while the oil inlet pressure of the motor-lh enters the variable
cylinder (29) of the travel motor-lh after passing through the check valve (27) and the transmission reverse
valve (28), thus, with the action of the oil inlet pressure, the left and right motors are in the position with the
least discharge capacity, which is called "fast gear" state;
3-228
The pressure oil output from the left pump (42) of the main pump reaches the port A of the left travel motor &
speed reducer (1) after passing through the pressure passage (36), left travel spool (35), center revolving joint
(30) and the port B piping (8) of left travel motor; the pressure oil enters the motor by passing through the
motor port B passage (10); at the same time, the pressure oil pushes the balanced valve (6) to reverse by
passing through the control passage (9), and the pressure oil enters the motor brake (3) to unlock after passing
through the balanced valve (6) and the control passage (4); the return oil of the motor connects with the
hydraulic oil tank (40) after passing through the return passage (5) and balanced valve (6) to port A, and then
passing through the port A piping (7) of left travel motor, the center revolving joint (30) and the left travel spool
(35); at the same time, the pressure oil of the right pump (43) reaches the port A of the right travel motor &
speed reducer (2) after passing through the check valve (45), right travel spool (46), center revolving joint (30)
and the port B piping (16) of right travel motor; the pressure enters the motor by passing through the motor port
A passage (17); at the same time, the pressure oil pushes the balanced valve (19) to reverse by passing
through the control passage (18), and the pressure oil enters the motor brake (25) to unlock after passing
through the balanced valve (19) and the control passage (26); the return oil of the motor reaches the port B of
the balanced valve (19) after passing through the return passage (20) and the balanced valve (19), and then
connects with the hydraulic oil tank (40) after passing through the port B piping (15) of right travel motor, center
revolving joint (30) and the right travel spool (46); thus, with the action of the pressure oil, the left and right
motors and the speed reducer drive the machine to move backward slowly. Since the reversing of the right
travel spool (46), the return passage outputting the control pressure from the pilot valve group (45) port B is
stopped and produced a pressure which acts on the pressure switch (44) after passing through the control
passage (47) and (48), and then the pressure switch (44) transmits the electrical signal to realize the function
of a travel warning.
3-229
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3-230
2. Rexroth System
Figure of Rexroth System Travel Forward (Fast)
CLG920E922E03052
3-231
1. Pilot pump 20. Motor brake

2. Upper pump 21. Unlock pressure oil passage
3. Hydraulic tank 22. Port B oil passage of left travel motor
4. Lower pump 23. Port B pipeline of left travel motor
5. Pilot valve group 24. Pressure passage
6. Solenoid valve 25. Port A oil passage of right travel motor
7. Solenoid valve 26. Transmission reversing valve
8. Pilot control oil line 27. Variable displacement cylinder
9. Travel pilot valve 28. Right travel motor
10. Left travel spool 29. Motor brake
11. Port A pipeline, left travel motor 30. Unlock pressure oil passage
12. Port A oil passage of left travel motor 31. Three-way shuttle valve
13. Control passage 32. Port B oil passage of right travel motor
14. Balanced spool 33. Balanced spool
15. Three-way shuttle valve 34. Control passage
16. Transmission reversing valve 35. Port A pipeline, right travel motor
17. Travel fast and slow gear control line 36. B port pipeline, right travel motor
18. Variable displacement cylinder 37. Pressure passage
19. Left travel motor 38. Right travel spool
When the travel fast-slow gear control switch is in the "Rabbit" state and the travel pilot valve (9) is operated
toward forward, the pilot pressure reaches the port 1 and port 3 of the travel pilot valve (9) after passing
through the pilot valve group (5) and the solenoid valve (6) from the pilot pump (1), and reaches the control
ports of the left travel spool (10) and the right travel spool (38) after passing through the pilot line (8)
respectively; at the same time, the control oil in the left control cavity of the left travel spool (10) and the right
travel spool (38) flows back to tank (3) after passing through the line (8), oil port 2 and 4 of the travel pilot valve
(9) and the pilot return line; with the action of the respective pilot control pressure, the left travel spool (10) and
the right travel spool (38) reverse to corresponding position respectively, at this moment, the travel fast-slow
gear control switch is in the "Rabbit" state of the fast gear, namely, energizing the solenoid valve group (7) to
make it reverse; the pilot control pressure reaches the transmission reverse valve (16) and (26) of the left
travel motor and the reducer (19) as well as the right travel motor and reducer (28) after passing through the
piping, center revolving joint and the travel fast-slow gear control line (17) to push the reverse valve to reverse;
at this moment, the oil inlet pressure of the right motor enters the variable cylinder (27) of the right travel motor
after passing through the three-way shuttle valve (31), transmission reverse valve (26) and control passage
(34), while the oil inlet pressure of the left motor enters the variable cylinder (18) of the left travel motor after
passing through the three-way shuttle valve (15) and the transmission reverse valve (16), thus, with the action
of the oil inlet pressure, the left and right motors are in the position with the least discharge capacity, which is
called "fast gear" state;
3-232
The pressure oil output from the lower pump (4) of the main pump flows through the pressure passage (24),
the left travel spool (10), the center revolving joint, the port B pipeline (23) of the left travel motor to the Port B
of the left travel motor and speed reducer (19). Pressure oil enters the motor through passage (22) at Port B of
the motor. At the same time, the control passage (13) pushes the balanced valve (14) to reverse, and the
pressure oil enters the motor brake (20) through the balanced valve (14) and the unlocking pressure passage
(21) to unlock. The return oil of the motor is sent to Port a of the motor through the oil return passage (12) and
the balanced valve (14), and then connected to the hydraulic tank (3) through the pipeline (11) of Port A of the
left travel motor, the center revolving joint and the left travel spool (10). At the same time, the pressure oil of
upper pump (2) flows through port a pipeline (35) of right travel valve element (38), center revolving joint and
right travel motor to Port A of right travel motor and speed reducer (28). Pressure oil enters the motor through
passage (25) at Port A of the motor. At the same time, the control passage (34) pushes the balanced valve
(33) to change direction, and the pressure oil enters the motor brake (29) through the balanced valve (33) and
the unlocking pressure passage (30) to unlock. The oil passage (32) at Port B of the right travel motor, the
balanced valve (33) to Port B of the motor are connected with the hydraulic oil tank (3) through the pipeline
(36) at port B of the right travel motor, the center revolving joint and the right travel spool (38). In this way, the
left and right motors and speed reducers drive the complete machine to move forward quickly under the action
of pressure oil.
3-233
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3-234
3.3.3.16 Travel Backward (Slow)

Travel backward (slow)
1. Kawasaki System
Figure of Kawasaki System Travel Backward (Slow)
LG922E930E03154
3-235
1. Left travel motor & speed reducer 25. Motor brake

2. Right travel motor & speed reducer 26. Control passage
3. Motor brake 27. Check valve
4. Unlock pressure oil passage 28. Transmission reversing valve
5. Port A oil passage of motor 29. Variable displacement cylinder
6. Balanced valve 30. Center revolving joint
7. Port A pipeline of left travel motor 31. Pilot control oil line
8. Port B pipeline of left travel motor 32. Pilot control oil line
9. Control passage 33. Solenoid valve
10. Port B port passage of motor 35. Left travel spool
11. Pilot control oil line 36. Pressure oil passage
12. Pilot control oil line 37. Solenoid valve
13. Travel pilot valve 38. Pilot return lines
14. Travel fast and slow gear control line 39. Four-step solenoid group
15. Port B pipeline of right travel motor 40. Hydraulic oil tank
16. Port A pipeline of right travel motor 41. Pilot pump
17. Port A oil passage of motor 42. Left pump
18. Control passage 43. Right pump
19. Balanced valve 44. Pressure switch
20. Oil return passage 45. Pilot valve group
21. Check valve 46. Right travel spool
22. Transmission reversing valve 47. Control passage
23. Control passage 48. Control passage
24. Variable displacement cylinder
3-236
When the travel fast-slow control switch is in the slow "Tortoise" state, the travel pilot valve (13) is operated
backward at the same time. The pilot pressure from the pilot pump (41) to the port 2 and port 4 of the travel
pilot valve (13) through the pilot valve group (45) and the solenoid valve (33), and then to the control ports of
the left travel valve spool (35) and the right travel valve spool (46) through the pilot lines (32) and (12),
respectively. At the same time, the control oil in the right control cavity of the left travel valve spool (35) and the
right travel valve spool (46) flows back to the tank (40) through the pipeline (31) and (11), the oil ports 1 and 3
of the travel pilot valve (13), and the pilot return pipeline (38). The left travel valve spool (35) and the right
travel valve spool (46) change the direction to corresponding positions under the respective pilot control
pressure. At this time, the travel fast-slow control switch is in the slow "Tortoise" state, that is, the solenoid
valve (37) of the quadruple solenoid valve group (39) is de-energized to reset it (as shown in the figure), and
the control pressure (14) is returned to the tank through the solenoid valve (37) of the pilot valve group (39).
The variable speed reversing valves (28) and (22) are reset under the action of springs. The control pressure
in the variable cylinders (29) and (24) of the left and right propelling motors are respectively connected with the
motor housing drainage port RDR through the variable speed reversing valves (28) and (22) and returned to
the tank. In this way, the variable cylinder of the left and right motors is under the action of the spring force, so
that the motor is in the position of the maximum displacement, that is, in the state of "slow gear". The pressure
oil output from the left pump (42) of the main pump flows through the pressure passage (36), the left travel
valve spool (35), the center revolving joint (30), the port A pipeline (7) of the left travel motor to the port A of the
left travel motor and the speed reducer (1); the pressure oil enters the motor through the port A oil passage (5)
of the motor. At the same time, the balanced valve (6) is pushed to change direction through the control
passage (9), and the pressure oil enters the motor brake (3) through the balanced valve (6) and the control
passage (4) to unlock. The returned oil of the motor is supplied to port B of the motor through the return
passage (10), the balanced valve (6), and then connected to the hydraulic tank (40) through the pipeline (8) of
port B of the left travel motor, the center revolving joint (30) and the left travel valve spool (35). At the same
time, the pressure oil of the right pump (43) flows through the check valve (45), the right travel valve spool (46),
the center revolving joint (30), and the B port pipeline (15) of the right travel motor to the B port of the right
travel motor and the reducer (2); the pressure oil enters the motor through the B port oil passage (20) of the
motor. At the same time, the balanced valve (19) is pushed to change direction through the control passage
(18), and the pressure oil enters the motor brake (25) through the balanced valve (19) and the control passage
(26) to unlock. The return oil of the motor is sent to port a of the motor through the return passage (17), the
balanced valve (19), and then connected to the hydraulic tank (40) through the pipeline (16) of port A of the
right travel motor, the center revolving joint (30) and the right travel valve spool (46). In this way, the left and
right motors and speed reducers drive the complete machine backward and slowly under the action of
pressure oil.
Since the reversing of the right travel spool (46), the return passage outputting the control pressure from the
pilot valve group (39) port B is stopped and produced a pressure which acts on the pressure switch (44) after
passing through the control passage (47) and (48), and then the pressure switch (44) transmits the electrical
signal to realize the function of a travel warning.
3-237
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3-238
2. Rexroth System
Figure of Rexroth System Travel Backward (Slow)
CLG920E922E03053
3-239
1. Pilot pump 20. Motor brake

2. Upper pump 21. Unlock pressure oil passage
3. Hydraulic tank 22. Port B oil passage of left travel motor
4. Lower pump 23. Port B pipeline of left travel motor
5. Pilot valve group 24. Pressure passage
6. Solenoid valve 25. Port A oil passage of right travel motor
7. Solenoid valve 26. Transmission reversing valve
8. Pilot control oil line 27. Variable displacement cylinder
9. Travel pilot valve 28. Right travel motor
10. Left travel spool 29. Motor brake
11. Port A pipeline, left travel motor 30. Unlock pressure oil passage
12. Port A oil passage of left travel motor 31. Three-way shuttle valve
13. Control passage 32. Port B oil passage of right travel motor
14. Balanced spool 33. Balanced spool
15. Three-way shuttle valve 34. Control passage
16. Transmission reversing valve 35. Port A pipeline, right travel motor
17. Travel fast and slow gear control line 36. B port pipeline, right travel motor
18. Variable displacement cylinder 37. Pressure passage
19. Left travel motor 38. Right travel spool
When the travel fast-slow control switch is in the fast "Tortoise" state, the travel pilot valve (9) is operated
forward at the same time. The pilot pressure from the pilot pump (1) to the port 2 and Port 4 of the travel pilot
valve (9) through the pilot valve group (5) and the solenoid valve (6), and then to the control ports of the left
travel valve spool (10) and the right travel valve spool (38) through the pilot pipeline (8). At the same time, the
control oil in the right control cavity of the left travel valve spool (10) and the right travel valve spool (38) flows
back to the tank (3) through the pipeline (8), the oil ports 2 and 4 of the travel pilot valve (9), and the pilot return
pipeline. The left travel valve spool (10) and the right travel valve spool (38) change direction to corresponding
positions under the respective pilot control pressure. At this time, the travel fast-slow control switch is in the
fast "Tortoise" state, that is, the solenoid valve group (7) is powered off to reset, the control pressure (17)
passes through the solenoid valve (7) and the pilot valve group (5) to the tank; the variable speed directional
valves (16) and (26) are reset under the action of springs, and the control pressure in the left and right travel
motor variable cylinders (18) and (27) is respectively connected with the oil drain port Dr of the motor housing
through the variable speed reversing valve (16) and (26) and returns to the tank. In this way, the variable
cylinder of the left and right motors is under the action of the spring force, so that the motor is in the position of
the maximum displacement, that is, in the state of "slow gear".
The pressure oil output from the lower pump (4) of the main pump reaches the Port A of the left travel motor &
speed reducer (19) after passing through the pressure passage (24), left travel spool (10), center revolving
joint (30) and the Port A pipeline (11) of left travel motor; the pressure oil enters the motor by passing through
the motor Port A passage (12); at the same time, the pressure oil pushes the balanced valve (14) to reverse by
passing through the control passage (13), and the pressure oil enters the motor brake (20) to unlock after
passing through the balanced valve (14) and the unlocking passage (21); the return oil of the motor connects
with the hydraulic tank (3) after passing through the oil return passage (22) and balanced valve (14) to the Port
B, and then passing through the left travel motor Port B pipeline (23), the center revolving joint and the left
travel spool (10); at the same time, the pressure oil of the upper pump (43) reaches the Port B of the right
travel motor & speed reducer (28) after passing through the pressure oil circuit (37), travel right spool (38),
center revolving joint and the right travel motor Port B pipeline (36); the pressure oil enters the motor by
passing through the motor Port B passage (32); at the same time, the pressure oil pushes the balanced valve
(33) to reverse by passing through the control passage (34), and the pressure oil enters the motor brake (29)
to unlock after passing through the balanced valve (33) and the unlocking pressure circuit (30); the return oil of
the motor reaches the Port A of the balanced valve (33) after passing through the return passage (25) and the
balanced valve (33), and then connects with the hydraulic tank (3) after passing through the left travel motor
Port A pipeline (35), center revolving joint and the right travel (38); thus, with the action of the pressure oil, the
left and right motors and the speed reducer drive the machine to move backward slowly.
3-240
3.3.3.17 Bilateral Travel and Boom Rising Compound Operation

Straight travel
1. Kawasaki System
Figure of Kawasaki System Straight Travel
3-241
1. Left travel motor & speed reducer 11. Pilot control oil line
2. Travel pilot valve 12. Pilot control oil line
3. Right-hand pilot valve 13. Orifice
4. Solenoid valve 14. Pilot control oil line
5. Boom spool 1 15. Pilot control oil line
6. Left travel spool 16. Pilot valve group
9. Straight travel valve 19. Pilot pump
10. Orifice 20. Right travel spool
21. Right travel motor & speed reducer
Under normal travel state (namely without other actions), the left pump (17) supplies oil to the left travel spool
(6) and the right pump (18) supplies the oil to the right travel spool (20). With the both sides traveling, when
any actions of the slewing or working implement are operated synchronously, the control pressure (11) of the
straight travel valve (9) is produced because of the stopping function of the spool reversing of the travel spool
and the boom or the work implement, which pushes the straight travel valve (9) to reverse, at this moment, the
output oils of the left and right pumps are distributed again by passing through the straight travel valve (9); the
pressure oil output from the right pump (18) is supplied to the left and right travel valve, and the pressure oil
output from the left pump (17) is supplied to the work implement preferentially, then, the redundant oil is
supplied to travel, thus, it is equal to that the left and right travel is supplied by one oil source, which keeps
them traveling straightly.
3-242
2. Rexroth System
Figure of Rexroth System Straight Travel
B
A
BOOM CYLINDER
动臂油缸
A
B
CLG920E922E03054
3-243
1. Right-hand pilot valve 9. Pilot pump

2. Travel pilot valve 10. Upper pump
3. Pilot control oil line 11. Hydraulic tank
4. Boom spool 12. Lower pump
5. Left travel motor & speed reducer 13. Pilot valve group
6. Left travel spool 14. Solenoid valve
7. Right travel motor & speed reducer 15. Solenoid valve
8. Right travel spool 16. Switching valve spool
Under normal travel state (namely without other actions), the lower pump (12) supplies oil to the left travel
spool (6) and the upper pump (10) supplies the oil to the right travel spool (8). With the both sides traveling,
when any actions of the slewing or working implement are operated synchronously, the solenoid valve (14) is
energized to supply oil to the switching valve spool (16) which (16) moves to the corresponding position under
the action of the pilot pressure. At this moment, the output oil of the upper and lower pumps is redistributed
through the switching valve (16); and the pressure oil of the upper pump (10) is supplied to the left and right
travel valve spool. The pressure oil output from the lower pump (12) is supplied to the work implement, thus, it
is equal to that the left and right travel is supplied by one oil source, which keeps them traveling straightly.
3-244
3.4 Work Implement CLG920E/922E/923E
3.4 Work Implement

3.4.1 Sizes of Components
K
3-245
CLG920E/922E/923E 3.4 Work Implement
No. Item Criteria Measures
Clearance Tolerance Standard Permissible

Standard size
between mounting Shaft Hole clearance clearance
pin shaft and -0.036 mm +0.187 mm 0.123~0.258 0.123~1.0
1
bushing of φ90 mm {-0.0014 In} {+0.0074 In} mm mm
revolving frame {3.54 In} -0.071 mm +0.087 mm {0.0048~0.01 {0.0048~0.03
and boom {-0.0028 In} {+0.0034 In} In} 9 In}
Clearance
-0.036 mm +0.202 mm 0.123~0.273 0.123~1.0
between mounting
φ90 mm {-0.0014 In} {+0.008 In} mm mm
2 pin shaft and
{3.54 In} -0.071 mm +0.087 mm {0.0048~0.01 {0.0048~0.03
bushing of boom
{-0.0028 In} {+0.0034 In} 1 In} 9 In}
and arm
Clearance
-0.03 mm +0.147 mm 0.105~0.207 0.105~1.0
between mounting
φ80 mm {-0.0012 In} {+0.0058 In} mm mm
3 pin shaft and
{3.15 In} -0.06 mm +0.075 mm {0.0041~0.00 {0.0041~0.03
bushing of arm and
{-0.0024 In} {+0.003 In} 81 In} 9 In} Replace
bucket
Clearance
-0.03 mm +0.154 mm 0.092~0.214 0.092~1.0
between mounting
φ70 mm {-0.0012 In} {+0.0061 In} mm mm
4 pin shaft and
{2.76 In} -0.06 mm +0.062 mm {0.0036~0.00 {0.0036~0.03
bushing of arm and
{-0.0024 In} {+0.0024 In} 84 In} 9 In}
rocker lever
Clearance
-0.03 mm +0.154 mm 0.092~0.214 0.092~1.0
between mounting
φ70 mm {-0.0012 In} {+0.0061 In} mm mm
5 pin shaft and
{2.76 In} -0.06 mm +0.062 mm {0.0036~0.00 {0.0036~0.03
bushing of link and
{-0.0024 In} {+0.0024 In} 84 In} 9 In}
rocker lever
Clearance
-0.03 mm +0.165 mm 0.114~0.225 0.114~1.0
between mounting
φ80 mm {-0.0012 In} {+0.0065 In} mm mm
6 pin shaft and
{3.15 In} -0.06 mm +0.084 mm {0.0045~0.00 {0.0045~0.03
bushing of link and
{-0.0024 In} {+0.0033 In} 89 In} 9 In}
bucket
3-246
3-247
3.4.2 Arm Part

3-248
Measurement Tolerance
No. Standard size
position Shaft Hole
-0.03 mm +0.074 mm
φ80 mm {-0.0012 In} {+0.0029 In}
1 -
{3.15 In} -0.076 mm 0 mm
{-0.003 In} {0 In}
+1.5 mm
108 mm {+0.059 In}
Arm side
{4.25 In} 0 mm
{0 In}
2
0 mm
106 mm {0 In}
Cylinder side
{4.17 In} -0.5 mm
{-0.0197 In}
-0.036 mm +0.054 mm
φ90 mm {-0.0014 In} {+0.021 In}
3 -
{3.54 In} -0.071 mm 0 mm
{-0.0028 In} {0 In}
+0.5 mm
310 mm {+0.0197 In}
Boom side
{12.2 In} 0 mm
{0 In}
4
0 mm
307 mm {0 In}
Arm side
{12.09 In} -0.5 mm
{-0.0197 In}
187.2 mm ±0.5 mm
5 -
{7.37 In} {±0.0197 In}
407.8 mm ±0.5 mm
6 -
{16.06 In} {±0.0197 In}
829.1 mm ±1 mm
7 -
{32.64 In} {±0.039 In}
2909 mm ±4 mm
8 -
{114.53 In} {±0.157 In}
2630.6 mm ±1 mm
9 -
{103.57 In} {±0.039 In}
410 mm ±1 mm
10 -
{16.14 In} {±0.039 In}
640 mm ±0.5 mm
11 -
{25.2 In} {±0.0197 In}
600 mm ±0.5 mm
12 -
{23.62 In} {±0.0197 In}
475 mm ±0.5 mm
13 -
{18.7 In} {±0.0197 In}
1450 mm
14 - -
{57.09 In}
3-249
Measurement Tolerance
No. Standard size
position Shaft Hole
-0.03 mm +0.174 mm
φ80 mm {-0.0012 In} {+0.0069 In}
15 -
{3.15 In} -0.06 mm +0.1 mm
{-0.0024 In} {+0.0039 In}
0 mm
306 mm {0 In}
Link itself
{12.05 In} -0.5 mm
{-0.0197 In}
16
0 mm
When pressing and 336 mm {0 In}
installing the bushing {13.29 In} -0.7 mm
{-0.028 In}
-0.03 mm +0.174 mm
φ80 mm {-0.0012 In} {+0.0069 In}
17 -
{3.15 In} -0.06 mm +0.1 mm
{-0.0024 In} {+0.0039 In}
0 mm
314.5 mm {0 In}
Arm itself
{12.38 In} -0.5 mm
{-0.0197 In}
18
0 mm
When pressing and 336.5 mm {0 In}
installing the bushing {13.25 In} -0.7 mm
{-0.028 In}
1680 mm ±4 mm
Minimum
{66.14 In} {±0.157 In}
19
2800 mm ±7 mm
Maximum
{110.24 In} {±0.28 In}
3-250
3.4.3 Bucket Part
2 5
9
6
7
A
4
11
1
3
B
8
10
A-A
15
14 12 13
19
18
17
16
18
19
20
B-B
15
14 12 13
19
18
17
16
18
19
20
LG936E4F03110
3-251
No. Standard size Tolerance

1 474.6 mm {18.69 In} ±0.5 mm {±0.0197 In}
2 19.1 mm {0.75 In} ±0.5 mm {±0.0197 In}
3 92.3° -
4 475 mm {18.7 In} ±0.5 mm {±0.0197 In}
5 1450 mm {57.09 In} -
6 195.6 mm {7.7 In} -
7 131.7 mm {5.19 In} -
8 100.2 mm {3.94 In} -
9 R110 mm {4.33 In} -
10 R95 mm {3.74 In} -
11 R1200 mm {47.24 In} -
+0.5 mm {+0.0197 In}
12 337 mm {13.27 In}
0 mm {0 In}
13 68 mm {2.68 In} -
14 93 mm {3.66 In} -
15 480 mm {18.9 In} -
+0.54 mm {+0.021 In}
16 φ80 mm {3.15 In}
0 mm {0 In}
17 φ85 mm {3.35 In} -
18 φ140 mm {5.51 In} -
19 φ160 mm {6.3 In} -
20 φ21 mm {0.83 In} -
3-252
3.5 A/C System CLG920E/922E/923E
3.5 A/C System

3.5.1 Layout Diagram of A/C Pipeline
1. A/C air duct 6. A/C Condenser

2. Evaporator assembly (HVAC) 7. Refrigerant pipeline
3. Thermal return pipeline A: Fresh air intake
4. Thermal inlet pipeline B: Internal circulation air
5. A/C Compressor C: Cold and hot air
3-253
CLG920E/922E/923E 3.6 Electrical System
3.6 Electrical System
3.6.1 Engine Control
Engine
Frequent power
Power supply signal supply signal
Control signal
Sensor signal
of start motor of start motor
ECM control start signal

Start signal of
main controller
Engine controller
Control signal
of pilot lever Start relay
(Sensor signal)
Power supply
signal
CAN bus
Speed control
signal and other
signals
Power-on signal
of electric lock
Main controller
Battery relay
Electric lock start signal
Accelerator knob signal
Fuel level signal
Battery
LG922E930E03161
1. Start the engine

When the engine start switch is turned to the "START" position, the engine start switch starting signal is
detected by the main controller, and then the main controller sends main controller control starting signal to
transmit the power supply signal to the power end of the start motor, then the engine is started.
(Note: The starting signal of the starter relay is controlled by the ECM, and the starter relay is driven jointly by
the main controller control starting signal and the pilot handle control signal. When the machine is free of
failure, and the excavator is started following the correct steps, the starting process of the engine is described
as above.)
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3.6 Electrical System CLG920E/922E/923E
At the same time, the main controller detects the accelerator knob signal, and sets the corresponding engine
speed of the accelerator knob as the set speed, then sends the speed control signal to the engine controller via
the CAN bus, so as to control the oil feed pump and make the current speed become the set speed steadily.
2. Engine speed control
Each gear of the accelerator knob corresponds to an engine speed, and the engine controller controls the oil
injection quantity according to the speed control signal sent by the main controller, so as to control the engine
speed.
3. Stop the engine
When the engine start switch is turned to the "OFF" position, the engine stops.
3.6.2 Display System
Engine controller
(Alarm signal and

engine state
CAN bus information)
(Alarm signal and

hydraulic system Command signal
information)
Main controller Display
The operator can obtain the operating condition of complete machine through the display system. The display
shares the data with the engine controller and the main controller via CAN bus, and the information of the
machine is displayed on the LCD screen.
The contents displayed on screen can be divided into the following parts.
1. Alarm information when the complete machine fails;
2. Working condition information of the machine (including the engine speed, hydraulic oil temperature, etc.).
3. Maintenance information of the machine.
4. The keys for special purposes (part of the keys are equipped with LED indicator) on the control panel of the
display are used to operate the control system of the machine.
LiuGong has two displays, which are as follows:
1. Ordinary display+
2. Smart display
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3.6.2.1 Ordinary Display
LCD
Button panel
Performance
1. With LCD screen, the backlight brightness is

adjustable.
2. Internal integrated microprocessor and storage
unit.
3. A build-in buzzer is installed, the volume is
adjustable and the mute is available.
4. Build-in button battery
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Pin definition
Signal Input and output port

Pin number Description
Name Function
1 CAN Low CAN Low
2 CAN Shield CAN Shield
3 NC1 The pin is not adopted
4 NC - The pin is not adopted
5 Earth Grounding
6 Battery power supply Battery voltage 24V, always connect with the battery
8 CAN High CAN High
10 Earth Grounding
Input 24V when the start switch is
26 Engine start switch ON Number input
turned to "on" position
1. NC indicates that the PIN is not adopted

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LCD Display Section

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Icon
Icon Content Description
color
Work mode The work mode is P, E, F, L, B and ATT.
Blue The accelerator has 12 gears changing from "1" to "12", and
Accelerator
when the accelerator knob is failed, the icon in this place is
Normal gear
nothing
display
Time Display the real time of that very day
Black
Operating hour Engine total operation time
Display when the travel speed is fast: , display when the

Travel speed
travel speed is slow:
Idling function When the idling function is enabled, the icon will be displayed
1) When the automatic power boosting function is valid, the

icon is always displayed on the main interface no matter
whether the engine is operating.
2) Manual power boosting, when the manual transient power
Function Transient
Black boosting knob is pressed, the icon will be displayed; when the
state display power boosting
manual power boosting knob is released, the icon will
function
disappear.
3) Under the L mode, the icon will be displayed all the time
unless the vehicle is in the travel state, and the automatic
power boosting cannot be canceled under the L mode.
Preheating When the preheating function is used, the icon will be
function displayed, otherwise it will not be displayed
Flattening When the flattening function is enabled, the icon will be
function displayed, otherwise, it will not be displayed
Digging When the digging function is enabled, the icon will be
function displayed, otherwise, it will not be displayed.
Battery is not It will warn when the battery is not charged, and at this
charged moment, check the charging circuit and eliminate the failure
Fuel contains
It will warn when the fuel contains water
water
Engine oil
Warning High alarm of engine oil pressure
pressure
information Red
display
Coolant level It will warn when the coolant level is low
Engine oil level It will warn when the engine oil level is low
Air filter alarm Blockage alarm of air filter

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Icon
color
Hydraulic oil
It will warn when the hydraulic oil temperature exceeds the limit
temperature
It will warn when the hydraulic oil level is low, and this function
Hydraulic oil
Warning requires that the hydraulic oil level switch is equipped on the
level
information Red machine
display It will warn when the lifting load is higher than the system
Over lifting load
specified value
Maintenance The icon will be displayed when there are some maintenance
service items not finished by the user
When the machine is failed, the failure will be displayed in the
Warning
form of text or the LiuGong DTCs.
information
In case of the warning caused by the system failures, the red
display
alarm bell icon will flicker all the time.
Scope
Color Description
%
When the icon is filled with red color
accompanied by the warning information
≤10 Red
of "Low fuel level", indicate that the fuel
Virtual gage Fuel Level level is too low
When the icon is filled with yellow color, it
Yellow
indicates that the fuel level is slightly low
When the icon is displayed normally, it
Green
indicates that the fuel level is normal
Range °C Color Description
Normal
Blue
temperature
Normal
Green
Coolant temperature
Virtual gage temperature Yellow High temperature
Overhigh
Red
temperature
Extremely high
Red
temperature
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Display Key Panel For the machine equipped with the attachment, the
B/ATT mode is invisible in the selecting menu
unless the B/ATT is enabled.
When the B mode or the ATT mode is selected, the
system will pop up the following information prompt
box:
Confirm to enter broken mode?
Yes No
Confirm to enter hydraulic cutter mode?
There are 6 buttons for special purposes on the

panel, and the LED indicators are equipped for part Yes No
of the buttons.
1. Working mode selecting key has no LED
indicator 2. A LED indicator is equipped for the digging
Press the key to make the mode selection menu function key at the top left corner.
pop up, and then the user can select the expected
working mode. Press the key to trigger the trenching mode When
the digging function is enabled, the corresponding
icon on the main interface and the LED indicators
(beside the key) on the panel will be illuminated.
High-speed mode
The digging function and the flattening function are
Economic mode not mutually exclusive - namely the both functions
can be enabled at the same time.
Fine mode 3. A LED indicator is equipped for the flattening
Lifting mode function key at the top left corner and press
Broken mode the key to trigger the flattening function When

the flattening function is enabled, the
Hydraulic cutter mode
corresponding icon on the main interface and
the LED indicators (beside the key) on the panel
will be illuminated.
When the working mode selecting menu pops up,
press the working mode key again to close the The digging function and the flattening function are
menu. not mutually exclusive - namely the both functions
About the B and ATT mode
5. LED indicator is equipped on both sides of the
travel speed control key (rabbit/tortoise)
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Press the key to switch between the low speed state Moreover, there are eleven common/navigation
and high speed state, and the corresponding icon keys on the panel:
(rabbit/tortoise) on the main interface and the two
1. The 4 keys are F1, F2, F3 and F4 respectively,
corresponding LED indicators (beside the key) will
which are defined as the display soft keys
switch synchronously.
2. Four navigation keys (up/down/left/right)
The travel icon on the display and the LED indicator
is only consistent with the state selected by the 3. Selection key is marked as "O" - the function of
user, not the state of the travel solenoid valve. which is similar to the clicking or selecting
Similarly, the selected state (indicating icon or light) function of the mouse left button
is not affected by whether the vehicle is in the
4. Confirm key (green), mark "√" signal - for OK,
running state or whether the travel solenoid valve is
entrance or confirm function
failed.
5. Cancel key (red) is marked as "×" - used to
4. A LED indicator is equipped for the automatic
cancel, exit or negate
idle speed control key at the top right
corner
Press the key to trigger the automatic idle speed
function. The corresponding icon on the main
interface and LED indicator (beside the key) will be
illuminated synchronously.
5. A LED indicator is equipped for the travel buzzer
mute key (outlaid horn) at the top right
corner
When the vehicle is running, the controller controls

the buzzer to enable. At this moment, the user can
turn off the travel buzzer (and turn it on again, if the
vehicle is still in running state).
When the buzzer is enabled, the LED indicator
beside it will be illuminated synchronously.
When the vehicle is stationary, the buzzer cannot be
enabled or turned off by pressing the key
Note: The main sequence is as follows:
a. Vehicle starts to run- the travel buzzer sounds
and the LED indicator is illuminated
b. User presses the mute key - the travel buzzer
is turned off and the LED indicator goes off
c. Vehicle stops running - travel buzzer mute
requests to turn off, namely, invalid
d. Vehicle runs again - travel buzzer sounds,
and the LED indicator is illuminated again
(namely, the previous mute operation is
invalid)
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Software Introduction
Soft key Name Function introduction

Internal buzzer The soft key can be displayed only when the internal buzzer sounds and is able to
mute become mute
Current fault Press the key and the system will enter the current failure interface.
Set Press the key and the system will enter the setting interface.
Display setting Press the key and the system will enter the display setting interface.
Press the key and the system will enter the maintenance interface, which mainly
Maintenance displays the information of the item requiring maintenance. The key will be displayed all
the time even if there is no maintenance item.
Maintenance
Press the key and the system will enter the maintenance help interface.
help
Press the key and the system will enter the main interface. Press the X key (with no
Main interface small windows popped up) to return to the main interface no matter what interface is
displayed.
Press the key and the system will enter the service mode menu interface. Note: The
Service mode key shares a same position with the internal buzzer mute key, and it will be hidden
menu when the internal buzzer mute key icon is displayed. This key and the corresponding
functions can be visible only when the mute key is pressed to make the buzzer silent.
Machine state Press the key and the system will enter the machine state interface.
Specific
machine state Press the key and the system will enter the specific machine state interface.
interface
Press the key and the system will make the parameter configuration window pop up
Parameter
under the machine state interface. Invoking this key will make the display enter a
configuration
specific working mode, under which the user can select the parameters expected to
mode
monitor in the popped up window list.
Historical failure Press the key and the system will enter the historical failure interface.
Maintenance Press the key and the system will enter the maintenance history interface. If there is no
history maintenance history record at present, the soft key function will be off (icon is gray).
New
Press this key and the system will enter the maintenance operation interface. Under
maintenance
this interface, the user can perform the maintenance operation and record.
record
This key and its function can be visible only in the maintenance operation interface, and
Save
can be used only when one or more maintenance items are selected. Press this key
maintenance
and a new maintenance record will be created, and the interface will be switched to the
record
"Save this record" interface under the maintenance history interface synchronously.
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Soft key Name Function introduction

This key and its function can be visible only in the maintenance operation interface.
Press this key and the system will cancel the saving of this maintenance record
Cancel
operation (namely cancel the selected maintenance item) and return to the
maintenance
maintenance interface. Note: In the maintenance operation interface, if any
record
maintenance item is selected, the display will ignore the X key operation (normally,
pressing the X key will return to the main interface) at this moment.
User Mode
1. Set
Press the "Set" key and the system will enter the setting interface. Some corresponding menu options for the
user to perform some basic settings are provided in this setting interface.
● Breaking hammer flow adjustment
● Attachment flow adjustment
● Date/ time set
● Language setting
● Lifting overload monitoring
● Automatic transient power boosting
Breaking hammer flow adjustment
Attachment flow adjustment
Set date/time
Language settings
Lifting overload monitoring
Automatic transient power boosting
1. Breaking hammer flow adjustment

It can be set only when the working mode is B mode, namely, the flow can be set and adjusted by the user.
This adjustment is invalid in other working modes, namely, this option is gray and cannot be selected.
Under the B mode, move the cursor to this option, and press the O-type key to activate the functions of this
option. Then, the user can adjust the level from 1 to 4 between the L level and H level using the left/right
navigation keys.
After that, press the "√" key to confirm. Press the "X" key to cancel the current setting.
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2. Attachment flow adjustment Select the required language using the navigation
keys (up/down) and press the "O" - type key or "√"
It can be set only when the working mode is in ATT
to confirm. Press the "×" key to cancel the current
mode, and the operation instruction is similar to that
setting.
of the breaking hammer.
Under the ATT mode, move the cursor to this
Breaking hammer flow adjustment
option, and press the 0-type key to activate the
functions of this option. Then, the user can adjust Attachment flow adjustment
the level from 1 to 4 between the L level and H level Set date/time
using the left/right navigation keys. Language
After that, press the "√" key to confirm. Press the "X"
key to cancel the current setting.
Automatic transient power boosting
3. Date/time set
When this option is selected, the following date/time
setting dialog box will pop up. The time is displayed
in 24-hour. Press the navigation key to select the
year, month, day, hour, minute and second
respectively, and then press the O type confirmation 5. Lifting overload monitoring
key to make the virtual numeric keyboard pop up
This option can be selected only when the working
and enter the number to be set.
mode is L. As long as in the L mode, the over lifting
load monitoring function will be enabled, namely,
Set date/time
the block in the front of this option will be selected.
User can close this function, and meanwhile the
mark in the block will disappear.
5. Automatic transient power boosting
Set date/time
During each power on, the mark of the block in the
front of this option is nothing.
Under the L mode, this option is gray and not
optional, and the block is marked as selected.
When the vehicle is running, this option is gray (not
optional) and the block mark is empty.
Press the confirmation key "√" or the cancel key "×" 2. Display setting
(with the virtual numeric keyboard not displayed),
and the system will turn off the date/time setting Display setting interface includes the menu options
dialog box and return to the setting interface. Pay with which the different characteristics of the display
attention to that if the cancel key "×" is pressed, all can be adjusted by the user.
the setting will be canceled. ● Contrast
4. Language setting ● Brightness setting
Different languages can be selected (Chinese, ● Buzzer volume
English, etc.) by different customers.
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● Keytone ● Interval
Maintenance item Interval

Replace engine oil
Replace engine oil filter element
Replace fuel filter element
Keypad tone
1. Maintenance items
1. Contrast This list mainly displays the item names which are
Generally, the contrast of the LCD screen is about to expire or have expired but not maintained.
implemented according to the factory setting. Refer to the following list for the maintenance item
However, the user can adjust the contrast by and the interval.
moving the cursor bar. Maintenance item Interval
6. Brightness setting Replace engine oil 250h
User can move the cursor bar to set the LCD Replace engine oil filter element 250h
backlight brightness. There are two independent
Replace fuel filter element 250h
settings, which are the day mode and night mode.
Fill the lubricant for the swing bearing 500h
When the vehicle work light is on, the system will
enter the night mode, and meanwhile, the icon will Check the fuel oil filter 500h
changed as the "Moon": . Clean the exterior of the radiator 500h
7. Buzzer volume Replacing the return oil filter element of
500h
hydraulic
User can move the cursor bar to set the buzzer
volume in the display. Replace the air filter element 500h
Replace the pump filter element 1000h
Note: In case of the failure of the system, the buzzer
will warn in the highest volume regardless of the Replace the swing reduction gear oil 1000h
volume set by the user. Replace the pilot engine oil filter 1000h
8. Keytone Replace the hydraulic oil
Turn on/off the keytone with this option. Rinse the inlet filter element 1500h
Change coolant and clean the inner of
3. Maintenance 2000h
radiator
Replace the gear oil of travel reduction gear 2000h
This interface mainly displays the items which are
about to expire or have expired but not maintained.
This interface has two lists of contents.
● Maintenance items
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2. Interval Moreover, this information bar also includes the

date when the warning is triggered and the engine
This list displays the count down (engine working
working hours.
hours) of the item which is going to be maintained,
or the expired time for the item not maintained. For
Current fault:
the former (it is not time to maintain), the time Mechanical type
number is black; Blockage of air filter
if the interval is less than or equal to 10 hours, the

time background will be highlighted and is yellow.
For the latter (beyond the service period),add "-"
before hour and display white fond and red
background. Blockage of air filter
3. Current fault
All the failures are classified as 3 types, which are
electrical failure, mechanical failure and ECM
(engine). The corresponding failure is displayed
under the related failure classification. Each failure
information is defined by the LiuGong DTC with 6
digits or the Cummins DTC (4 digits), and is
displayed together with its failure information (at the
current failure interface). The failure information
displayed is red.
Current fault:
Mechanical type
Blockage of air filter
When a failure information is selected, press the

confirmation key and then a information bar of the
warning information will pop up? In this information
bar, different icons and colors indicate the different
warning levels. Namely, yellow color indicates the
general warning level while the red color indicates
the serious warning level.
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3.6.2.2 Smart Display
LG925E4F03166
Performance
1. With LCD screen, the backlight brightness is

adjustable.
2. Internal integrated microprocessor and storage
unit.
3. A build-in buzzer is installed, the volume is
adjustable and the mute is available.
4. Support CAN bus communication.
7\FR
1 7
20 26
LG925E4F03167
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Definition of connector pin:
Input and output

Pin number Signal name Description
port function
1 CAN Low CAN Low CAN Low
2 CAN Shield CAN Shield CAN Shield
5 Earth Grounding Grounding
8 CAN High CAN High CAN High
10 Earth Grounding Grounding
26 Engine start switch ON Switch input Input 24V when the ignition switch is turned to "on" position
Note: NC indicates that the stitch is not adopted.
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LCD Display Section
LG925E4F03168
The working modes are separately of "P", "E", "F", "L", "B" and
1 Working mode
"ATT".
2 Accelerator gear Accelerator has 12 gears in total from 1 to 12 respectively
3 Engine warming up The illuminated icon indicates the engine is warming up
When the flattening function is enabled, the icon will be displayed,

4 Flattening function
otherwise, it will not be displayed
When the digging function is enabled, the icon will be displayed,

5 Digging function
otherwise, it will not be displayed.
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1. When the automatic power boosting function is valid, the icon is
always displayed on the main interface no matter whether the
engine is operating.
2. Manual power boosting, when the manual transient power
Transient power boosting knob is pressed, the icon will be displayed; when the
6
boosting function manual power boosting knob is released, the icon will
disappear.
3. Under the L mode, the icon will be displayed all the time unless
the vehicle is in the travel state, and the automatic power
boosting cannot be canceled under the L mode.
Automatic idling When the automatic idling function is enabled, the icon will be
7
function displayed
It is displayed when the travel speed is fast: , display when

8 Travel speed
the travel speed is slow:
The illuminated icon indicates the engine is preheating and the

9 Preheating function
preheating time is 30s at most.
When the engine is running, the hour meter reading can increase
Operating hours of even if the machine does not move. The least significant digit of
10
engine the hour meter increases by one when the engine works for six
minutes.
It is normal when the indicator is within the green range.
If the indicator enters the red range when the hydraulic oil
Hydraulic oil temperature alarms as high, very high and extremely high during
11 -
temperature gauge operation, it indicates the oil temperature is 82°C or above, run the
engine at low idling speed or shut the engine to wait the oil
temperature decreases to the normal range.
It is normal when the indicator is within the green range.
If the indicator enters the red range when the coolant temperature
Engine coolant alarms as high, very high and extremely high during operation, it
12 -
temperature gauge indicates the coolant temperature is 102°C or above, run the
engine at low idling speed or shut the engine to wait the coolant
temperature decreases to the normal range.
Indicate the fuel quantity percent left in the fuel tank.
It is normal when the indicator is within the green range. If the
indicator enters the red range when the fuel quantity alarms as low
13 - Fuel gauge
level during operation, it indicates the fuel quantity percent is lower
than10% and then the time and alarm zone displays words and the
buzzer sounds. Replenish fuel in time.
It is illuminated to warn the operator that the set time is exceeded
since the latest maintenance. After 30s, the monitor screen goes
Maintenance interval
14 out and returns to the standard status.
hint
If the maintenance items are not reset, the monitor screen will go
out after 30s every time the machine is powered on.
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The zone displays alarm word, fault code, hint information when
Time and alarm necessary, otherwise, it displays the current time. When there are
15
indication several massages to be displayed, these massages will be shown
cyclically.
Switch function It indicates the detailed functions of F1~F6 buttons in the current
16
indication interface.
Display Key Panel
LG925E4F03270
The standard screen is displayed as the figure above.

There are 12 buttons (every button has backlight to indicate its position) , of which 6 are special buttons and 6
function buttons.
There are 6 function switches from F1 to F6 on the bottom of the display. According to the display contents,
every function switch has different function; the function from F1 to F6 buttons can be confirmed through the
indication icons on the top every switch.
Indication icon Content
1 "Menu" indicator
2 "Maintenance" indicator
3 "Silence" indicator
4 "Silenced" indicator
"Video" indicator,
5
It will appear if the instrument is mounted on the machine with a video system
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Indication icon Content
6 "OK" indicator
7 "Cancel/Return" indicator
8 Up/Increase indicator
9 Down/Decrease indicator
10 Rightwards indicator
11 Leftwards indicator
12 Previous Page indicator
13 Next Page indicator
1. Selector mode switch of video screen:
For the machine with camera (if equipped) , if press down the button F3 on the standard screen, the image
screen will be displayed (see the figure below) .
For the machine without camera, no indication image will be displayed on the top of the button F3 ,
and even pressing down the button F3, the screen will not switch to the camera screen to display.
Please contact with the LiuGong dealer if you want to install camera.
LG925E4F03194
On the image display screen, the standard screen will be returned to if the button F6 is pressed down.
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2. Maintenance selector switch:
When pressing down the button F5 on the standard screen, the monitor screen will switch to the maintenance
category screen.
LG925E4F03195
On the maintenance category screen, if the time left for maintenance of any item (the indicator is ON) is less
than 30 hours, the left time will be highlighted with yellow color. If the time left for maintenance of any item is 0,
the left time will be highlighted with red color.
If you want to change the setting of maintenance interval, please contact with the LiuGong dealer.
The items displayed on the maintenance category screen are as follows:
Maintenance item Default maintenance interval (period)

Check instruments
Check engine oil level
Check coolant level
Check hydraulic oil level 8 hours (every day)
Fuel tank drainage
Oil-water separator drainage
Check the looseness of bolts and screws routinely
Lubricate pins work implement (applying grease) 50 hours (once every day within the previous 100 hours)
Check the leakage of A/C refrigerant
Check and adjust the travel track looseness
Clean the external filter parts of filter 100 hours
Check and adjust the fan belt looseness
Check and adjust the compressor belt looseness
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Maintenance item Default maintenance interval (period)

Check the gear oil level of swing reduction gear
Check the gear oil level of travel reduction gear
Clean the strainer for internal and external air of air conditioner
250 hours
Replace engine oil
Replace engine oil filter element
Replace the fuel pre-filter element
Lubricate the swing bearing ball (applying grease)
Lubricate the swing bearing gear (applying grease)
Replace the fuel filter element 500 hours
Replace the fuel coarse filter element
Replace the air filter
Replace the gear oil of travel reduction gear
Replace the swing reduction gear oil
Lubricate the swing reduction gear bearing (applying grease) 1000 hours
Replace the return oil filter element of hydraulic oil tank
Replace the pilot oil filter
Replace the hydraulic oil
Replace the suction oil filter element of hydraulic oil 2000 hours
Replace the anti-freeze
On the maintenance category screen, use the Operation of maintenance interval resetting:
button from F1 to F6 to do the following work:
On the maintenance category screen, pressing
● F1: Display the next page. It displays the first down the button F6 can switch to the resetting
page when at the last page. screen of maintenance interval. On this screen, the
● F2: Display the previous page. It displays the left time can be reset.
last page when at the first page. When at the screen of resetting maintenance
● F3: Move to the next item (next line) . It moves interval:
to the first line of the next page when at the last
line.
● F4: Move the previous item (the previous line) .
It moves to the last line of the previous page
when at the first line.
● F5: Return to the standard screen.
● F6: If you press and hold this button, the screen
will switch to the display screen used for
resetting left time of chosen item (the highlighted
item with yellow color) .
LG925E4F03196
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● Press the switch F5 down to cancel the resetting The digging function and the flattening function are
and the screen returns to the maintenance not mutually exclusive - namely the both functions
category screen. can be enabled at the same time.
● Press the button F6 down to switch to the (3) Working mode selector button
confirmation screen.
Press the key to make the mode selection menu
When at the confirmation screen of resetting pop up, and then the user can select the expected
maintenance interval: working mode.
LG925E4F03197 LG925E4F03201
● Press the switch F5 down to cancel the resetting P--High speed mode: for operation with heavy load
and the screen returns to the maintenance E--Economic mode: for operation of saving fuel consumption
category screen. F--Fine mode: for operation of accurate control
L--Lifting mode: for operation of lifting control
● Press down the switch F6, and setting the B--Breaking hammer mode: for operation of breaking
remaining time and change this screen to the hammer
ATT--Hydraulic shear mode For double functional oil
maintenance directory screen. passage accessories , such as hydraulic caliper
(machine can be installed with accessories)
3. The introduction to the special button About the B and ATT mode
function:
For the machine equipped with the attachment, the
(1) Flattening function button B/ATT mode is invisible in the selecting menu
unless the B/ATT is enabled.
Press this button to activate or cancel the flattening
function. When the flattening function is enabled,
the corresponding icon on the main interface will be
illuminated.
The digging function and the flattening function are
not mutually exclusive - namely the both functions
(2) Digging function button
Press this button to activate or cancel the digging
function. When the digging function is enabled, the
corresponding icon on the main interface will be
illuminated.
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When the B mode or the ATT mode is selected, the (4) Travel speed control button (rabbit/tortoise)
system will pop up the following information prompt
box:
Press the key to switch between the low speed state
and high speed state, and the corresponding icon
(rabbit/tortoise) on the main interface will switch
synchronously. When starting the engine, the speed
will be set ti low speed automatically.
When pressing the button , the display will be
switched as the sequence of → →
.
The travel icon on the display is only consistent with

the state selected by the user, not the state of the
travel solenoid valve. That is, indicating icon is not
LG925E4F03202
affected by whether the vehicle is in the running
state or whether the travel solenoid valve is failed.
When starting to work and keep at the B mode, (5) Automatic idling control button
press the function switch F6 (confirmation). If F5 is
pressed down (canceling) , the system will work with Pressing this button down will activate or cancel the
E mode. automatic idling function and the corresponding icon
on the main interface will be illuminated or go out
simultaneously.
(6) Travel buzzer mute button (external horn)
This button controls the status of the travel buzzer.

When the buzzer sounds, press this button to switch
between the Mute Mode →Cancel Mute mode
.
If the buzzer always does not sound, pressing this

button is invalid.
LG375A02003
User Menu
When starting to work and keep at the ATT mode, Set

press the function switch F6 (confirmation) . If F5 is
On the main interface, press the button F6 to enter
pressed down (canceling) , the system will work with
the User Menu, and then if no operation of the menu
E mode.
is not conducted with15s, it will return to the main
If you want automatic setting of P, E, F, L, B, or ATT interface automatically.
(any default setting) at the beginning, please
contact with the LiuGong dealer to change the
setting.
If you want to keep the activated mode last time at
the beginning, please contact with the LiuGong
dealer to change the setting.
3-277
Some corresponding menu options for the user to 1. Attachment flow setting
perform some basic settings are provided in this
When the machine is at the B or ATT mode, press
setting interface. Thereof, part of menu items only
the button Up/Down to select the Attachment Flow
appear under special conditions.
Setting under the User Menu, and then press the
button Confirmation to enter the interface of
Attachment Flow Setting.
Breaking hammer flow setting and hydraulic shear
flow setting:
LG925E4F03212
1. Attachment flow setting

2. Automatic power boost activation/deactivation
3. Monitor of over load lifting activation/deactivation
4. Clock adjustment
5. Language setting LG925E4F03213
6. Brightness setting
7. Current fault
8. Machine information
9. Instrument information
10.Controller information
11.Accelerator calibration
12.Fan emergency control
13.Fan control
14.No regeneration
15.Manual regeneration
LG925E4F03214
3-278
When the machine is at the B mode, press the 2. Automatic boost activation/deactivation
button Up/Down to select the Breaking Hammer
Press the button Up/Down to select the Automatic
Flow Setting under the User Menu, and then press
Boost Activation/Deactivation under the User Menu,
the button F6 Confirmation to enter the interface of
press the confirmation button to enter Automatic
Breaking Hammer Flow Setting.
Boost Activation/Deactivation interface, press the
button Up/Down to select activation or deactivation
and complete selection by pressing the confirmation
button. When choosing activation or deactivation,
the corresponding box is selected. After operation,
press Return key to return to the previous menu.
LG925E4F03215
LG925E4F03217
LG925E4F03216
When the machine is at the ATT mode, press the

button Up/Down to select the Hydraulic Shear Flow
Setting under the User Menu, and then press the
button F6 Confirmation to enter the interface of
Hydraulic Shear Flow Setting.
It can be set only when the working mode is in ATT
mode, and the operation instruction is similar to that
of the breaking hammer.
User can adjust the flow setting from 1 to 4 level
through the left /right navigation key.
After that, press the F6 "√" key for confirmation.
Press the F5 "Return" key to cancel the current
setting.
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3. Monitor of over load lifting activation/

deactivation
This interface only appears at L mode. Press the
button Up/Down to select the Monitor of Over Load
Lifting Activation/Deactivation under the User Menu,
press the confirmation button to enter Monitor of
Over Load Lifting Activation/Deactivation interface,
press the button Up/Down to select activation or
deactivation and complete selection by pressing the
confirmation button. When choosing activation or
deactivation, the corresponding box is selected.
After operation, press Return key to return to the
previous menu.
LG925E4F03219
5. Language settings
Different languages can be selected (Chinese,
English, etc.) by different customers.
Enter the Language Setting interface through
pressing Up/Down button to select Language
Setting under the User Menu and then pressing the
Confirmation button. Press the Up/Down button to
select desired language and press Confirmation
button to complete setting and return to the previous
menu.
LG925E4F03218
4. Clock adjustment
Clock adjustment function is used for setting the
instrument clock. Enter the Clock Adjustment
interface through pressing Up/Down button to select
Clock Adjustment under the User Menu and then
pressing the Confirmation button. Under the Clock
Adjustment interface, firstly press the Up/Down
button to select the desired date, secondly press the
Confirmation button to enter the setting status. And
then press Left/Right button to choose the desired
focus; finally, press the Up/Down button to change
the size and press the Confirmation button to LG925E4F03220
complete modification and return to the previous

step. Press the Cancel button to return to the
previous menu.
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6. Brightness setting 8. Machine information

Brightness setting function is used for adjustment of It is used for checking the machine information.
LED backlight brightness. Press the Up/Down Enter the Machine Information interface through
button to select Brightness Setting under User pressing Up/Down button to select Machine
Menu and press the Confirmation button to enter Information under the User Menu and then pressing
the Brightness Setting interface. And then press the the Confirmation button. This interface includes the
Up/Down button to choose the brightness setting of information of machine model and machine serial
daytime/nighttime, press the Left/Right button to number, etc. The machine model and machine
modify brightness and press Confirmation button to serial number are kept in the instrument and can not
complete and keep the setting to return to the be modified. Press the "Return" button to return to
previous menu. the previous menu.
LG925E4F03221 LG925E4F03223
7. Current fault
It is used for checking the current faults of the
machine. Enter the Current Fault interface through
pressing Up/Down button to select Current Fault
under the User Menu and then pressing the
Confirmation button.
LG925E4F03222
3-281
9. Instrument information
It is used for check the instrument information. Enter
the Instrument Information interface through
pressing Up/Down button to select Machine
Information under the User Menu and then pressing
the Confirmation button. This interface includes the
information of instrument model, ex-factory date,
hardware version, software version, instrument
serial number and product name. The instrument
information is kept in the instrument and can not be
modified. Press the "Return" button to return to the
previous menu.
LG925E4F03225
11. Accelerator calibration

Accelerator calibration is only applicable to the
model with mechanical accelerator. Enter the
Accelerator Calibration interface through pressing
Up/Down button to select Accelerator Calibration
under the User Menu and then pressing the
Confirmation button.
Operate step by step according to the screen
indication.
LG925E4F03224
10. Controller information

It is used for checking the controller information.
Enter the Controller Information interface through
pressing Up/Down button to select Controller
Information under the User Menu and then pressing
the Confirmation button. This interface includes the
information of hardware version, software version,
controller model. Press the "Return" button to return
to the previous menu.
LG925E4F03226
12. Fan emergency control

When the controller is equipped with fan logic
control function, the function setting option will be
displayed for the user to cancel the fan rotation
speed logic control and run at full speed. This option
is only available after the machine is equipped with
fan control function and the engine starts.
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Press the button Up/Down to select the Fan Press the button Up/Down to select the Fan
Emergency Control under the User Menu, press the Reverse under the User Menu, press the
confirmation button to enter Fan Emergency Control confirmation button to enter Fan Reverse interface,
interface, press the button Up/Down to select press the button Up/Down to select activation or
activation or deactivation and complete selection by deactivation and complete selection by pressing the
pressing the confirmation button. When choosing confirmation button. When choosing activation or
activation or deactivation, the corresponding box is deactivation, the corresponding box is selected.
selected. After operation, press Return key to return After operation, press Return key to return to the
to the previous menu. previous menu.
LG925E4F03227 LG925E4F03228
13. Fan reverse

When the controller is equipped with fan logic
control function, the function setting option will be
displayed for the user to set the fan reverse at full
speed. This option is only available before the
machine is equipped with fan control function and
the engine starts (that is, the machine is equipped
with fan control system and the fan is at static
status) . After starting the engine, this option is not
available. If the user wants the fan normal mode
(forward operation) , stop the engine firstly until the
fan is static.
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User menu structure
1.1.1 Breaking hammer flow setting

1.1 Attachment flow setting
1.1.2 Hydraulic shear flow setting
1.2 Automatic boost activation/deactivation -
1.3 Monitor of over load lifting activation/
-
deactivation
1.4 Clock adjustment
1.5.1 Chinese
1.5.2 English
1.5.3 Portuguese
1.5 Language setting 1.5.4 Spanish
1.5.5 Russian
1 User menu 1.5.6 French
1.5.7 Arabic
1.6 Brightness setting -
1.7 Current fault -
1.8 Machine information -
1.9 Instrument information -
1.10 Controller information -
1.11 Accelerator calibration -
1.12 Fan emergency control -
1.13 Fan reverse -
1.14 Forbidden regeneration -
1.15 Manual regeneration -
Appendix 1 - Comparison table of system unit
All system monitor vales are displayed as one of the two units: most of default units are metric system except
for the pressure unit of ISO or British system. The following table lists the units in the display; if the table of
British system is empty, it indicates that the unit is the same as the metric system:
Monitoring variable Default unit ISO British system

Temperature °C °F
Volume L gal
Flow L/h gal/h
Pressure kPa or MPa ü psi
Rotate speed RPM
Current mA
Voltage V
Percentage %
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3.6.3 Electrical Control System
Sensor signal
Engine controller Control signal Engine
Display
Accelerator
Accelerator knob
knob signal
Electric lock signal
Main controller Electric lock
Fuel level signal
Sensor signal
Fuel level sensor
GPS
Hydraulic system
3.6.3.1 Work Mode
Select the corresponding work mode by the display, and then the controller implements the corresponding
functions of the selected mode. The work mode is classified into 6 kinds as follows.
● P --- Heavy load mode, it is applicable for the heavy load condition to take efficiency as priority.
● E --- Economic mode, it is applicable for the general operation to take the oil consumption as priority.
● F --- Fine mode, it is applicable for the operation with fine actions.
● L --- Lifting mode, it is applicable for the operation to lift the materials.
● B --- Breaking hammer mode, it is applicable for the operation to use breaking hammer.
● ATT --- Attachment mode, it is applicable for the operation of the attachment such as the hydraulic crusher
and grapple.
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3.6.3.2 Automatic Idling Function
Engine controller
CAN bus
(Automatic idling command
and worke mode command)
Main controller Display

Switch signal of handle pilot pressure
Switch signal of pedal pilot pressure
Switch signal for secondary

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

Level-2 deceleration
Current speed
Current speed -100RPM
Idle speed
Without hydraulic With hydraulic

Time (s)
request signal request signal
3-287
3.6.3.3 Transient Power Boosting Function
Display
(Automatic power boosting command)

CAN bus
Control signal of transient

Signal of transient power boosting solenoid
power boosting button valve
Main controller
Transient power
boosting solenoid valve
P1 pump-lh pressure signal
P2 pump-lh pressure signal

pedal pilot pressure
Switch signal of
Function:
Under the P, E and F mode, it will increase the digging force of the excavator within certain time. Under the L
mode, it will increase the digging force of the excavator continuously. Under the B and ATT mode, this function
is unavailable. When the vehicle is running, the transient power boosting function will be unavailable.
The transient power boosting function is divided into manual power boosting and automatic power boosting.
1. Manual power boosting
The operator presses the transient power boosting button to increase the digging force for 8s, then the button
will reset automatically. 10s later, whether the power boosting function being enabled depends on if the
transient power boosting button is pressed or not.
2. Automatic power boosting
The automatic power boosting function can be selected from the display menu. When the P1 pump pressure
signal is detected by the main controller or the P1 pump pressure signal is greater than or equal to 34MPa and
maintains for several time, the main controller will output the transient power boosting solenoid valve control
signal to increase the digging force.
3-288
When the conditions of the automatic power boosting function are met, the machine will increase the digging
force for 8s, then the button will reset automatically. 10s later, whether the power boosting function being
enabled depends on if the conditions of the transient power boosting are met or not.
3.6.3.4 Overheating Protection Function
Engine controller
(Hydraulic oil temperature

signal and coolant
temperature signal)
CAN bus
(Pump current signal

and engine speed
control signal)
Main controller
Function:
When the coolant or the hydraulic oil temperature is high, in order to protect the engine and the hydraulic
element from overheating, the pump current and the engine speed will be reduced to protect the engine and
the hydraulic element.
The overheating protection function is divided into level 1, level 2 and level 3.
Protection
Working conditions Measures Reset conditions
level
Work mode: P
Hydraulic oil temperature Engine speed: keep as original Hydraulic oil temperature: less
Level 1 Pump current: reduce the pump than 82°C
above 86°C or the coolant
protection current Coolant temperature: less than
temperature above 102°C Display: Warning appears 100°C
Warning buzzer: Sounds
Work mode: P, E, F, L, B and ATT
Hydraulic oil temperature Engine speed: keep as original Hydraulic oil temperature: less
Level 2 Pump current: reduce the pump than 82°C
protection current Coolant temperature: less than
temperature above 105°C
Display: Warning appears 100°C
Warning buzzer: Sounds
Work mode: P, E, F, L, B and ATT Hydraulic oil temperature: less
Engine speed: gear 1st speed than 82°C
Hydraulic oil temperature
Level 3 Pump current: pump current in 1st Coolant temperature: less than
protection gear 100°C
temperature above 108°C Display: Warning appears Accelerator knob: back to the 1st
Warning buzzer: Sounds gear position for once
3-289
3.6.3.5 Traveling Speed Control Function 2. When the travel speed is high, the main
controller (IPC controller) will change the travel
speed automatically based on the pressure
output by the pump. If the pump pressure is
Display higher than 28MPa for at least 1s, the travel
speed will be changed as slow speed
automatically. If the pump pressure is more than
(Travel speed or less than 15MPa for 1s, the traveling speed
command)
CAN bus will automatically recover to high speed.
Switch signal of
pedal pilot pressure Travel speed
P1 pump pressure signal
Main controller
High speed
P2 pump pressure signal
Travel speed solenoid valve control signal
Low speed
Pump output pressure
Travel speed solenoid valve
3.6.3.6 Various Components

Function: Pressure switch
The machine travel speed can be changed
artificially and can also be changed automatically
based on the pump pressure during travel.
1 2
1. Operate the travel speed control button on the
display to switch between the low speed and
high speed.
LG922E930E03184
1. Switch
2. Connector
3-290
Resistor type temp sensor

Refer to the following table for the corresponding
relation between the temperature sensor resistance
and the temperature:
1 2 3 Resistance (Ω) Temperature (°C)

169 150
191 145
215 140
244 135
277 130
316 125
361 120
414 115
LG922E930E03185
476 110
1. Seal ring 549 105
2. Sensor
3. Connector 637 100
741 95
865 90
1015 85
1195 80
1678 70
2401 60
3509 50
10000 25
12000 20
14800 15
19300 10
25000 5
31400 0
40000 -5
52000 -10
69000 -15
95000 -20
138100 -25
188500 -30
261500 -35
361100 -40
3-291
Current type pressure transmitter The relation between the 400 bar pressure sensor
output current and the pressure is as the following
figure.

Current /mA
LG922E930E03186
Pressure MPa
1. Combination cushion
2. Sensor
3. Connector Voltage type pressure transmitter
The relation between the 60 bar pressure sensor
output current and the pressure is as the following
figure. 1
3
Current /mA
1. Combination 2. Sensor 3. Connector

Pressure MPa cushion
3-292
The relation between the 50 bar pressure sensor output voltage and the pressure is as the following figure.
Voltage/V
⭫ু/V
4.5
0.5
0 5 Pressure
঻࣋Mpa LG915EII III03368
The relation between the 500 bar pressure sensor output current and the pressure is as the following figure.
Volatage/V
⭫ু/V
4.5
0.5
0 50 Pressure/Mpa
঻࣋Mpa LG915EII III03369
3-293
Door control switch
1 2
LG922E930E03191
1. Switch
2. Connector
Fuel level sensor
A-direction
B-direction
1. Block 2. Floater 3. Connector

3-294
Floater Output
Percentage
Floater Output position resistance (Ω)
Percentage
position resistance (Ω)
65% L13-L14 450±4.5
0% Below L1 1100±11
70% L14-L15 400±4
5% L1-L2
75% L15-L16 350±3.5
10% L2-L3
80% L16-L17 300±3
15% L3-L4 950±9.5
85% L17-L18 250±2.5
20% L4-L5 900±9
90% L18-L19 200±2
25% L5-L6 850±8.5
95% L19-L20 150±1.5
30% L6-L7 800±8
100% L20-L21
35% L7-L8 750±7.5
40% L8-L9 700±7
45% L9-L10 650±6.5
50% L10-L11 600±6
55% L11-L12 550±5.5
60% L12-L13 500±5
3-295
Three-wire throttle knob
Lead Pin
Power line
Slot
Earthing cable
Signal line
Connector: DEUTSCH DT04-3P
Working temperature: -40°C~+85°C. Output type: PWM

Working voltage: 5V±0.25V Output current (MAX): 20mA
Corresponding parameters and specifications of each gear

Accelerator gear Duty ratio (precision ± 3.2%) Rotation angle (°) Voltage (V)
1 10.0 0
2 17.27 13.63
3 24.55 27.27
4 31.82 40.91
5 39.09 54.55
6 46.36 68.18
7 53.64 81.82 2.71~2.72
8 60.91 95.45 3.07~3.08
9 68.18 109.09 3.43~3.45
10 75.45 122.73 3.80~3.82
11 82.73 136.36 4.16~4.19
12 90.0 150 4.52~4.53
3-296
Five-wire throttle knob
KNOB
Hole B,
blocked u by self-carried screw
VIEW A
VIEW B
Hole O,
blocked u by screw of hole M
P29E00136
The principle of gear display is as follows:

In the schematic diagram, D is the ground wire, and A\F\B\E respectively indicates several contacts in the
knob, which are respectively turned on with D to indicate different values (see the truth table below).
Gear switch truth table
A F B E D
Gear 1 2 4 8 0
3-297
Controller CM3620
254
238
144
128
4× 8
47
29
LG922E930E03193
Black White
LG922E930E3195
3-298
1. J1
Pin Input and output port

Signal name Description
NO. function
1 Travel alarm buzzer High level output Output 24V to the buzzer
2 Battery is always energized Battery voltage 24V, always connect with the battery
7 1 - The pin is not adopted
NC
8 Handle pilot pressure switch Number input Low level is valid
High level is valid, and input 24V when the start switch
10 Engine starting Number input
is turned to "START" position
Input 24V when the start switch is turned to "on"
11 Power on Number input
position
13 Power boost solenoid valve High level output Output 24V to drive solenoid valve
14 Power grounding Grounding
18 Hoist overload pressure Analog input Input 4 ~ 20mA
Hydraulic oil level warning
20 Number input Low level is valid
switch
22 Boom light signal input Number input High level is valid
23 CAN Shield CAN Shield
24 Power supply relay High level output Output 24V to drive the relay
Digging function solenoid
25 High level output Output 24V to drive solenoid valve
valve
26 Travel lifting solenoid valve High level output Output 24V to drive solenoid valve
27 Flattening solenoid valve High level output Output 24V to drive solenoid valve
28 5V power supply Sensor power supply Output 5V voltage
12-Gear accelerator
29 Frequency input PWM signal of variable duty ratio
potentiometer
33 CAN Low CAN Low
3-299
34 CAN High CAN High

2. J2

NO. function
Pump solenoid current Form circuit with J2-5 and control the pump
1 Low level output
feedback proportional solenoid valve
2 NC1 - The pin is not adopted
3 Power boost switch Number input Low level is valid
Output PWM signal and control the pump proportional
5 Pump solenoid current High level output
solenoid valve
6 Refueling pump relay High level output Output 24V to drive the relay
Secondary regulating
8 High level output Output PWM signal
proportional solenoid 2
Secondary regulating
9 High level output Output PWM signal
proportional solenoid 1
Travel switching solenoid It is low speed when 0V is output and high speed when
10 High level output
valve 24V is output
12 ATT solenoid valve High level output Output 24V to drive solenoid valve
13 Pedal pressure switch Number input Low level is valid
17 Manual preheating switch Number input High level is valid
19 N1 Negative flow pressure Analog input Input 4 ~ 20mA
Pump proportional solenoid
20 Analog input Input 4 ~ 20mA
valve
22 Sensor grounding Sensor grounding
23 Start cut-off valve relay High level output Output 24V to drive the relay
Pq1 & Pq2 flow adjustment Form circuit with J2-8 and J2-9 and control the auxiliary
24 Low level output
solenoid valve adjustment proportional solenoid valve 1 and 2
Subsidiary secondary
25 Number input Low level is valid
pressure switch
26 Engine oil level switch Number input Low level is valid
27 Intake air filter alert Number input Low level is valid
3-300

NO. function
Battery charging indicator High level is valid, which is connected to the P point of
28 Number input
switch the engine
30 Fuel level Analog input 0 ~ 5V voltage signal (signal transformation is weak)
31 P1 left pump pressure Analog input Input 4 ~ 20mA
32 P2 right pump pressure Analog input Input 4 ~ 20mA
33 N2 Negative flow pressure Analog input Input 4 ~ 20mA
Controller C101-D1
P29E00134
3-301
P29E00135
1. J1
Pin NO. Signal name Description

1 Un_switched Power
2 Power grounding
4 A5-Secondary regulating proportional valve 2 PWM
5 A2-Travel switching solenoid valve Switching value (output)
6 A8-Digging function solenoid valve Switching value (output)
7 NC The pin is not adopted
8 Fuel level Analog quantity (input)
9 Battery charging indicator switch High level is valid
10 Throttle position 3_B Low level is valid
11 Throttle position 4_E Low level is valid
12 Power on High level is valid
13
Short-circuit Short-circuit
14
15 A7-Power boost solenoid valve Switching value (output)
16 A6-Secondary regulating proportional valve 1 PWM
17 A5&A6 solenoid valve grounding
18 Throttle position 2_F Low level is valid
3-302

19 Power boost switch Analog quantity (input) is valid as low level
20 Auxiliary secondary pressure switch Analog quantity (input) is valid as low level
21 Boom lamp signal input High level is valid
23 Lifting overload pressure sensor
24 GND
27 Un_switched Power
28 Power grounding
30 A4-Travel lifting solenoid valve
31 Pump proportional solenoid valve current PWM
34 Manual preheating switch High level is valid
35 N1 Negative flow pressure sensor
36 Pressure sensor 5V power supply
37 P1 Main pump pressure sensor Analog quantity (input)
38 Pressure sensor grounding
39 CAN1_H
40 CAN1_L
41 Power supply controlled by engine start switch
42 Un_switched Power
43 CAN1/2 Shield
44 Throttle position 1_A Low level is valid
46 N2 Negative flow pressure sensor Analog quantity (input)
48 P2 Main pump pressure sensor Analog quantity (input)
49 Grounding
50 RS232 RX
51 RS232 TX
52 RS232 RTS
3-303
2. J2

53 Intake air filter alert switch Low level is valid
Pump proportional solenoid valve current
56
feedback
60 Engine starting High level is valid
61 Handle pilot pressure switch Low level is valid
64 Hydraulic oil temperature sensor Analog quantity (input)
68 Travel alarm buzzer Switching value (output)
69 Bucket confluence solenoid valve Switching value (output)
71 Start cut-off relay Switching value (output)
72 A3-Flattening function solenoid valve Outputs 24V to drive solenoid valve
73 Pedal pressure switch Low level is valid
74 ATT Solenoid valve Switching value (output)
75 Refueling pump relay Switching value (output)
76 Power supply relay Switching value (output)

3-304
3.6.4 Descriptions of Partial Circuits
3.6.4.1 Travel 2-Speed Circuit
1. When the controller is CM3620, the relevant circuit diagram is as follows:
IPC Controller
Travel switching solenoid
valve (valve A2)
A2 Travel speed solenoid valve
2. When the controller is C101-D1, the relevant circuit diagram is as follows:
P29E00127
When the travel speed control key on the display is pressed, the pin J2-10 of the main controller (IPC
controller) (or the pin J1-5 of main controller C101) will output 24V voltage to the travel transmission solenoid
valve coil to make the travel speed switch to the high-speed state.
When the travel speed control key on the display is pressed again, the pin J2-10 of the main controller (IPC
controller) (or the pin J1-5 of main controller C101) will output 0V voltage to the travel transmission solenoid
valve coil to make the travel speed switch to the high-speed state.
3-305
3.6.4.2 Transient Pressure Boosting Circuit

Transient power
boosting button (right)
IPC Controller
Power boosting switch
A7 Power boosting solenoid valve
Tranisent power boosting

solenoid valve (valve A7)
P29E00128
3-306
When the transient power boosting button is pressed, the pin J1-13 of the main controller (IPC controller) (or
the pin J1-15 of main controller C101) will output 24V voltage to the power boosting solenoid valve for 8s, and
then the button will reset automatically, namely, the pin J1-13 of the main controller (IPC controller) (or the pin
J1-15 of main controller C101) outputs 0V voltage to the power boosting solenoid valve. 10s later, whether the
power boosting function is enabled depends on if the transient power boosting button is pressed.
3.6.4.3 Start Circuit
1. When the controller is CM3620 (IPC controller):
Ignition switch
Pilot cut-off valve switch
IPC Controller
Engine starting
Start shut-off valve relay
Engine controller
Start protection
Preheating
ground wire
Start relay K1
Electric lock power 20A
Battery
Start moter
Start relay K11 Pilot control start relay K7 Controller control start relay K8 ECM control start relay K9
Battery relay
GND
3-307
When the engine start switch is turned to the "ON" position, the battery relay coil circuit is conducted, making
the battery relay main contact closed, and the main controller (IPC controller) and the engine controller are
powered on to work.
When the engine start switch is turned to the "START” position, the starter relay K1 coil circuit is conducted,
making the starter relay K1 main contact closed, and then the engine is started.
● When the engine start switch is turned to the "START" position, the pilot shut-off valve switch will always be
in closed state and the safety relay K11 main contact will be closed making the pilot control starter relay K7
main contact closed.
● When the engine start switch is turned to the "START" position and the starting signal is detected by the
main controller (IPC controller), the pin J2-23 of the main controller (IPC controller) will output 0V voltage to
the controller control starter relay K8 coil, making the controller control starter relay K8 main contact always
in closed state.
● When the engine start switch is turned to the "START" position, and the engine controller detects no failure,
the pin 9 of the engine controller will output 0V voltage to the ECM to control the starter relay K9 coil,
making the ECM control the starter relay K9 main contact always in the closed state.
(1) Starter motor circuit:
“Battery positive pole — battery relay main contact — 50A fuse — safety relay K11 main contact — start motor
starting end — start motor — grounding”
(2) Battery relay coil circuit
"Battery positive pole — 50A fuse — engine start switch power supply 20A (fuse box) — ignition switch B1 end
— ignition switch B2 end — battery relay coil — grounding"
(3) Starting relay K1 coil circuit:
— ignition switch S end — pilot control starter relay K7 main contact (fuse box) controller control starter relay
K8 main contact (fuse box) — ECM control starter relay K9 main contact (fuse box) — starter relay K1 coil —
grounding"
(4) Pilot control starter relay K7 coil circuit:
"Battery positive pole — battery relay main contact — 50 A fuse — pilot shut off 10 A (fuse box) — safety relay
K11 main contact (fuse box) — pilot shut-off valve switch main contact — pilot control starter relay K 7 coil
(fuse box) — grounding"
(5) Starter relay K11 coil circuit:
— ignition switch B2 end — safety relay K11 coil (fuse box) — grounding"
(6) Controller control starter relay K8 coil circuit:
"Pin J2-23 of IPC controller — controller control starter relay K8 coil (fuse box) — grounding"
3-308
(7) ECM control starter relay K9 coil circuit:

"Pin 9 of engine controller — ECM control starter relay K9 coil (fuse box) — pin 7 of engine controller"
When the engine start switch is turned to "ON" position, the B1 end and the B2 end of the ignition
switch are conducted. When the engine start switch is turned to the "START" position, the end B1 and
the end B2 of the ignition switch are conducted with the end S.
3-309
2. When the controller is C101-D1:
P29E00129
When the engine start switch (also called ignition switch) is turned to the "ON" position, the battery relay coil
circuit is conducted, making the battery relay main contact closed, and the main controller and the engine
controller are powered on to work.
When the engine start switch is turned to the “START” position, the starter relay coil circuit is conducted,
making the starter relay main contact closed, and then the engine is started.
3-310
● When the engine start switch is turned to the "START" position, the pin 1 and pin 3 of the pilot shut-off valve
switch are in a normally closed state, and the main contact 30 end and 87 end of the pilot control starter
relay K7 are closed.
● When the engine start switch is turned to the "START" position and the starting signal is detected by the
main controller, the pin J2-71 of the main controller will output 0V voltage to the controller control starter
relay K8 coil, making the main contact 30 end and 87A end of the controller control starter relay K8 always
in closed state.
● When the engine start switch is turned to "START" position, and the engine controller detects no failure, the
pin 9 of the engine controller will output 0V voltage to the ECM to control the starter relay K9 coil, making
the ECM control the starter relay K9 main contact always in the closed state.
(1) Starter motor coil end circuit:
“Battery positive pole — battery relay main contact — starter relay main contact — start motor starting end —
grounding”
(2) Battery relay coil circuit
"Engine start switch power supply 20A (fuse box) — ignition switch B1 end — ignition switch B2 end —
freewheeling diode — battery relay coil — grounding"
(3) Starting relay K1 coil circuit:
"Engine start switch power supply 20A (fuse box) — ignition switch B1 end — ignition switch S end — pilot
control starter relay K7 main contact (fuse box) — controller control starter relay K8 main contact (fuse box) —
ECM control starter relay K9 main contact — starter relay coil — grounding"
(4) Pilot control starter relay K7 coil circuit:
"Pilot shut off 5 A (fuse box) — pilot shut-off valve switch main contact — pilot control starter relay K 7 coil (fuse
box) — grounding"
(5) Controller control starter relay K8 coil circuit:
"Pin J2-71 of controller — controller control starter relay K8 coil (fuse box) — grounding"
(6) ECM control starter relay K9 coil circuit:
"Pin 9 of engine ECM controller — ECM control starter relay K9 coil (fuse box) — pin 57 of engine ECM
controller"
When the engine start switch is turned to "ON" position, the B1 end and the B2 end of the ignition
switch are conducted. When the engine start switch is turned to the "START" position, the end B1 and
the end B2 of the ignition switch are conducted with the end S.
3-311
3.6.4.4 Digging Function Circuit
IPC Controller
Digging proportional
solenoid valve A8
A8 Digging solenoid valve
P29E00130
When the digging function key on the display is pressed, the pin J1-25 of the main controller (IPC controller)
(or the pin J1-6 of main controller C101) outputs 24V voltage to the trenching solenoid valve coil.
When the digging function key on the display is pressed again, the pin J1-25 of the main controller (IPC
controller) (or the pin J1-6 of main controller C101) outputs 0V voltage to the digging function solenoid valve
coil.
Note: the digging function is only available under the P, E and F mode.
When the digging function is enabled. The trenching solenoid valve is powered on, and the swing logic valve is
in the maximum opening when the boom is operated upward. Namely, the swing speed is not restricted. That is
what we often called the swing has the priority to the boom lifting.
3-312
When the digging function is pressed again. The trenching solenoid valve is powered off, and the swing logic
valve is in the minimum opening when the boom is operated upward. Namely, the swing speed is restricted.
When the lifting and swing operation of the boom are carried out at the same time, the flow distributed to the
boom lifting is larger. That is what we often called the boom lifting has the priority to the swing.
3.6.4.5 Flattening Function Circuit
IPC Controller
Flattening solenoid valve (valve A3)
A3 Arm speed 2nd

gear solenoid valve
P29E00131
When the flattening function key on the display is pressed, the pin J1-27 of the main controller (IPC controller)
(or the pin J2-72 of main controller C101) outputs 24V voltage to the arm speed-2 gear solenoid valve coil.
When the flattening function key on the display is pressed again, the pin J1-27 of the main controller (IPC
controller) (or the pin J2-72 of main controller C101) outputs 0V voltage to the arm speed-2 gear solenoid valve
coil.
Note: the flattening function is only available under the P, E and F mode.
3-313
When the flattening function key is pressed, the flattening solenoid valve coil is powered on. When the arm
logic valve of the arm 2 valve stem is in the maximum opening, the arm speed will increase which facilitates the
grader operation.
When the flattening function key is pressed again, the flattening solenoid valve coil is powered off. When the
arm logic valve of the arm 2 valve stem is in the minimum opening, the arm speed will decrease which
facilitates the loading operation.
3.6.4.6 Charging Circuit
Alternator
IPC Controller
Battery charging indicator switch
GND
Battery
Start motor
Battery relay
GND
GND
3-314
P29E00132
The pin J2-28 pin of the main controller (IPC controller) (or the pin J1-9 of main controller C101) will monitor
the P end of the alternator.
The electric energy outputted from the B end of the alternator charges the battery via the wire 120 and 108 and
the battery relay. The PWM signal is output from the P end of the alternator to the main controller, which is
used to judge whether the alternator generates electricity normally. A light can be installed on the outside of the
alternator L end to judge whether the alternator generates electricity normally. The light will come on when the
alternator does not generate electricity. The light will go off when the alternator generates electricity. Here, we
do not judge from the L end, so the L end of the alternator is suspended.
3-315
3.6.4.7 Working Circuit of Pump Proportional Solenoid Valve
Pump proportional solenoid valve

IPC Controller
Pump solenoid valve current feedback
Pump solenoid valve current

Main pump PWM signal
P29E00133
The main controller will output PWM signals to the pump proportional solenoid valve according to the matching
strategy of pump power and engine output power.
3-316
4-1
September 15, 2020 Parameters
CLG920E/922E/923E
4 Parameters
4.1 Basic Parameters................................................................................................................ 4-3
4.2 Performance Parameters of Diesel Engine....................................................................... 4-11
................................................................................................................................................ 4-12
4.3 Performance Parameters of Complete Machine ............................................................... 4-13
4-2
Parameters September 15, 2020
CLG920E/922E/923E
4-3
CLG920E/922E/923E 4.1 Basic Parameters
4.1 Basic Parameters

The machine is capable of digging and loading at levels I - IV (the earth’s soil and rock can be divided into 16
levels based on the digging complexity, in which the soil is below IV level). According to the requirements of
different engineering operations, this machine can also be installed with the backhoe, blade, hydraulic breaker,
lotus catch, and other various work implements.
• Altitude: ≤ 3658m
• Ambient temperature: -32 °C ~ 40 °C
Wading depth: no matter what kind of position (horizontal or slope) the machine, the wading depth is not
allowed to exceed the center of the carrier roller.
Main Technical Parameters

All operations of the machine are obtained when the machine operates on a hard and horizontal supporting
surface. If the ambient working conditions of the machine differ from the above standard conditions (for
example, working on soft or uneven ground or slopes), the operator shall consider these conditions.
Overall Dimension Drawing

4-4
4.1 Basic Parameters CLG920E/922E/923E
Complete Vehicle Parameters
Item Unit 920E/922E 922E/923E

Engine Model QSB7/ India Cummins B5.9 Cummins QSB7
Operating weight kg 21500 22000/22700
Standard bucket capacity m³ 0.9/0.95 1/1.1
Driving speed (high/low) km/h 0~5.3, 0~3.0 0~5.3, 0~3.0
Slewing speed r/min 10.5/11.5 10.5
Gradeability 35° (70%) 35° (70%)
Pressure to the ground (track width of 600mm) KPa 48.2 45.8/47.2
J: Overall length mm 9570 9570
Overall width (track width of 600mm) mm 2800 2990
Overall height mm 3140 3140
D: Height of cab roof mm 3040 3040
E: Overall width of upper platform mm 2760 2760
*H: Counterweight ground clearance mm 1070 1070
*C: Minimum ground clearance mm 440 440
I: Tail length of upper platform mm 2780 2780
Rotating radius at tail end mm 2780 2780
G: Underframe wheelbase mm 3370 3650
F: Underframe length mm 4160 4440
A: Underframe track distance mm 2200 2390
B: Underframe width (track width is 600mm) mm 2200 2990
Note: the sizes marked with * exclude grouser height.

4-5
Components Parameters
Components Item Unit CLG920E/CLG922E

Model Cummins QSB7 II Cummins QSB7 III
Turb0 charger/air-air inter- Turb0 charger/air-air inter-
cooling/high pressure cooling/high pressure
Type
common-rail/electric control common-rail/electric control
injection injection
Non-road China Stage III Non-road China Stage III
Emission and Europe STAGE II and Europe STAGE III A
Emission stage Emission stage
Cooling mode Water-cooled
Ignition sequence 1-5-3-6-2-4
Bore × Stroke mm 107X124
Cylinder displacement L 6.7
Engine
Compression ratio 17.3:1
Rated power 120kW/2100r/min 124 kW/2050r/min
Net power 117kW
Maximum torque (1500r/min) Nm 658
Oil volume L 25
Net weight of diesel engine kg 490
Maximum no-load speed r/min 1850
Minimum no-load speed r/min 1000
Rated fuel consumption rate g/kW.h 225 231
Starter motor 24V-7.5kW
Alternator 24V-70A (Bosch)
4-6

Main pump Double-block axial variable plunger pump
Maximum system flowrate L/min 2X224
Main relief
Setting pressure 34.3
valve
When
instantaneously MPa 37.3
supercharging
Set pressure Big cavity/small
MPa 39.2
of outlet cavity of boom
safety valve Big cavity/small
MPa 39.2
cavity of arm
Big cavity/small
MPa 39.2
cavity of bucket
Set pressure of slewing motor relief
MPa 25.5
valve
Hydraulic system Set pressure of travel motor safety
MPa 34.3
valve
Pilot pump Gear pump
Pilot circuit MPa 3.9
Quantity - bore ×
rod diameter × mm 2-φ120×φ85×1335
Boom cylinder stroke
Buffer When stretching out

Quantity - bore ×
rod diameter × mm 1-φ135×φ95×1490
Arm cylinder stroke
Buffer When stretching out and retracting
Quantity - bore ×
Bucket rod diameter × mm 1-φ115×φ85×1120
cylinder stroke
Buffer When stretching out
Boom (standard configuration) mm 5710
Work implement
Arm (standard configuration) mm 2915
Track shoe width mm 600
Track assembly PC(s) 2
920E:46
Number of track shoe (each bar)
922E:49
Track tensioner PC(s) 2
Travel device
Sprocket PC(s) 2
Idler assembly PC(s) 2
920E: 7 each side
Track roller
922E: 8 each side
Carrier roller 2 pcs on each side
4-7

System voltage V 24
Electrical System
Battery 2×12V
Refrigerating capacity W 5000
Cooling air output m³/h 550
Heating capacity W 5800
Heating air output m³/h 400
A/C system Voltage V.DC 24
Total power consumption W ≤310
Compressor shaft consumption
kW 3.02
power
Refrigerant R134a
Components Item Unit CLG920E/CLG922E/CLG923E

Model India Cummins B5.9
Six-cylinder, in-line/ four-stroke turbocharged/ air-air
Type
intercooler/ water cooling
Emission CEV BS II
Cooling mode Water-cooled
Bore × Stroke mm 102X120
Cylinder displacement L 5.9
Engine Rated power 110kW/2000r/min
Net power 100kW
Maximum torque (1300r/min) Nm 626
Oil volume L 20
Net weight of diesel engine kg 432
Maximum no-load speed r/min 2000
Minimum no-load speed r/min 900
Rated fuel consumption rate g/kW.h 224
Starter motor 24V-4.5kW
Alternator 24V-75A
Boom (standard configuration) mm 5710
Work device
Arm (standard configuration) mm 2915/2400
4-8
Components Item Unit CLG920E/CLG922E/CLG923E

Track shoe width mm 600
Track assembly PC(s) 2
920E:46
Number of track shoe (each bar) 922E:46 or 49
923E:49
Track tensioner PC(s) 2
Travel device
Sprocket PC(s) 2
Idler assembly PC(s) 2
920E: 7 each side
Track roller 922E: 7 or 8 pcs on each side
923E: 9 each side
Carrier roller 2 pcs on each side
Refrigerating capacity W 5000/5200
Cooling air output m³/h 550/580
Heating capacity W 5800/5600
Heating air output m³/h 400
Voltage V.DC 24
Total power consumption W ≤310/380
A/C system
Compressor shaft consumption
kW 3.02/3.68
power
Refrigerant R134a
Refrigerant filling quantity G 950±50
Compressor 10S15C/VS10ZSA15
Refrigeration oil ND-OIL8/PAG-46
4-9
Working Range
4-10
Item Unit CLG920E/CLG922E CLG923E

Arm length mm 2915 2400
Boom length mm 5710
*A: Maximum digging height mm 9945 9464
*B: Maximum unloading height mm 7170 6832
*C: Maximum digging depth mm 6560 6100
*E: Maximum vertical digging depth mm 5080 4408
H: Maximum digging radius mm 9870 9328
G: Maximum ground digging radius mm 9685 9136
*D: Maximum digging depth (2.5m horizontal plane) mm 6390 5820
F: Minimum slewing radius mm 3090
Maximum bucket digging force (ISO) kN 152.5
Maximum arm digging force (ISO) kN 105 124.6
Note: the sizes marked with * exclude grouser height.

4-11
CLG920E/922E/923E 4.2 Performance Parameters of Diesel Engine
4.2 Performance Parameters of Diesel Engine
Name 922E China II 922E China III

Engine Model QSB7 QSB7
Turbocharging / air-air intercooler / Turbocharging / air-air intercooler /
Type high-pressure common rail / electronic- high-pressure common rail / electronic-
controlled injection / water-cooling controlled injection / water-cooling
Number of cylinders 6 6
Bore × stroke 107mm×124mm(4.21in×4.88in) 107mm×124mm(4.21in×4.88in)
Displacement 6.7L(1.77US gal) 6.7L(1.77US gal)
Compression ratio 17.3?1 17.3?1
Ignition sequence 1-5-3-6-2-4 1-5-3-6-2-4
Rated power 120kW/2100RPM(161HP/2100rpm) 124kW/2050RPM(166HP/2050rpm)
Maximum power 125kW/1900RPM(168HP/1900rpm) 125kW/1900RPM(168HP/1900rpm)
Maximum Torque 658N·m/1200RPM(485lbf·ft/1200rpm) 658N·m/1200RPM(485lbf·ft/1200rpm)
Engine oil volume 24L(6.34 US gal) 24L(6.34 US gal)
Low idling Min. 69kPa (10psi) Min. 69kPa (10psi)
Oil pressure
Rated speed Min. 207kPa (30psi) Min. 207kPa (30psi)
Fan 7-φ700mm(7-φ27.56in) 7-φ700mm(7-φ27.56in)
Starter motor 24V-7.5kW(24V-10HP) 24V-7.5kW(24V-10HP)
Air intake heater 24V-112A 24V-112A
Alternator 24V-70A 24V-70A
0.25Mm (Limiting value: 0.17mm- 0.25Mm (Limiting value: 0.17mm-
Intake valve 0.33mm)[0.0098in (Limiting value: 0.33mm)[0.0098in (Limiting value:
0.0067in-0.0130in)] 0.0067in-0.0130in)]
Valve lash
0.51mm (Limiting value: 0.43mm- 0.51mm (Limiting value: 0.43mm-
Exhaust valve 0.59mm) [0.0201in (Limiting value: 0.59mm) [0.0201in (Limiting value:
0.0169in-0.0232in)] 0.0169in-0.0232in)]
Open
79°C-83°C(174°F-181°F) 79°C-83°C(174°F-181°F)
temperature
Thermostat
Full open
95°C(203°F) 95°C(203°F)
temperature
4-12
4.2 Performance Parameters of Diesel Engine CLG920E/922E/923E
Name 922E India Cummins II

Engine Model B5.9.
Type Six-cylinder, in-line/ four-stroke turbocharged/ air-air intercooler/ water cooling
Number of cylinders 6
Bore × stroke 102Mm×120mm (4.02in×4.72in)
Displacement. 5.9L (1.56US gal)
Rated power 110kW/2000rpm (148HP/2000rpm)
Maximum power 110kW/2000rpm (148HP/2000rpm)
Maximum Torque 626N·m/1300rmp (461lbf·ft/1300rpm)
Engine oil volume 20L (5.28US gal)
Low idling Min. 69kPa (10psi)
Oil pressure
Rated speed Min. 207kPa (30psi)
Fan 7-Φ700mm (7-φ27.56in)
Starter motor 24V-4.5kW (24V-6HP)
Air intake heater 24V-112A.
Alternator 24V-70A.
0.25mm (Limit value: 0.17mm-0.33mm)
Intake valve
[0.0098in (limit value: 0.0067in-0.0130in)]
Valve lash
0.51mm (Limit value: 0.43mm-0.59mm)
Exhaust valve
[0.0201in (limit value: 0.0169in-0.0232in)]
Open temperature 79°C -83°C (174°F -181°F)
Thermostat
Full open temperature 95°C (203°F)
4-13
CLG920E/922E/923E 4.3 Performance Parameters of Complete Machine
4.3 Performance Parameters of Complete Machine
Item Unit Performance standard

Minimum speed (idling) 1000±50
Engine speed (A/C OFF) r/min
Maximum speed (idling) 1850±50
Rabbit position/forward 13.5±1.5
Rabbit position/backward 13.5±1.5
Driving speed Sec/20m
Tortoise position/forward 23±2.5
Tortoise position/backward 23±2.5
Tortoise position/forward 32±2.5
Left track
Rabbit position/forward 19±1.5
Travel speed Rabbit position/backward 19±1.5
Sec/3rev
(Idling speed) Tortoise position/forward 32±2.5
Right track
Rabbit position/forward 19±1.5
Rabbit position/backward 19±1.5
Tortoise position ≤600
Travel deviation mm/20m
Rabbit position ≤800
Slewing speed Sec/3rev 17±1.5
Counterclockwise Deg. ≤140
Slewing service braking angle
Clockwise Deg. ≤140
Slewing bearing clearance Vertical direction mm ≤1.3
Stretching of boom cylinder 3.5±0.5
Retracting of boom cylinder /
Action time of hydraulic
cylinder (at the top engine Stretching of arm cylinder 2.9±0.5
sec
speed with the A/C is turned Retracting of arm cylinder 2.5±0.5
off)
Stretching of bucket cylinder 2.6±0.5
Retracting of bucket cylinder 1.9±0.5
Retracting of boom cylinder (mm) ≤30
Stretching of arm cylinder (mm) ≤30
Cylinder settlement mm/10min
Retracting of arm cylinder (mm) ≤40
Retracting of bucket cylinder (mm) ≤40
Boom control lever 10±3
Arm control lever 10±3
Bucket control lever 10±3
Control force of control lever Slewing control lever N 10±3
Travel control lever 17±5
Travel control pedal (forward) 60±10
Travel control pedal (backward) 70±10
4-14
4.3 Performance Parameters of Complete Machine CLG920E/922E/923E
Item Unit Performance standard

Boom control lever 88±10
Arm control lever 87±10
Control lever stroke Bucket control lever mm 90±10
Slewing control lever 91±10
Travel control lever 146±10
Boom lifted, upper frame rotated by 90° with
sec 3.67±0.5
Check the boom lifting and no-load in the bucket
slewing action Tooth ground clearance after boom lifting
mm 7400±200
action and frame is rotated by 90°.
Engine: high idling MPa 3.9 ~ 4.1
Adjustment of pilot pressure
Engine: low idling MPa 3.5 ~ 4.1
Lifting of the boom MPa 3.9 ~ 4.1
Lowering of the boom MPa 3.9 ~ 4.1
Retracting of arm MPa 3.9 ~ 4.1
Stretching of arm MPa 3.9 ~ 4.1
Secondary pilot pressure Left slewing MPa 3.9 ~ 4.1
(Handle is in full stroke) Right slewing MPa 3.9 ~ 4.1
Tuck-in of the bucket MPa 3.9 ~ 4.1
Stretching of bucket MPa 3.9 ~ 4.1
Forward MPa 3.9 ~ 4.1
Backward MPa 3.9 ~ 4.1
Pressure in main relief valve MPa 34.3 ~ 35.3
Left slewing MPa 25.5±1
Main circuit pressure
Right slewing MPa 25.5±1
Drive (travel hold pressure) MPa 34.3±1
Lifting of the boom MPa 39±0.5
Lowering of the boom MPa 39±0.5
Pressure testing of oil port Retracting of arm MPa 39±0.5
relief valve Stretching of arm MPa 39±0.5
Tuck-in of the bucket (big cavity) MPa 39±0.5
Stretching of bucket (small cavity) MPa 39±0.5
Main pump flow rate L/min 215×2 (2 pumps)
Slewing motor oil draining
Drainage pressure MPa ≤0.2
(drainage)
Travel motor oil draining
Drainage pressure MPa ≤0.2
(drainage)
5-1
September 15, 2020 Test and Adjustment
CLG920E/922E/923E
5 Test and Adjustment

5.1 Performance Test of Complete Machine ............................................................................ 5-3
5.1.1 Diesel Engine Speed ....................................................................................................... 5-5
5.1.2 Travel Speed (Idling Speed) ............................................................................................ 5-5
5.1.3 Driving Speed (Measured Speed).................................................................................... 5-6
5.1.4 Travel Deviation ............................................................................................................... 5-7
5.1.5 Slewing Service Brake Angle ........................................................................................... 5-9
5.1.6 Slewing Speed ............................................................................................................... 5-10
5.1.7 Slewing Bearing Clearance............................................................................................ 5-11
5.1.8 Action Time of Cylinder .................................................................................................. 5-13
5.1.9 Cylinder Settlement........................................................................................................ 5-15
5.1.10 Operating Force of Control Lever ................................................................................ 5-17
5.1.11 Control Lever Stroke .................................................................................................... 5-17
5.1.12 Boom Lifting and Slewing Action ................................................................................. 5-18
5.1.13 Pilot Pressure............................................................................................................... 5-19
5.1.14 Secondary Pilot Pressure ............................................................................................ 5-20
5.1.15 Output Pressure of Solenoid Proportional Valve ......................................................... 5-21
5.1.16 Setting Pressure of Main Relief Valve ......................................................................... 5-23
Attached Table........................................................................................................................ 5-26
5.2 Other Tests ....................................................................................................................... 5-29
5.2.1 Adjustment of Valve Lash .............................................................................................. 5-29
5.2.2 Measurement of Blow-By of Crankcase......................................................................... 5-39
5.2.3 Oil Pressure Measurement ............................................................................................ 5-47
5.2.4 Measurement and Adjustment of Track Tension ........................................................... 5-50
5.2.5 Inspection and Adjustment of Minus Feedback Pressure N1 ........................................ 5-51
5.2.6 Inspection and Adjustment of Minus Feedback Pressure N2 ........................................ 5-53
5.2.7 Release Residual Pressure in Hydraulic Lines .............................................................. 5-53
5.2.8 Bleeding of Various Devices .......................................................................................... 5-55
5.2.9 Inspection of Diode ........................................................................................................ 5-58
5.2.10 Adjustment of Compressor Belt Tensioner .................................................................. 5-59
5.2.11 Performance Test of Travel Motor and Speed Reducer .............................................. 5-60
5-2
Test and Adjustment September 15, 2020
CLG920E/922E/923E
5-3
CLG920E/922E/923E 5.1 Performance Test of Complete Machine
5.1 Performance Test of Complete Machine

The standard data values obtained from the tests involved in this chapter are as follows:
1. List of standard diesel engine speed value
Model CLG920E/CLG922E (QSB7II?)

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th
Gears
gear gear gear gear gear gear gear gear gear gear gear gear
No-load
1000± 1200± 1300± 1450± 1500± 1600± 1650± 1700± 1750±5 1800±5 1850±5
speed (r/ 1550±50
50 50 50 50 50 50 50 50 0 0 0
min)
Hold
Mode P
pressure 100±2 580±2 590±2 600±2 600±2 600±2 600±2

0 ~ 20 600±20 600±20 600±20 600±20
current 0 0 0 0 0 0 0
(mA)
Idling
100 100 100 100 100 100 100 100 100 100 100
current 0 ~ 20
±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10
(mA)
No-load
1000± 1100±5 1100±5 1150±5 1200± *1300/ 1400± 1500± 1550± 1700±5 1750±5 1800±5
speed (r/
50 0 0 0 50 1350±50 50 50 50 0 0 0
min)
Hold
Mode E
pressure 100±2 430±2 450±2 480±2 500±2 500±2 560±2

0 ~ 20 490±20 570±20 570±20 600±20
current 0 0 0 0 0 0 0
(mA)
Idling
100 100 100 100 100 100 100 100 100 100 100
current 0 ~ 20
±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10 ±10
(mA)
5-4
5.1 Performance Test of Complete Machine CLG920E/922E/923E
Model CLG922E (India Cummins III)

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th
Gears
gear gear gear gear gear gear gear gear gear gear gear gear
No-load
speed
1000 1150 1250 1350 1550 1650± 1700 1800 1900 2000 2100 2150
Mode P
(r/min) ±50 ±30 ±30 ±30 ±30 30 ±30 ±30 ±30 ±30 ±30 ±30
Set current 200± 250± 300± 400± 520±1 520± 540± 560± 575± 575± 580±
(mA) 0
10 10 10 10 0 10 10 10 10 10 10
No-load
speed
1000 1150 1250 1350 1550 1650± 1700 1750 1800 1850 1900 2050
Mode E
(r/min) ±50 ±30 ±30 ±30 ±30 30 ±30 ±30 ±30 ±30 ±30 ±30
Set current 200± 250± 300± 400± 520±1 520± 530± 540± 555± 560± 570±
(mA) 0
10 10 10 10 0 10 10 20 10 10 10
Description:
*: QSB7II E Mode Gear 6 idling speed is 1300 r/min; and QSB7? E Mode Gear 6 idling speed is 1350 r/min.
Notice: Firstly test whether diesel engine speed reaches the technical specification before all other tests. If the
diesel engine speed is not adjusted correctly, the data of all other performances are not reliable.
2. For standard performance parameters of the
complete machine, please see the Section 4.3
5-5
5.1.1 Diesel Engine Speed 5.1.2 Travel Speed (Idling Speed)

A. Tools and testing instruments A. Tools and testing instruments
1. Reflective sheeting 1. Stopwatch.
2. Tachometer 2. A tool used for marking a starting point.
B. Preparations 3. The test is performed by two workers.
Turn the gear to the position to be tested when the B. Machine status and parking site
air conditioner and the automatic idling are turned
1. A solid and flat parking site.
off and there is no load.
2. Retain hydraulic oil temperature between 45°C
C. Test method
and 55°C.
1. Open the diesel engine hood.
3. Set the engine to maximum speed (turn off the
2. Stick the reflective sheeting on the output end of A/C).
diesel engine crankshaft or the fan spindle. It is
4. The working current of the pump is within the
required to multiply by the speed ratio of the fan
normal range.
and the diesel engine at this moment.
5. The complete machine works in the normal
3. Start the engine, shift the gear to the one to be
mode.
tested and illuminate the paste location of the
reflective sheeting using a tachometer. If it is 6. The working pressure and the pilot pressure of
safe to do so, then the diesel engine speed can the pump are within the normal range.
be obtained from the instrument.
C. Travel speed test
4. Repeatedly measure for 3 times and calculate
1. Park the machine at a solid and plain site.
the average value.
2. Keep hydraulic oil temperature between 45°C
and 55°C.
3. Operate the right slewing until the upper
mechanism is vertical to the lower one.
4. Operate the boom, arm, and bucket until the
bucket bottom is on the ground as shown in the
Figure below.
5. Lower the boom until the right track is raised for
about 100~200mm from the ground to keep the
track away from the ground during operation.
Marks the appropriate positions on the track as
5-6
5.1.3 Driving Speed (Measured

Speed)
A. Tools and testing instruments
1. Stopwatch.
2. 50m measuring tape.
3. The test is performed by two workers.
B. Machine status and parking site
(5.9In)
150mm
and 55°C.
LG922EIII05001
6. Set the accelerator linkage or knob to the A/C).
position of top engine speed.
7. Turn the travel speed selection switch to gear normal range.
“1” (tortoise position).
8. Push the right travel control lever to the front mode.
end, and then measure and record the time for
the right track rotating three circles. 6. The working pressure and the pilot pressure of
the pump are within the normal range.
9. Repeat Step 7 and 8 to measure three times.
Calculate the average value of the data based C. Travel speed test
on the three measurements. 1. Park the machine in a solid and flat site where
10. Measure the data of the backward right track "1" applicable for straight travel about 30m.
(tortoise position) using the same method. 2. Keep hydraulic oil temperature between 45°C
11. Turn the travel speed selector switch to "2" and 55°C.
(rabbit position), repeat Steps 8 to 10, to 3. Operate the work implement to make it in the
compare the average value of measured data transport status, as shown in the figure below.
with the standard values in the Table below.
12. Lift the boom till the bucket bottom off the
ground for 300 mm. Operate the left slewing and
turn the upper mechanism by 180°.
13. Repeat Steps 4 to 11 and measure the travel
speed of the left track in the same way.
14. Refer to the attached table 1 for determination.
5-7
4. Draw a 30m line on the ground starting from the 5.1.4 Travel Deviation
track front end, and then draw another line
approx. 10m away from the starting point to A. Tools and testing instruments
make it paralleled with the machine. As shown in
the figure below. 1. 30m measuring tape.
2. A tool used for marking the location of the
machine.
and 55°C.
A/C).
At the At the
start timing end point 4. The working current of the pump is within the
P P
normal range.
5. The complete machine works in normal mode.
LG922EIII05003
6. The working pressure and the pilot pressure of
5. Set the accelerator linkage or knob to the the pump are within the normal range.
position of top engine speed. 7. The maximum wind speed shall be no more
6. Turn the travel speed selection switch to gear than 6m/s during the test.
“1” (tortoise position). C. Travel deviation detection
7. Drive into the test road at a steady speed. The 1. Park the machine in a solid and flat site.
first 10m is used for acceleration. It starts
timekeeping when the front end of the track
and 55°C.
enters the timing line and stops it when the front
end of the track reaches the finishing line. 3. All work implements, such as boom, arm and
Record the time for the machine running through bucket cylinder, all extended, as shown in Figure
the test road. below.
8. Repeat Step 7 to measure for three times, and
calculate the average value.
9. Turn the upper mechanism by 180°, and
measure the data of reversing at the right track nce
ta
"1" position (tortoise position) using the same dis
um ion
method. m rat
Maxi ce
l e
a
Ac are m
10. Turn the travel speed selection switch to Gear 35
-
m
“2” (rabbit position) and repeat the Step 6~9. 20
11. Refer to the attached table 1 for determination.
5-8
4. Draw a line of 25m on the ground starting from 11. Rotate the lower parts by 180°, repeat Steps 3 to
the track front-end and make it paralleled with 10, and measure the offset travel values when
the machine. Draw a line at each position about the excavator reverses and compare them with
5m and 15m away from the front end of the the standard values in the Table below.
excavator track and at the finishing point
12. Refer to the attached table 2 for the
respectively.
determination of travel deviation.
5. Set the accelerator linkage or knob to the
6. Turn the travel speed selection switch to gear
“1” (tortoise position).
7. Push forward the left and right travel control
lever to the topmost at the same time. The
machine reaches the position about 5m away
from the starting point, where A is marked on the
track on the relative location of the ground.
Similarly, correctly mark the B and C when the
excavator reaches the position about 15m away
from the starting point. As shown in the Figure
below.
8. Measure the perpendicular distance “e” of point

“B” to straight-line AC.
Calculate the average value of measured data
for three times.
10. Turn the travel speed selection switch to gear
“2” (rabbit position), repeat steps 7~9 to
measure the travel deviation value at gear "2"
(rabbit position).
5-9
5.1.5 Slewing Service Brake Angle
Please confirm that the testing site allows a

360° slewing of the machine! Please confirm
that there are no other workers or facilities
within 3m of the slewing area!

1. A tool used for marking a starting point.
2. Measuring tape.
3. Plumb. 4. Retract the bucket completely (extend cylinder),
as shown in Figure below.
4. Measurement is performed by three workers.
5. Adjust the boom height until the distance
B. Machine status and parking site reaches 1.5m between bucket tooth and the
1. A solid and flat parking site. ground, as shown in the Figure below.
2. Retain hydraulic oil temperature between 45°C 6. Confirm the projection point of the middle tooth
and 55°C. of the bucket on the ground with plumb bob and
make corresponding mark A, measure the
3. Set the engine to maximum speed (turn off the distance L2 of the projection point to track front
A/C). end, and get the distance L1 of slewing bearing
4. The working current of the pump is within the center to track front end, as shown in the figure
normal range. below.

mode (and the no-load state).
C. Test of Slewing Service Braking Angle
1. Park the machine at a solid and flat site, as
3. Stretch the arm completely (retract the cylinder),
as shown in the figure below.
Please honk the horn prior to slewing action!

5-10
7. Measure the distance between A and B with the 5.1.6 Slewing Speed
tape (chord length which slewing angle
corresponds to), as shown in the figure below.
8. Repeat Steps 6 and 7 to measure three times,
then calculate the average value.
Please confirm that the testing site allows a
9. Measure the distance between A and B during
anticlockwise slewing with the same method. 360° slewing of the machine! Please confirm
that there are no other workers or facilities
determination of the steering service braking within 3m of the slewing area!
angle.
1. Stopwatch.
2. A tool used for marking a starting point.
3. Two test workers who are familiar with operating
the excavator.
and 55°C.
A/C).
normal range.
mode.
C. Slewing speed test
1. Park the machine in a solid and flat site.
5-11
5.1.7 Slewing Bearing Clearance

Slewing bearing clearance (vertical direction)
1. Dial indicator.
2. Dial indicator bracket (free rotation).
3. Measuring tape.
4. Measurement is performed by two workers
and 55°C).
4. Retract the bucket completely (stretch the
cylinder). 3. Set the engine to maximum speed (turn off the
5. Adjust the boom height to make the bucket A/C).
bottom at the height of the boom hydraulic 4. The working current of the pump is within the
cylinder articulated axle. normal range.
mode.
Please honk the horn prior to slewing action!
6. After operation is allowed by beeping, turn the
slewing right pilot valve to maximum stroke,
slewing clockwise as fast as possible. Start
timekeeping from the third circle, record the time Pay close attention to the machine conditions
for three circles in total, and then stop slewing.
when reading the dial indicator! During
7. Repeat the Step 3 ~ 6 to measure three times. maintenance and test, the qualified protective
Calculate the average value of the clockwise
slewing time measured for three times. suit, safety shoes, and helmet must be worn!
Make sure that there are no obstacles within
8. Measure the time of anticlockwise slewing of 3
circles with the same method. the maximum slewing radius.
9. Refer to the attached table 4 for the C. Measurement of slewing bearing clearance
determination of slewing speed. (vertical direction)
2. As shown in the Figure below, install the magnet
base on slewing bearing support, and the probe
of dial indicator contacts with mounting bolt of
slewing bearing outer ring.
5-12
8. Release the bucket completely and lift or lower

the boom and make the distance between the
In front of machine bucket tooth and ground 450mm, as shown in
Figure below.
Magnet base
Dial
indicator
3. Retracting or stretching out the arm and make

the included angle between it and boom around 9. Record readings of dial gauge
90°, as shown in the figure below.
10. Repeat the Step 3 ~ 9 to measure three times.
4. Retracting or stretching out the bucket and Calculate the average value of the data
make the bucket bottom parallel with the measured three times.
ground.
11. Rotate the upper part by 180°, repeat Step
5. Lower the boom and make the bottom of the 2~10, and measure the vertical clearance of the
bucket contact with the ground. Continue to other slewing bearing.
lower the boom, and jack up the front end of the
machine so that the track is off the ground about 12. Refer to the attached table 5 for slewing bearing
450mm as shown in figure below. clearance (vertical direction).
6. Place the pointer of dial gauge to "0".

7. Lift the boom and release the arm until the arm
is extended completely, as shown in Figure
below.
5-13
5.1.8 Action Time of Cylinder 2. Set the accelerator linkage or knob to the
3. The height of bucket tooth is in accordance with
the front pin of the arm, as shown in Figure
below.
Be sure to move the machine (standard
configuration) out of the route of other
machines before testing so that there are no
obstacles within maximum slewing radius
Other workers cannot approach the machine
when the machine is stated for adjustment or
test.
Only the time to buffer stroke starting point is

required to be measured when measuring the
action time of cylinder. 4. The arm cylinder retracts completely.
A. Tools and testing instruments 5. Lower the boom until the bucket touches the
ground.
1. Stopwatch.
6. Operate the boom lifting pilot valve to the
2. Two test workers who are familiar with operating maximum stroke and lift the boom as fast as
the excavator. (1 excavator operator and 1 time possible. The timekeeper starts once the boom
recorder) is acting, and records the time from action
B. Machine status and parking site starting to boom cylinder reaching the buffer
stroke starting point.
7. Operate boom lowering pilot valve to the
2. Maintain hydraulic oil temperature between maximum stroke and lower the boom as fast as
45°C~55°C (subject to the temperature on the possible. The timekeeper starts once the boom
display, similarly hereinafter). is acting, and records the time from action
3. Set the engine to maximum speed (turn off the starting to bucket touching the ground.
A/C). 8. Repeat Step 6 and 7 to measure three times.
4. The working current of the pump is within the Respectively calculate the average values of the
normal range. boom lifting & lowering time for three times.
5. The complete machine works under the normal 9. Refer to the attached table 6 for the
mode. determination of boom cylinder action time.

C. Measurement of the boom cylinder action
time
5-14
D. Measurement of the arm cylinder action time 7. Operate arm pilot valve to the maximum stroke
and release the arm as fast as possible (the
cylinder retracts). The timekeeper begins to time
as soon as the arm is acting, and records the
time of action start to arm cylinder reaching
This test method is applicable to the excavator buffer stroke starting point.
with standard configuration. If the tested
machine equipment has optional parts, check Calculate the average values of time for arm
and confirm that there is no interference retracting and stretching out three times
between the frontal attachments and the cab! respectively and compare them with the
standard values in the Table below.
2. Set the accelerator linkage or knob to the determination of arm cylinder action time.
E. Measurement of the bucket cylinder action
3. Lift the boom cylinder to a certain height, as time
3. Lift the boom to the highest position.
4. Adjust the arm and make the angle between the
arm and its cylinder around 90 °, as shown in
Figure below.
5. Adjust the arm to make the angle between the
arm and its cylinder about 90 °, as shown in
Figure 17.
4. The bucket cylinder must be retracted to ensure

the bucket cannot bump against the ground
when the arm cylinder is actuating forward and
back.
5. Stretch the arm completely (retract the cylinder).
6. Operate arm pilot valve to the maximum stroke
and retract the arm as fast as possible (stretch
the cylinder). The timekeeper begins to time as
soon as the arm is acting, and records the time
of action start to arm cylinder reaching buffer
stroke starting point.
6. Lower the boom until the height of the front pin
of arm in accordance with that of rear pin of the
boom.
5-15
7. Retract the bucket completely (stretch the 5.1.9 Cylinder Settlement

cylinder).
8. Operate bucket pilot valve to the maximum A. Tools and testing instruments
stroke and release the bucket as fast as 1. 30cm steel ruler.
possible (the cylinder retracted). The timekeeper
starts the bucket is acting and records the time 2. Stopwatch.
from action starting to bucket cylinder reaching 3. A tape used for marking staring point.
cushioning stroke starting point (if any).
4. 3m measuring tape.
9. Operate bucket pilot valve to the maximum
stroke and retract the bucket as fast as possible 5. Plumb.
(stretch the cylinder). The timekeeper starts the 6. Two test workers who are familiar with operating
bucket is acting and records the time from action the excavator.
starting to bucket cylinder reaching cushioning
stroke starting point (if any). B. Machine status and parking site
10. Repeat Step 7 and 8 to measure three times. 1. A solid and flat parking site.
Calculate the average values of time for bucket 2. Retain hydraulic oil temperature between 45°C
stretching out and retracting three times and 55°C.
respectively and compare them with the
standard values in the Table below. 3. The working current of the pump is within the
normal range.
11. Refer to the attached table 6 for determination of
bucket cylinder action time. 4. The complete machine works in the normal
mode.
Be careful to aerial work operation. 6. Engine flameout
C. Measurement of cylinder settlement
1. Park the machine in a solid and flat site and
maintain the hydraulic oil temperature between
45°C and 55°C.
5-16
3. Retract the bucket completely (cylinder 8. Shut down the engine for 10 minutes, then
extended), as shown in Figure 15. measure and record moving distance of arm
cylinder piston.
4. Adjust the boom height until the distance is 1.5m
between the bucket tooth and the ground. 9. Repeat Step 8 to measure three times.
Calculate the average value of moving distances
5. Shut down the engine for 10 minutes, then
of the arm cylinder piston rod.
measure and record the moving distances of the
boom, arm and bucket cylinder piston and 10. Refer to attached table 7 for the determination of
settlement distance of the tooth. cylinder settlement.
Calculate the average values of the moving
distances of the boom, arm, and bucket cylinder
piston and settlement distance of tooth for three
times, respectively.
7. Bucket cylinder and arm cylinder is stretched out
completely, and the boom is lowered to a certain
height to make the articulated joint between link
and bucket cylinder is 250~300mm off the
ground, as shown in the figure below.
5-17
5.1.10 Operating Force of Control 5.1.11 Control Lever Stroke

Lever
A. Tools and testing instruments Steel ruler
Spring balance: range of 200N B. Machine status and parking site
B. Machine status and parking site 1. A solid and flat parking site.
1. A solid and flat parking site. 2. Shut down the diesel engine.
2. Shutdown the engine C. Measurement of control lever stroke
1. Measure control lever stroke from the neutral
position to ending point respectively at the tops
of the boom, arm, bucket, slewing and travel
control levers.
the average value.
3. Record measurement value.
C. Measurement of the control-lever operating

force
1. Hook the spring balance onto the control lever
as shown in Figure above and operate the
following functions: boom lifting and lowering,
arm retracting and stretching out, bucket
retracting and stretching out, left and right
slewing and travel.
2. Measure the maximum operating force when
each actuating mechanism is in its maximum
stroke.
3. Record measurement data.
the average value.
5-18
5.1.12 Boom Lifting and Slewing

Action
1. Stopwatch
2. Measuring tape
2. Set accelerator linkage or knob to the highest
engine speed. Lift the boom cylinder and make
sure that the cylinder runs smoothly without
collision.
3. Stretch the arm completely, retract the bucket 3. When upper mechanism slewing 90°, release
completely, and lower the bucket to the ground, control lever to stop two kinds of actions as
and the buckets shall be no load. As shown in shown in the figure above. Measure the time of
the figure below. slewing for 90° and the height of bucket tooth
4. Maintain hydraulic oil temperature at 50±5°C. (H).
C. Inspection of boom lifting and slewing action 4. Repeatedly measure for 3 times and calculate
the average value.
position of top engine speed. A/C and automatic
idling are stopped.
2. Conduct full-stroke operation while lifting boom
and conducting slewing. As shown in the figure
below.
5-19
5.1.13 Pilot Pressure
Press the exhaust

If the cab display screen of your machine has valve stem
the setting of pressure display, you can use
the information on the display screen to
conduct the following tests. If your machine
does not support this function, the following
steps will guide you to install a pressure
gauge.
A. Tools and testing instruments 2) Connect the pressure gauge at position (1) as
Pressure gauge, range 0~10MPa (0~1450psi); shown in the figure below.
2. Keep hydraulic oil temperature at 50 ±5°C (122±
41°F).
C. Measurement of pilot pressure
1. Install the pressure gauge. Specific operations
are as follows
1) Release the residual pressure in the tank:
Turn off the diesel engine, and loosen the dust
cover on the breather valve, as shown in figure
below
3) Start the diesel engine, and make sure there is

no obvious oil leaking at the pressure gauge
connection.
position of top engine speed. A/C and automatic
Dust cover idling are stopped.
3. Record the pressure values.
the average value.
Press the air-bleed valve stem on the breather

valve, as shown in the figure below.
5-20
5.1.14 Secondary Pilot Pressure Press the air-bleed valve stem on the breather
valve, as shown in the figure below.
If the cab display screen of your machine has

the setting of pressure display, you can use Press the exhaust
the information on the display screen to valve stem
gauge.

1. Pressure gauge, range 0~10MPa (0~1450psi);
2. Tee union (material # 32c0411) 2) Connect the pressure gauge. Connect the tee
union (material # 32c0411) and pressure gauge
B. Machine status and parking site in the pilot line. Start the diesel engine, and
1. A solid and flat parking site. make sure there is no obvious oil leaking at the
pressure gauge connection.
41°F)
C. Measurement of secondary pilot pressure
are as follows:
cover on the breather valve, as shown in Figure
below.
Dust cover
5-21
5.1.15 Output Pressure of Solenoid

Proportional Valve
If the cab display screen of your machine has

gauge.

1. Transition joint (material # 00a0969)
2. O-ring (material # 12b0428)
3. Pressure gauge, range 0~10MPa (0~1450psi)
1. Pressure gauge
2. Secondary pilot hose 41°F).
2. Set the accelerator linkage or knob to the C. Measurement of output pressure of solenoid
position of top engine speed. A/C and automatic proportional valve
idling are stopped.
3. Full-stroke operates the corresponding control are as follows:
lever and measures the pilot pressure,
including:
1) Boom lifting and lowering
cover on the breather valve, as shown in Figure
2) Arm retracting and stretching below.
3) Bucket retracting and stretching
4) Slewing to left and right
5) Travel forward and backward
4. Operate the control lever and record the
measured values.
the average value.
5-22
Dust cover

Press the air-bleed valve stem on the breather position of top engine speed. A/C and automatic
valve, as shown in the figure below. idling are stopped.
3. Full-stroke operation of corresponding control
lever and measurement of the pressure of the
solenoid proportional valve, include:
(1) Boom lifting and lowering
Press the exhaust (2) Arm retracting and stretching
valve stem
(3) Bucket retracting and stretching
(4) Slewing to left and right
(5) Travel forward and backward
the average value.
2) Remove the plug from the main pump as

shown in the figure below. Connect the O-ring
(material # 12b0428) and transition joint
(material # 00a0969), and then connect the
pressure gauge.
connection.
5-23
5.1.16 Setting Pressure of Main

Relief Valve
If the cab display screen of your machine has Dust cover

gauge.
Press the air-bleed valve stem on the breather
A. Tools and testing instruments valve, as shown in the figure below.
1. Tee union (material # 32c0529)
2. O-ring (12b0428)
3. Transition joint (00a1964)
4. Pressure gauge, range 0~10MPa (0~1450psi)
41°F).
C. Measurement of setting pressure for the main
relief valve
are as follows:
2. Connect with the pressure gauge (take the left
1) Release the residual pressure in the tank. pump as an example), see the figure below:
Turn off the diesel engine, and loosen the dust 1) Unscrew the plug (1) shown in the Figure;
cover on the breather valve, as shown in figure
below, 2) Install the O-ring(2)?
3) Install the transition joint (3);
4) Install the tee (4);
5) Connect the sensor of electrical system into
port A of tee;
6) Connect the pressure measurement joint into
port B of tee.
connection.
5-24
The method for connecting the right pump with the pressure gauge is the same as that of the left pump.
Pressure test port

of right pump
Pressure test port

of left pump
Port A
Port B
1. Plug on the pump (originally equipped on the pump) 3. Transition joint

2. O-ring 4. Tee
3. Set the accelerator linkage or knob to the position of top engine speed. A/C and automatic idling are
stopped.
5-25
4. Slowly operate control levers of the bucket, arm, and boom to maximum strokes, at the moment, hydraulic
system overflows, and measure and record pressure value.
5. For slewing function, make the upper revolving frame fixed, and slowly operate the slewing control lever in
order to make slewing function overflow. Record measurement value.
6. For the travel function, fix the track on the immobile object to make the travel function overflow. Record
measurement value.
7. Press the transient boost switch, operate the bucket, arm, and boom control lever slowly within 8s to the
maximum stroke to make the hydraulic system overflow, and then measure and record the pressure value.
5-26
Attached Table
Attached table 1
Test table for travel speed (idling speed/actual measured speed)
Machine model: Testing date:
Machine number: Testing site:
Testing worker:
Travel Travel time (s)

Speed
Testing items distance Average Remarks
1 2 3 (m/s)
(m) value
Forward gear I
Forward gear II Hydraulic oil temperature
Idling speed at initial measurement:
Backward gear I °C
Backward gear II
Forward gear I
Forward gear II Hydraulic oil temperature
Travel speed at initial measurement:
Backward gear I °C
Backward gear II
Attached table 2
Offset travel test table

Testing worker:
Offset (mm)
Testing items Average Remarks
1 2 3
value
Forward gear I
Forward gear II Hydraulic oil temperature at
Offset travel value initial measurement:
Backward gear I °C
Backward gear II
5-27
Attached table 3
Test Table of Slewing Service Braking Angle

Testing worker:
AB chord length (mm) Slewing

L1+ L2
Testing items Averag brake angle Remarks
(mm) 1 2 3
e value (°)
Clockwise Hydraulic oil temperature at

initial measurement:
Counterclockwise °C
Attached table 4
Slewing speed test table

Testing worker:
Slewing time(s) Slewing

Slewing
Testing items Averag speed Remarks
circles 1 2 3
e value (s/circle)
Clockwise Hydraulic oil temperature at

initial measurement:
Counterclockwise °C
Attached table 5
Measurement table for the slewing bearing clearance

Testing worker:
Slewing bearing clearance(mm)

Testing items Remarks
1 2 3 Average value
Hydraulic oil temperature at initial
Vertical direction
measurement: °C
5-28
Attached table 6
Test table for action time of excavator work implement

Testing worker:
Measured value Standard

Working condition
Testing items Average requiremen Remarks
for measurement 1 2 3
value ts
Lifting
Boom
Lowering
Retracting Hydraulic oil
Work implement
Arm temperature at initial
action time (s) Stretching measurement: °C
Excavation
Bucket
Unloading
Attached table 7
Cylinder settlement test table

Testing worker:
Cylinder settlement (mm)
Testing items Testing time (min) Remarks
1 2 3 Average value
Lowering of the boom
Retracting of arm
Hydraulic oil temperature at
Stretching of bucket
initial measurement: °C
Bucket excavation
Bucket unloading
5-29
CLG920E/922E/923E 5.2 Other Tests
5.2 Other Tests

5.2.1 Adjustment of Valve Lash
Preparation steps
Figure Steps
Explosive gas may leak from the battery. To avoid
personal injury, the diesel compartment must be with
good ventilation before the maintenance of the bat-
tery. To avoid generating the electric arc, the wire of
the battery negative pole (-) must be removed at first
and connected at last.
1. Disconnect the battery.
2. Remove the inlet joint if necessary.

Remove the four mounting screws, inlet joints, and
gaskets.
Remove the air intake heater component and the
gasket.
Caution: Various inlet joints are equipped for
the diesel engine, and the two shown in the right
figure are the common ones.
5-30
5.2 Other Tests CLG920E/922E/923E
Figure Steps
Caution: If the inlet joint needs to be

removed, regardless of the duration of removal,
seal the pipe hole with an adhesive tape to avoid
the falling of the fragments into the intake pipe.
3. Remove the crankcase breather from the valve

chamber cover.
Caution: It may be possible to remove the
diesel engine cover to access the crankcase
breather/rocker arm compartment cover.
4. Disconnect the crankcase breather pipe from the

crankcase breather assembly.
5. Disconnect the crankcase breather oil return pipe
from the crankcase breather assembly.
6. Remove the mounting screws.

7. Vertically pull the breather assembly upward to
remove the respirator from the rocker cover.
5-31
Figure Steps
6. Remove the rocker cover and the valve chamber
cover gasket.
Warning: You shall wear the proper goggle
and the protective mask when using compressed
air. The flying fragments and the dirt may cause
personal injury.
Before removing any components, clean the

surrounding of the mounting fasteners and the
connector to remove the loose fragments.
Caution: For the diesel engine whose rocker

cover gasket is installed in the groove at the
bottom of the rocker cover, do not remove the
rocker cover gasket. This can be used
continuously. The gasket must be replaced once
it is removed from the rocker cover.
7. Remove the mounting bolts and the vibration

insulator from the rocker cover.
8. Remove the rocker cover.
5-32
Figure Steps
9. Clean it and check whether it can be used
continuously.
Warning: When cleaning with solvent, acid,
or alkali materials, please follow the advice of the
manufacturer. Wear the goggle and the protective
suit to avoid personal injury.
Warning? Some solvent is flammable and

toxic. Please read the instructions provided by
the manufacturer prior to use.
Warning: You shall wear the proper goggle

personal injury.
Caution: When cleaning the rocker cover, if

the rocker arm gasket is still installed on the base
of the rocker cover, do not soak the bucket lever
chamber in the solvent. Do not soak the gasket in
the solvent too much. This can be used
continuously. The gasket must be replaced once
it is removed from the rocker cover.
Clean the rocker cover with the solvent. Dry it with the
compressed air.
Caution: When installing the gasket into the

valve chamber cover, check the gasket. The
gasket must be replaced once it is removed from
the rocker cover.
Check the silicone clad layer for flaw.

Replace the gasket if any damage is found.
If the gasket is removed from the rocker cover groove,
replace the gasket with a new one.
5-33
Figure Steps
Check the rubber vibration insulator for flaw.
Replace it if any flaw or break is found.
Adjust it
Figure Steps
Caution: The temperature of the diesel

engine coolant must be less than 60°C(140°F).
1. Rotate the crankshaft until the cylinder 1 is in the

TDC.
5-34
Figure Steps
The TDC can be confirmed by the following methods:
Align to the shock absorber/crankshaft speed indicat-
ing ring, so as to make the TDC pointer at the position
of 12 o'clock. If the two rocker arms of cylinder 1 are
loose, go to the following steps. If the two rocker arms
of cylinder 1 are not loose, rotate the crankshaft by
360°.
2. When the diesel engine is in this position, you can

conduct the following clearance check of the
rocker arm:
(E=Exhaust, I=Intake)
1I -1E - 2I - 3E - 4I - 5E.
Limit value of the lash inspection:

Minimum: 0.17mm (0.0067In)
Maximum: 0.33mm (0.0130In)
Air Inlet
Minimum: 0.43mm (0.0169In)
Maximum: 0.59mm (0.0232In)
Caution: Generally, checking the setting
value of the top-mounted mechanism is a part of
the fault diagnosis procedure. As long as the
clearance measurement value is within the range
above, it is not necessary to reset the value
during the check.
5-35
Figure Steps
When the feeler gauge slides between the bridging
pressure plate and the rocker arm bearing support, if
a certain resistance can be "felt", the clearance is
correct.
3. Insert the feeler gauge between the jumper plate
and the rocker arm bearing support to measure
the clearance. If the lash measurement value is
beyond the technical specification, loosen the
locknut, and adjust the lash to the nominal
technical specification.
Technical specification of valve lash:
Intake: 0.25mm (0.0098In)
Exhaust: 0.51mm (0.0201In)
4. Tighten the locknut and conduct the
measurement.
Torque value: 24 N.m (17.7lbf.ft)

5. Rotate the crankshaft by 360°.
6. Measure the following rocker arm clearance
according to the same procedures and the
technical specifications above:
(E=Exhaust, I=Intake).
2E, 3I, 4E, 5I, 6I, and 6E.
If the clearance does not meet the technical
specification, reset it.
5-36
Last step
Figure Steps
Warning: Explosive gas may leak from the

battery. To avoid personal injury, the diesel
compartment must be with good ventilation
before the maintenance of the battery. To avoid
generating the electric arc, the wire of the battery
negative pole (-) must be removed at first and
connected at last.
1. Install the rocker cover gasket and the cover.

Caution: If the gasket has been removed from
the rocker cover, new gasket must be installed.
If the bucket lever gasket is replaced, the installation

procedure below must be followed when the press-in
mating gasket is installed.
• Press the molded gasket into the corners of the
rocker cover.
• Press the rest of the gasket into the rocker cover.
2. Install the rocker cover on the mounting screw.
3. Install the vibration insulator and the mounting
nut.
4. Tighten the mounting nut.
Torque value: 24 N.m (17.7lbf·ft)

5-37
Figure Steps
5. Install the crankcase breather.
6. Install the breather and the mounting screw in the
rocker cover.
7. Lubricate the O-ring and the rocker cover with oil.
8. Tighten the screw.
Torque value: 10 N.m (7.4lbf·ft)
9. Install the crankcase breather pipes to the

10. Install the crankcase breather oil return pipe to the
Caution: It may need to install the diesel
engine cover that has been removed before.
11. Install the inlet joint (if it has been removed)

12. Clean it and check whether it can be used
continuously.
Clean the sealing surface of the air intake heater
core.
Clean the sealing surface of the inlet cover.
Clean the sealing surface of the inlet joint.
Caution: Sealing and any other materials are
prohibited to enter the air inlet.

5-38
Figure Steps
Caution: Remove the adhesive tape from the

intake manifold, if any.
13. Install the new gasket and the inlet joint on the air
starting auxiliary device - heater.
14. Install and tighten the 4 mounting screws.
Torque value: 24 N.m (17.7lbf.ft)

15. If equipped, install the single black (ground)
heater lead wire.
16. Connect the battery.

17. Run the diesel engine and check for leakage.
5-39
5.2.2 Measurement of Blow-By of

Crankcase
1. Overview
Ventilation
device pipe
for crankcase
The actual diesel engine configurations are not
showed in some figures in this step. However, To
pressure
the steps are identical. gauge
If crankcase pressure and/or blow-by volume is too

much, it indicates that fault occurs in the diesel
engine or its related components, and consequently
burning gas or air leaks into the crankcase. The
result is that the generated pressure exceeds nor-
mal crankcase pressure, and therefore the blow-by
level is increased.
How to measure the crankcase pressure/blow-by
and how to determine the fault components are
described in this step.
2. The general purpose of blow-by measurement
lies in:
1) Check the diesel engine running-in after re-
installation;
2) For the open crankcase ventilating system,
conduct fault diagnosis and troubleshooting
when excess engine oil overflows from the
crankcase breather pipes (generally known as
oil carry-out); It is worth noticing that the two terms about “blow-
by” and “carry-out (engine oil overflows from the
3) Conduct troubleshooting for probable diesel respirator pipe)” are usually equivalent.
engine internal damages, such as worn piston
rings, oil seals or tubes of valve rods, The engine oil quantity will directly affect the mea-
turbochargers, air compressors, etc. surement results of blow-by if excess engine oil
overflows from the respirator pipes when measuring
3. These steps provide the general guideline about blow-by.
the measurement of blow-by related to the
above conditions. The blow-by measurement results may also be
affected by the engine oil collected on the metering
holes of blow-by measurement and maintenance
tools. This reduces the sizes of metering holes, and
therefore, the measurement results always exceed
the actual blow-by measurement values.
4. If so, the following measures shall be taken:
5-40
1) Find different measuring positions on the diesel 2) Cut the engine oil filter and check whether there
engine to measure the crankcase pressure are chippings.
(engine oil filler, engine oil filler cover, drainage
3) Get an engine oil sample and check whether
position of unused turbocharger, etc.).
there are pollutions.
2) Clean the residual engine oil on the respirator
Measurement tools
before measuring blow-by, and dry it
completely. The tools used for measuring blow-by are generally
similar in the structure. The sizes of metering holes
3) Confirm whether some factors making the
are their main distinctions. Different sizes of meter-
respirator full with engine oil, for example:
ing holes are designed for accurately measuring
4) Engine oil level is incorrect blow-by, which can also meet the needs for various
diesel engine configurations and rated power.
5) Vehicle operation (excessive incline, excessive
Because the diesel engine blow-by depends on the
all-round rotation of the diesel engine)
volume of inlet air.
6) The diesel engine internal components make
For example:
engine oil deviate to the breather cavity (piston
cooling nozzle, attachment drain pipe of engine If the measurement of blow-by is conducted on two
oil, etc.) diesel engines with the same configurations and
sizes, but with different horsepowers and rated
7) Confirm whether there is another breather
speeds, the measured maximum blow-by values will
option for the diesel engine being repaired.
be different.
5. Other steps can be adopted to verify the doubt
that the internal faults of the diesel engine cause Part number of blow-by tool: 3822566
excess blow-by. Size of metering hole: 7.67 mm
Blow-by measurement shall be considered only Pictures of blow-by tools

when confirming the running in or other symptoms
of the diesel engine after reassembly. Emerging
symptoms include:
1) Excess engine oil carry-out (the engine oil is
carried-out from the crankcase breather pipes)
2) Over-high crankcase pressure (for the diesel
engine equipped with crankcase pressure
sensor)
3) Low power
4) Engine oil consumption
5) Exhaust smoking
6. It is not necessary to measure the blow-by if
there are no other symptoms.
Connect the hydraulic gauge (the part number is
Other steps can be adopted to verify the doubt that ST1111-3), pressure gauge or sensor on the blow-
the internal faults of the diesel engine cause excess by measurement and maintenance tools when mea-
blow-by. These steps include: suring the crankcase/blow-by pressure.
1) Confirm the diesel engine maintenance
procedures.
5-41
50.8[2] 84[2.966]
76.2[3] 103[3.637]
101.6[4] 119[4.202]
It is supposed to measure the water column for 127[5] 133[4.697]
944mm at most by using the hydraulic gauge 152.4[6] 145[5.121]
(the part number is ST1111-3). 177.8[7] 155[5.474]

203.2[8] 164[5.792]
228.6[9] 172[6.074]
254[10] 180[6.357]
279.4[11] 187[6.604]
304.8[12] 193[6.816]
330.2[13] 200[7.063]
355.6[14] 206[7.275]
381[15] 211[7.451]
406.4[16] 217[7.663]
431.8[17] 222[7.840]
457.2[18] 226[7.981]
482.6[19] 229[8.087]
508[20] 235[8.299]
533.4[21] 239[8.440]
558.8[22] 242[8.546]
584.2[23] 246[8.687]
609.6[24] 248[8.758]
The relationship between the measured pressure

value of orifice with 7.67-mm diameters and flow
velocity is shown in the table below.
The blow-by conversion table for the orifice

with 7.67mm diameters and blow-by
mmH2O[inH2O] Liter/min [cfm]
25.4[1] 50[1.766]
5-42
Initial inspection
Figure Steps
Initial inspection
Caution: Locations and types of crankcase
breathers may be changed along with the
differences in diesel engine configurations (front/
rear gear power train) and/or diesel engine
applications.
1. Check whether the crankcase respirator pipes are

blocked before measuring the blow-by pressure.
2. If troubleshooting for excess engine oil overflowing
from the respirator pipe is carried out, the
respirator components shall be removed prior to
blow-by measurement in order to clean and clear
all collected engine oil away.
3. Check the engine oil level in the diesel engine. If
the oil level is too high, the blow-by pressure will
exceed the normal level and/or excess engine oil
will be carried out.
5-43
Measurement
Figure Steps
1. Connect the hydraulic gauge (the part number is
ST1111-3), pressure gauge or sensor on the
blow-by measurement and maintenance tools
when measuring the crankcase/blow-by pressure.
Caution: Locations of crankcase breather
pipes may change along with the diesel engine
configurations and/or the specific applications.
2. Installation of applicable blow-by maintenance

tools:
• For the open crankcase breather/ventilating
system, connect applicable blow-by maintenance
tools at the end of crankcase breather respirator
pipes. Connect a water pressure gauge, pressure
gauge or sensor on the blow-by maintenance
tools.
3. Check the effects of diesel engine blow-by on the
following conditions.
3.1 The following methods for operating the diesel
engine with rated speed and load are optional:
1) Use chassis dynamometers or diesel
dynamometers for the diesel engine running-in.
2) Use chassis dynamometers or diesel
dynamometers for the diesel engine test.
3) Stall test (for the diesel engine only equipped with
an automatic transmission).
5-44
Figure Steps
Notice: Excess engine oil overflows from the

respirator pipes during the blow-by measurement.
So the engine oil volume also directly affects the
blow-by measurement results.
3.2 Operate the diesel engine with rated speed and

full load until stable values are obtained.
Caution: During measuring the blow-by, a
"peak" will appear initially in the values when the
diesel engine achieves peak power and rated
speed. Start to read the readings after the blow-by
measured value is stable.
Caution: For diesel engine running-in, if the

blow-by is increased suddenly or exceeded the
maximum allowed limit in any running-in steps,
return to the previous step to continue the
running-in. If the blow-by does not reach an
acceptable level, interrupt the running-in and
confirm the causes.
3.3 Record the blow-by measured values in a steady

state.
Remove the diesel engine blow-by maintenance tools
and hydraulic gauges or pressure gauges if blow-by is
within the technical specifications.
4. Check the effects of turbocharger blow-by on the
following conditions.
If the diesel engine blow-by maintenance tools and
hydraulic gauges or pressure gauges are still
installed on the turbocharger:
4.1 Isolate a turbocharger (if equipped), and confirm
whether the high blow-by pressure is caused by the
leakage of turbocharger seals.
4.2 Disconnect turbocharger engine oil tubes when
measuring the blow-by generated by the
turbocharger.
5-45
Figure Steps
Caution: Do not run the diesel engine for

more than 1 min. Supervise the engine oil quantity
in the vessel. Otherwise, the diesel engine oil will
be used up, consequently causing severe damage
to the diesel engine.
The methods of turbocharger isolation are described

in these steps.
4.3 Place the turbocharger oil tube into a big vessel
when the turbocharger oil drain tube and the diesel
cylinder body are disconnected.
4.4 Seal the ports of turbocharger engine oil drain
tubes on the cylinder body.
4.5 The following methods for operating the diesel
engine with rated speed and load are optional:
• Use chassis dynamometers or diesel
dynamometers for the diesel engine test.
4.6 Record the measured peak value of blow-by
pressure.
5. Determine the distributions of turbocharger blow-
by pressures by confirming the blow-by pressure
measurement difference values between them
under the disconnected condition with isolation
and the connected condition without isolation
between turbocharger oil tubes and turbocharger
engine oil tubes.
Blow-by pressure difference

Blow-by generated by a turbocharger Maximum: 30%
Check the engine oil for not leaking in the

compressors of the turbocharger and turbine areas if
the blow-by generated by turbocharger does not
conform to the technical specifications. Change the
turbocharger if necessary.
5-46
Figure Steps
6. Install the turbocharger oil tubes.
7. Check the diesel engine oil level, fill engine oil if
necessary.
5-47
5.2.3 Oil Pressure Measurement
Measurement tools Material # Figure
Compuchek™ pipe joint 3824842
Figure Steps
Warning: Some states and federal agencies

in America have firmly believed that the used
engine oil has a carcinogenic effect and can
cause reproduction disease. It is supposed to
avoid inhalation of engine oil steam, swallowing
by mistake and contacting the used engine oil for
a long time. If not used again, such coolant and oil
should be treated according to the local
environmental protection regulations.
Warning: Avoid the skin directly contacting

with hot oil to reduce the possibilities of
personnel injury.
1. Find proper ports to measure the engine oil

pressure. For most diesel engines, the ports can
be on the locations near ECM along the main
engine oil passage.
2. Remove the plugs.
Note: It is preferred to check the engine oil pressure
in the main passages if applicable.
3. Install Compuchek™ pipe joint.
5-48
Figure Steps
Caution: If there is no oil pressure generated

in the diesel engine within 15 seconds upon
starting, shut down the engine to avoid internal
damage.
4. Connect the pressure gauge. Start the diesel

engine.
5. Operate the diesel engine until it reaches the

operating temperature. Check whether there is no
leakage.
6. Record the diesel engine oil pressure values in
idle running.
The engine oil pressure under low idling:
Minimum is 69kPa (10psi)
7. Increase the diesel engine speed to rated value

and keep it running continuously for 30 seconds.
Record the oil pressure reading of the diesel engine
at rated speed.
Oil pressure at rated diesel engine speed:
Minimum is 207kPa (30psi)
5-49
Figure Steps
8. Remove the engine oil pressure gauge /
Compuchek™ pipe connectors, and then install
the plugs removed previously.
9. Apply a layer of plug sealed glue (the part number
is 3375066) or similar object on the thread.
10.Install and tighten the plugs by referring to the
torque table below.
Plug torque value

Dimension Torque Torque
Actual thread external Install it into aluminum Install it into the cast iron
Thread
diameters components. or steel components.
in. mm [in] N.m [ft-lbs] N.m [ft-lbs]
1/16 8.1 [0.32] 5 [45 in-lb] 15 [10]
1/8 10.4 [0.41] 15 [10] 20 [15]
1/4 13.7 [0.54] 20 [15] 25 [20]
3/8 17.3 [0.68] 25 [20] 35 [25]
1/2 21.6 [0.85] 35 [25] 55 [40]
3/4 26.7 [1.05] 45 [35] 75 [55]
1 33.5 [1.32] 60 [45] 95 [70]
1¼ 42.2 [1.66] 75 [55] 115 [85]
1½ 48.3 [1.90] 85 [65] 135 [100]
5-50
5.2.4 Measurement and Adjustment

of Track Tension
Measurement of the track tension
Tools and testing instrument
1. Steel ruler.
Machine state and parking site
~55°C (113~131°F).
3. Set the diesel engine to top speed (with the air
conditioning turned off).
4. The working current of the pump is within the Standard value of the track tension
normal range.
Track type Standard value
5. The complete machine works in the normal Metal track 275--350Mm (10.83—13.78In)
mode.
6. The working pressure and the pilot pressure of Adjustment of track tension
the pump are within the normal range. If the track tension does not seem right, adjust it
Measurement of the track tension according to the following steps.
1. After the machine is driving forward (with idler in 1. Increase the tension
the front) for 20m (65’7”), park it in a solid and 1) Fill the grease by the grease fitting of the
flat site. grease gun. As shown in the Figure below.
and 55°C (113~131°F).
3. Put the level gauge on the track between the
sprocket and carrier roller, and measure the sag
quantity A at the maximum sag between the
level gauge and the track by a steel ruler, as
2) To determine whether the tension of the track

shoe is normal or not, operate the diesel engine
in low idle speed, then drive the machine
forward for the length of the track shoe on the
ground and then stop the machine slowly.
5-51
3) After adjustment, measure the tension again 5.2.5 Inspection and Adjustment of
according to the steps above to make sure that Minus Feedback Pressure N1
the tension of the track is normal.
2. Reduce the tension Inspection
1) Loosen the filling valve 2 to discharge the 1. Directly read the minus feedback pressure N1
grease, and then tighten it. As shown in the on the display. Please contact LiuGong Service
figure below: Provider if needing to read the pressure.
2. Measure the minus feedback pressure N1 on its
port shown in the figure below.
Feedback
pressure N1
Measurement steps:
1. Remove the joint group (1) from the main pump;
Due to the high pressure of the internal grease,
2. Connect it with the main pump feedback
the valve may fly off. Therefore, do not loosen
pressure port N1 after installing the O-ring (3)
the filling valve 2 for more than two cycles. into the pressure tee (2).
2) To determine whether the tension of the track 3. Install the tie-in (4) into the pressure port of the
shoe is normal or not, operate the diesel engine pressure tee(2).
in low idle speed, then drive the machine
4. Insert the pressure gauge (6 MPa measuring
forward for the length of the track shoe on the
range) with pressure hoses into the pressure
ground and then stop the machine slowly.
measurement joint (4) and measure the
3) After adjustment, measure the tension again pressure on the main pump feedback pressure
according to the steps above to make sure that port N1.
the tension of the track is normal.
5-52
List:
No. Material # Name

32C0529 Tee
1
12C2000 Shuttle valve
2 32C0617 Pressure tee
3 12B0428 O-ring
Pressure
4 12C1140
measurement joint
Adjust it
Change the minus feedback pressure values by
changing the current values of octa-electromagnet
A6. The corresponding curve of current with output
feedback pressure N1 is shown in the figure below.
Pressure test tee and

pressure test notch
Secondary pressure (MPa)
Input Current (average) (mA)

5-53
5.2.6 Inspection and Adjustment of 5.2.7 Release Residual Pressure in

Minus Feedback Pressure N2 Hydraulic Lines
1. Directly read the minus feedback pressure N2
on the display. Please contact LiuGong Service
Provider if needing to read the pressure.
2. Measure the minus feedback pressure F2 on its High-pressure liquid medium in the hydraulic
port shown in the figure below. system and hot hydraulic medium upon
operation may cause personnel injury.
There is still high pressure in the hydraulic system

after the diesel engine is stopped. If the pressure is
Feedback
not released before maintaining any hydraulic sys-
pressure N2
tem, it may cause serious personal injury. Be sure
that all the accessories have been put on the
ground, and hydraulic oil has been cooled before
removing any components or lines. The oil filler cap
can be removed only when the diesel engine has
been stopped, and the oil filler cap has been cooled
enough that can be touched by hands.
Release the hydraulic system pressure according to
the following steps:
1. Park the excavator on a flat ground.
The measuring steps are the same with that of N1
2. Completely place the work implement on a level
3. Change the minus feedback pressure values by ground. Lower down the bucket to contact the
changing the current values of octa- ground completely as shown in the figure below:
electromagnet A5. The corresponding curve of
current with output feedback pressure F2 is
Secondary Pressure (MPa)
Input Current (average) (mA) 3. Stop the diesel engine.

4. Turn the diesel engine starting switch to "ON"
position, but do not start the diesel engine.
5. Turn the pilot cut-off lever to "ON" position.
5-54
6. Repeatedly turn the pilot lever or foot pilot valve

to the maximum angle, release high-pressure oil
in corresponding lines, and meanwhile, release
pressure in corresponding pilot lines.
7. Turn the pilot cutoff lever to "OFF" position.
8. After the pressure is released from the line, turn
the pilot cut-off lever to "OFF" position
9. Turn the diesel engine starting switch to "OFF"
position.
10. Turn the diesel engine starting switch to "ON"
position to start the diesel engine, operate it at
low idle speed for about 10 seconds for storing
pressure into the accumulator, and then stop the
diesel engine.
11. Repeat Step 3-10 above for several times.
12. Screw out the exhaust valve protective caps of
the air filter above the hydraulic tank, then press
down the exhaust valve to release the pressure
in the tank until the gas with pressure is
released completely.
13. Tighten the exhaust valve protective caps of the
air filter.
14. When the pressure in the hydraulic system
pipeline has been released, the corresponding
lines or components can be removed.
Although the pressure in lines is being

released to the most extent by the above steps,
there is a small part of pressure still cannot be
released fully. When removing fittings and
other connectors, make necessary protections
to avoid personnel injury.
5-55
5.2.8 Bleeding of Various Devices

Air bleeding shall be carried out upon the following repairs:
Exhaust project
Steps
Job content Hydraulic Start the Oil 6ZLQJ 7UDYHO :RUN

pump diesel cylinder motor motor ODXQFKLQJ
exhaust HQJLQH exhaust exhaust exhaust
ƒ 5HSODFHWKHK\GUDXOLFRLO
ƒ &OHDQLQJRIILOWHUHOHPHQW
ƒ 5HSODFHPHQWRIEDFNIORZILOWHU
element
ƒ 5HSDLURUUHSODFHPHQWRI
hydraulic pump
ƒ 5HPRYDORIVXFWLRQWXEH
ƒ 5HSDLURUUHSODFHPHQWRI
FRQWUROYDOYH
ƒ 5HSODFHPHQWRIRLOF\OLQGHU
ƒ 5HPRYDORIF\OLQGHUOLQHV
ƒ 5HSODFHPHQWRIVZLQJPRWRU
ƒ 5HPRYDORIVZLQJPRWRUOLQH
ƒ 5HSODFHPHQWRIWUDYHOPRWRU
ƒ 5HPRYDORIWUDYHOPRWRU
pipeline
5-56
Empty the air in the pump 3. Loosen the exhaustion plug and check for oil
outflow.
When repairing the main pump or replacing the
hydraulic oil lines, bleed the air according to the fol- 4. If no oil outflows, refill hydraulic oil to the pump
lowing methods: housing body.
5. Make the diesel engine idling. If there is no
bubble anymore, tighten the bleeding plug and
the bleeding is over.
Hydraulic oil pressure and hot oil may cause
personal injury.
After the diesel engine is stopped, hydraulic oil If the pump runs without oil at the top level in
is still staying in the hydraulic system. If the it, the abnormal heat may be produced
pressure is not released before maintaining resulting in the early damage for the pump.
any hydraulic system, it may cause serious
Empty the air in the cylinder
personal injury.
1. Start the diesel engine and operate it for 5min at
Be sure that all the accessories are lowered onto low idling.
the ground, and oil has been cooled before remov-
ing any component or line. 2. Operate the diesel engine at low speed and
telescope the cylinder to the position about
The oil filler cap can be removed only when the die- 100mm (3.94In) away from the stroke end for 4-
sel engine has been stopped, and the oil filler cap 5 times.
has been cooled enough that can be touched by
hands.
Do not telescope the cylinder to the stroke

end; otherwise, the piston seal will be
damaged by the air in the cylinder.
3. Operate the cylinders to the stroke end for 3-4

times.
4. Operate the cylinders to the stroke end for 4-5
times to empty the air.
Empty the air in the travel motor
1. Exhaustion plug The air can be exhausted only after the

1. Park the machine on a flat ground. Lower the hydraulic oil in the travel motor housing was
bucket to the ground and pull the pilot control drained.
level to the locking position.
2. Shut down the diesel engine and take the key
out.
5-57
1. Before starting the diesel engine, remove the oil 5. Repeat the operations on both left and right
drain hose on the travel motor housing. Refill the sides. Rotate the track forward and backward
hydraulic oil to the motor housing until the level evenly.
reaching the discharge port, and then connect
Exhaust the air in the accessories (if any)
the oil drain hose.
1. If the knapper or other accessories are
equipped, make the diesel engine running at low
speed, and repeatedly operate the auxiliary
pedal (1) for about 10 times until the air is
emptied from the oil line of the accessories.
1. Oil drain hose

2. Operating the diesel engine in low idle speed,
unscrew the nuts of oil drain hose connector on
the motor housing, and tighten the nuts when
the hydraulic oil outflows.
1. Auxiliary pedal
3. Operate the diesel engine at low speed and
slewing the work implement by 90° to make it
locate in the side of the track.
Air-bleeding should be conducted according to

the method specified by the manufacturer.
2. After air bleeding, turn off the diesel engine and

leave the machine alone for 5 minutes to
eliminate the bubbles in the hydraulic cylinder.
After exhausting the air, check the oil level, and refill
in case of a low level.
4. Jack up the machine with the work implement to

make the track slightly off the ground and
operate the track in no-load condition for 2
minutes.
5-58
5.2.9 Inspection of Diode 2) Connect the red probe (+) to the negative pole
(N) of the diode, and the black probe (-) to the
Diode Checking Procedure positive pole (P) of the diode, then the diode is
in negative biased. If the diode is normal, the
The diode, also called crystal diode, is electronic multimeter will display 0L or a very large value.
device capable of unidirectional conduction current.
There is one PN joint and two lead terminals in the 3) If the values measured for two times are very
semiconductor diode. According to the direction of small during the measurement, it indicates a
the applied voltage, the electronic device has the short circuit in the diode; if the values measured
transduction performance of the unidirectional cur- for two times are very large or shows 0L, then
rent. there is an open circuit in the diode.
2. Measure the diode by using the Ohm posi-
tion of the digital multimeter:
1) The diode is positive if you connect the red
probe (+) to the positive pole (P) of the diode,
and the black probe (-) to the negative pole (N)
of the diode. Read the measured resistance
value.
2) The diode is reversal if you connect the red
probe (+) to the negative pole (N) of the diode,
and the black probe (-) to the positive pole (P)
of the diode. Read the measured resistance
value.
3) If the two values measured are quite different,
then it indicates that the performance of the
diode is good; if not, it indicates that the
performance of the diode is poor, or the diode is
damaged -- internally short or an open circuit.
1. Measure the diode by using the DIO position

of digital multimeter:
1) The diode is positive if you connect the red
probe (+) to the positive pole (P) of the diode
and the black probe (-) to the negative pole (N)
of the diode. The multimeter will display a
certain value If the diode is normal.
5-59
5.2.10 Adjustment of Compressor

Belt Tensioner
Before inspection, move the machine to the

level ground, and lower the work implement to
the ground and turn off the diesel engine.
Inspection
1. Open the engine hood, remove the left and right
fan shields above the compressor.
2. Press the middle parts of the belt between the
diesel engine pulley and compressor pulley to
measure the flexibility (f) of the belt. When the
belt pressing pressure is Wd = 58.5 N (13.2lbf)
(about 6 kg/13.2lb), the produced flexibility shall
be f=5 ~ 8mm (0.2 ~ 0.3In). (1) If the belt cannot be tensed because of
excessive stretch, or there are scratches and
cracks on the belt, replace a new belt timely.
(2) If the belt is replaced, adjust the tension of
the belt again after the machine works for 1
hour.
(3) After tightening the bolt, check the tension
of the belt according to the methods above.
4. Reinstall the removed components upon the

completion of belt flexibility measurement.
Adjust it
If the belt flexibility is abnormal, perform adjust-
ments according to the following procedures.
1. Unscrew the tension pulley locknut (1);
2. Clockwise screw the bolt (2) to adjust the A/C
belt tension.
3. Adjust the tension pulley (3) to an appropriate
position, and fasten the tension pulley locknut
(1).
5-60
5.2.11 Performance Test of Travel

Motor and Speed Reducer
Carry out the following performance tests upon dis-
assembly and maintenance of travel motors and
speed reducers.
Test method
Measure the pressures of following test points: left
side motors a1, a2, T1; right side motors: a1, a2, T1
Pressure measure-
ment side
Left side
Right
side
LG922E930E05096
Test conditions:
1. Air is not allowed in the lines
2. Hydraulic oil temperature is approx 50±5°C
(122±41°F).
5-61
Test items and standard values:
Operation status
Test
No. Contents Operation Gears Criteria
Horizontal Vertical ground
direction direction
Left and right pumping pressure

difference < 3MPa (435psi),
Low without dragging drainage <
0.2MPa (29 psi), Max <
Flat walking 0.69MPa (100.1psi)
1
and stop Left and right pumping pressure
difference < 3MPa (435psi),
High without dragging drainage <
0.2MPa (29 psi), Max <
0.69MPa (100.1psi)
Slowly Low Curve is flat, without dragging

operate
2 Oil drainage < 0.2MPa (29 psi),
forward →
Max<0.69MPa (100.1psi)
back High
Atmospheric pressure <

34.3MPa (4973.5 psi); Max <
Unilateral
3 High 34.3MPa (4973.5 psi) oil
drive
drainage Max < 0.69MPa
(100.1psi)
Concrete Atmospheric pressure <

34.3MPa (4973.5 psi); Max <
Unmovable
4 High 34.3MPa (4973.5 psi) oil
rotation
drainage Max < 0.69MPa
(100.1psi)
Left and right pumping pressure
difference < 3 MPa (435psi),
Rapid Left and right pumping pressure
5 alternate High Max < 34.3MPa
(forward) (4973.5psi4973.5psi); oil
drainage Max < 0.69MPa (100.1
psi)
Go forward by
Synchronous switching, without
switching
Low dragging
6 between high
High Oil drainage < 0.2MPa (29 psi),
and low
Max<0.69MPa (100.1psi)
velocity
Go forward
7 and backward Low
slope
5-62
6-1
September 15, 2020
CLG920E/922E/923E
6 Fault Diagnosis
6.1 Precautions for Fault Diagnosis.................................................................................. 6-3
6.2 Basic Fault Detection Before Maintenance ................................................................ 6-4
6.3 Classification of Faults............................................................................................... 6-7
6.4 Diagnostic Trouble Code (DTC) ................................................................................. 6-9
6.4.1 DTC 101001 Extremely Low Battery Voltage .......................................................... 6-9
6.4.2 DTC 101003 High Battery Voltage ........................................................................ 6-18
6.4.3 DTC 101017 Low Battery Voltage ......................................................................... 6-24
6.4.4 DTC 111001 System Charging Fault..................................................................... 6-34
6.4.5 DTC 121015 Oil Pressure Switch Disconnected ................................................... 6-38
6.4.6 DTC 121018 Low Oil Pressure.............................................................................. 6-42
6.4.7 DTC 121305 Handle Pressure Switch OFF........................................................... 6-45
6.4.8 DTC 121405 Pedal Pressure Switch Disconnected .............................................. 6-50
6.4.9 DTC 121604 Air Filter Switch Shorted to Ground.................................................. 6-55
6.4.10 DTC 121615 Air Filter Clogging........................................................................... 6-59
6.4.11 DTC 131000 High Engine Speed ........................................................................ 6-62
6.4.12 DTC 131005 Engine Speed Sensor Fault ........................................................... 6-65
6.4.13 DTC 131100 Extremely High Coolant Temperature............................................ 6-68
6.4.14 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value..... 6-71
6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value ..... 6-74
6.4.16 DTC 131115 High Coolant Temperature............................................................. 6-78
6.4.17 DTC 131116 High Coolant Temperature............................................................. 6-81
6.4.18 DTC 1131200 Extremely High Hydraulic Oil Temperature.................................. 6-84
6.4.19 DTC 131203 Hydraulic Oil Temperature Sensor Voltage Above the
Range Value................................................................................................................... 6-87
6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the
Range Value................................................................................................................... 6-90
6.4.21 DTC 131215 High Hydraulic Oil Temperature..................................................... 6-94
6.4.22 DTC 131216 Extremely High Hydraulic Oil Temperature.................................... 6-97
6.4.23 DTC 131303 Fuel Level Sensor Voltage Above the Range Value .................... 6-100
6.4.24 DTC 131304 Fuel Level Sensor Shorted to Ground.......................................... 6-107
6.4.25 DTC 131317 Low Fuel Level ............................................................................. 6-112
6.4.26 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value............... 6-116
6.4.27 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value ............... 6-119
6-2
September 15, 2020
CLG920E/922E/923E
6.4.28 DTC 131605 Water-in-Fuel Sensor Open-Circuited.......................................... 6-122

6.4.29 DTC 131615 Water in Fuel................................................................................ 6-125
6.4.30 DTC 131703 Sensor Power (5V) Shorted to Battery......................................... 6-127
6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground ........................................ 6-130
6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-Circuited .... 6-134
6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent.......... 6-138
6.4.34 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground................ 6-142
6.4.35 DTC 141105 Pump Proportional Solenoid Valve Open-Circuited or
Shorted to Battery......................................................................................................... 6-145
6.4.36 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground ........ 6-148
6.4.37 DTC 151005 Attachment Confluent Solenoid Valve Open-Circuited or
6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground............................. 6-154
6.4.39 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to
Battery .......................................................................................................................... 6-158
6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground ........................ 6-163
6.4.41 DTC 151305 A3 Travel Shift Solenoid Valve Open-Circuited or Shorted to
Battery .......................................................................................................................... 6-167
6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground ........................ 6-172
6.4.43 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to
Battery .......................................................................................................................... 6-176
6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground........................... 6-181
6.4.45 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to
Battery .......................................................................................................................... 6-185
6.4.46 DTC 151605 A6 Flow Adjusting Solenoid Open-Circuited or Shorted to
Battery .......................................................................................................................... 6-190
6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground ............... 6-195
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground.................... 6-204
6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or
6.4.51 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited .................... 6-213
6.4.52 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent ......................... 6-218
6.4.53 DTC 171004 Battery Relay Shorted to Ground ................................................. 6-223
6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground................................... 6-227
6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to Battery...... 6-231
6.4.56 DTC 171204 Start Cut-off Relay Shorted to Ground ......................................... 6-235
6-3
September 15, 2020
CLG920E/922E/923E
6.4.57 DTC 171205 Start Cut-Off Output Open-Circuited or Shorted to Battery.......... 6-240
6.4.58 DTC 201004 Travel Alarm Shorted to Ground .................................................. 6-246
6.4.59 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value ...... 6-250
6.4.60 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value....... 6-254
6.4.62 DTC 211104 P2 Pump Pressure Sensor Voltage Below the Range Value....... 6-262
6.4.63 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the
Range Value................................................................................................................. 6-266
6.4.64 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the
Range Value................................................................................................................. 6-269
Range Value................................................................................................................. 6-273
Range Value................................................................................................................. 6-276
6.4.67 DTC 211316 High N2 Negative Flow Pressure ................................................. 6-280
6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage Below
the Range Value........................................................................................................... 6-285
6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value ................... 6-289
6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value................... 6-293
6.4.72 DTC 221007 Actuator GettingStuck .................................................................. 6-297
6.4.73 DTC 221013 Actuator Outside Calibrated Range ............................................. 6-300
6.4.74 DTC 221104 Actuator AC1 Shorted to Ground ................................................. 6-305
6.4.75 DTC 221204 Actuator AC2 Shorted to Ground ................................................. 6-309
6.4.76 DTC 221305 Actuator AC1 Open-Circuited....................................................... 6-313
6.4.77 DTC 221306 Actuator AC1 Overcurrent............................................................ 6-317
6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited........................................ 6-321
6.4.79 DTC 221406 Actuator AC2 Overcurrent............................................................ 6-325
6.4.80 DTC 231012 Abnormal Controller Heartbeat .................................................... 6-329
6.4.81 DTC 231014 CAN Bus Communication Error ................................................... 6-333
6.4.82 DTC 241014 Accelerator Knob Outside Measurement Range.......................... 6-336
6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground ........................................... 6-341
6.4.84 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to Battery .............. 6-345
6.4.85 DTC 261011GPS Antenna Fault ....................................................................... 6-350
6.4.86 DTC 261111GPS Module Fault......................................................................... 6-352
6.4.87 DTC 261211 GSM Signal Fault ......................................................................... 6-353
6.4.88 DTC 261311 GPRS Connection Fault............................................................... 6-355
6-4
September 15, 2020
CLG920E/922E/923E
6.4.89 DTC 261411 SIM Card Read Fault ................................................................... 6-355

6.4.90 DTC 261512 Abnormal GPS Heartbeat ............................................................ 6-357
6.4.91 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat,
Machine Is Limited for Use ........................................................................................... 6-360
6.4.92 DTC 261614 Forced Locking Level 1 Payment Expired, Machine Is
Limited for Use ............................................................................................................. 6-363
and the Machine is Prohibited for Use.......................................................................... 6-364
6.4.94 DTC 261714 Forced Locking Level 2 Overdue Payment, and the
Machine is Prohibited for Use....................................................................................... 6-367
6.4.95 DTC 261814 Pay Due Loan Promptly ............................................................... 6-367
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to ground .......................... 6-368
Short-Circuited to Battery ............................................................................................. 6-371
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground ........................... 6-375
6.4.99 DTC 271405 Fan Drive Solenoid Valve Open-Circuited or Short to Battery ..... 6-378
6.4.100 DTC 271505 Fan Drive Solenoid Valve Feedback Open-Circuited................. 6-381
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent.......................... 6-384
6.5 Fault Diagnosis of Electrical System ...................................................................... 6-387
6.5.1 E1 Troubleshooting Solution for Battery Power Loss .......................................... 6-387
6.5.2 E2 Troubleshooting Solution for Abnormal Battery ............................................. 6-389
6.5.3 E3 Automatic Slowdown Failed ........................................................................... 6-392
6.5.4 E4 Engine cannot be Started............................................................................... 6-396
6.5.5 E5-Engine Shuts Down during Operation............................................................ 6-410
6.5.6 E6 Engine cannot be Shut Down......................................................................... 6-415
6.5.7 E7 Preheater does not work ................................................................................ 6-419
6.5.8 E8 All the Work Implements, Revolving and Traveling cannot Move .................. 6-426
6.5.9 E9 Display Panel Showing Nothing ..................................................................... 6-432
6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature....................................... 6-438
6.5.11 E11 Fuel Gauge cannot Display correctly ......................................................... 6-442
6.5.12 E12 Windshield wiper out of work ..................................................................... 6-447
6.5.13 E13-Travel alarm unable to sound .................................................................... 6-453
6.5.14 E14 A/C panel unable to display ....................................................................... 6-456
6.5.15 E15 A/C no air or abnormal air volume ............................................................. 6-460
6.5.16 E16 Poor A/C Refrigeration ............................................................................... 6-463
6.5.17 E17 A/C Abnormal Alarm Display E13 -- Defrost Sensor Wire Broken ............. 6-466
6-5
September 15, 2020
CLG920E/922E/923E
6.5.18 E18 A/C Abnormal Alarm Display E14 -- Defrost Sensor Short Circuited ......... 6-468
6.5.19 E19 A/C Abnormal Alarm Display E17 -- Solar Sensor Wire Broken ................ 6-470
6.5.20 E20 A/C Abnormal Alarm Display E19 -- External Air Sensor Wire Broken ...... 6-472
6.5.21 E21 A/C Abnormal Alarm Display E20 -- External Air Sensor Short-Circuited.. 6-474
6.5.22 E22 Air Conditioning Abnormal Alarm E43--Air Blowing Valve Abnormal......... 6-476
6.5.23 E23 Abnormal A/C Alarm E44 - Air Mixing Valve Abnormal.............................. 6-478
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System......................... 6-480
6.6.1 System Table of the Hydraulic System and Mechanical System ........................ 6-480
6.6.2 H1 Excessive barking angle for slewing stop ...................................................... 6-482
6.6.3 H2 Abnormal Noise from Pump Mounting Position ............................................. 6-483
6.6.4 H3 Start the Engine, and All Operations have no Response............................... 6-484
6.6.5 H4 Hydraulic Oil Emulsification ........................................................................... 6-485
6.6.5 H5 Abnormal increase of hydraulic oil temperature............................................. 6-486
6.6.7 H6 Slewing abnormally to Left and Right Directions ........................................... 6-487
6.6.8 H7 No Response for Slewing Single Direction Operation ................................... 6-488
6.6.9 H8 Slewing cannot be Stopped ........................................................................... 6-489
6.6.10 H9 Fail to Actuate Unilateral Travel Mechanism ............................................... 6-490
6.6.11 H10 Travel Deviation ......................................................................................... 6-491
6.6.12 H11 Slow Speed of the Boom, Arm or Bucket................................................... 6-492
6.6.13 H12 Weak Actions of the Boom, Arm or Bucket................................................ 6-493
6.6.14 H13 Significantly reduced engine speed or engine stalling ............................... 6-494
6-6
September 15, 2020
CLG920E/922E/923E
6-7
September 15, 2020 6.1 Precautions for Fault Diagnosis
CLG920E/922E/923E
6.1 Precautions for Fault Diagnosis
• Park the machine on the flat ground, check whether the locking pin, block and parking brake are
fixed firmly.
• When two or more workers operate the machine, follow the agreed signal strictly, and any
unauthorized people are not allowed to get close to the machine.
• If the radiator cover is removed when the engine is still hot, the hot coolant may spray out which will
cause scald. Therefore, start the fault diagnosis when the engine is cooled.
• Specially notice that do not touch any hot components or do not be jammed by any rotating
components.
• When disconnecting the wire, be sure to disconnect the negative pole (-) of the battery firstly.
Be sure to release the inner pressure first when removing the plug or cover where the oil pressure, water
pressure or air pressure may exist. When installing the measuring device, make sure that it is connected
correctly.
6-8
6.2 Basic Fault Detection Before Maintenance September 15, 2020
CLG920E/922E/923E
6.2 Basic Fault Detection Before Maintenance
Do the following tests before having your authorized LiuGong dealer repair your machine or when your
machine is not functioning properly. Doing these tests can help the maintenance personnel to repair your
machine as soon as possible.
Do the following tests when the engine is running and shuts down, respectively.
If the machine runs in a closed space, be sure to discharge the exhaust gases before starting the
engine for maintenance of the machine.
No irrelevant personnel is allowed to be close to the machine working and detection area.
Some tests may be required to be done when the machine is traveling. Therefore, before starting
any test, make sure the driver has been trained specially and has been qualified.
Some tests may require the appropriate hearing protection devices.
Some tests may need the help of the specialized testing tools. Therefore, before starting any test, make
sure the operators understand these tools fully.
Before performing any of the following tests, make sure all routine examination items have been
completed.
Start the engine and do the testing by following the relevant guidance steps. When detecting the
hydraulic system components, make sure that the hydraulic system has been fully heated and all
hydraulic components have reached normal operating temperature.
No. Test items Test requirements
1 Turn the start switch to "ON" position but do not start the engine.
6-9
September 15, 2020 6.2 Basic Fault Detection Before Maintenance
CLG920E/922E/923E
Tire
Shut down the engine, park Hydraulic oil testing state
the machine on a firm and
1. Check whether the oil level is within the normal range.
level ground, and make the
Notice: Check before the engine is started.
machine in the hydraulic oil
2 testing state (the arm is 2. Check whether the oil level is between the MIN and MAX scales of the
stretched completely, the dipstick.
bucket is retracted, and the 3. Check whether the cold hydraulic oil level is between the MIN and MAX
work attachment is lowered scales of the dipstick.
to ground). 4. Check the hydraulic oil lines or the connectors for damage or leakage.
5. Visually check the machine for wear or damage sign. Whether the parts are
damaged or lost? Whether the welding piece has cracks?
6. Check whether any parts are lost.
7. Check whether the track has obvious scratches or wear.
Horn Check whether the horn sounds. (Yes or No)
Wiper Check whether the front wiper works normally. (Yes or No)
Fan Check whether the internal circulation fan works. (Yes or No)
Lighting equipment (work
light, revolving signal light, Check whether the outdoor light and dome light work normally.
3 brake light, dome light, etc.)
Instrument, meter and Check whether all the indicators come on.
indicator If not, do not start the engine.
Operate all the switches and control units to check whether they can work
Switches and control units normally.
If not, do not start the engine.
Cab Check whether all the control levers are in the correct positions.
Safety warning label Check whether the safety warning labels on the machine can be seen clearly.
Check whether the cab windows and doors can be opened smoothly.
4
Door lock and engine hood Whether the door lock can be locked or not?
lock Check whether the engine hood can be closed. Whether the engine hood can
be locked?
Check the surrounding of the engine for obvious damage or oil leakage sign.
Start the engine and listen to the engine for abnormal noise.
When the engine runs at idle, whether the oil pressure indicator goes off?
Check whether the engine speed is normal. Whether the operation is
5 Engine system smooth?
After the engine runs for a period, check whether the engine temperature is
within the normal working range.
After the engine is preheated and started, observe whether the exhaust gas is
discharged. If any, what is color of the exhaust gas? Grayish white, white or
black?
Check whether the engine working temperature is within the normal range.
6 Engine runs at idle speed After the engine runs at idle for several minutes, check whether the A/C
refrigerates.
6-10
6.2 Basic Fault Detection Before Maintenance September 15, 2020
CLG920E/922E/923E

Start the engine and check the system voltage. The voltage after starting
7 Charging of battery should be higher than that before starting (battery voltage), normally greater
than 26V.
6-11
September 15, 2020 6.3 Classification of Faults
CLG920E/922E/923E
6.3 Classification of Faults
In this chapter, the faults are divided into three categories
1. DTC
If the machine display shows DTC, perform the fault diagnosis corresponding to the code according to
the displayed DTCs
2. Electrical system faults (for E series)
In the Electrical System Faults, the typical electrical faults are introduced. The location drawing for main
faulted parts, relevant circuit diagram and the detailed diagnosis procedures are equipped.
The faults introduced in this chapter are shown in the table below:
Fault SN Fault symptom Consequence
E1 Battery power loss The battery is damaged.
E2 The battery is abnormal The battery is damaged.
E3 Automatic slowdown failed Increased fuel consumption and noise
Engine cannot be started (the engine does
E4 Failed to work.
not rotate)
E5 Engine shuts down during operation System fault.
E6 The engine can not be shut down System fault.
E7 Preheater fails to work The machine is difficult to start or won’t start.
All the work implements, revolving and
E8 No motion, failed to work.
travel cannot move
E9 Display panel shows nothing It can not display the machine information.
Reducing the pump current and engine speed can
Incorrectly displayed hydraulic oil affect the working performance of the complete
E10
temperature machine, or cause damage to the engine and
hydraulic components
The fuel level display is inaccurate, and it brings
E11 Fuel gauge cannot display correctly
trouble to the work.
Foreign matters on glass cannot be removed; the
E12 Windshield wiper fails to work
sight for operator is poor.
E13 A/C panel unable to display Air conditioning system cannot work
No wind or abnormal air volume of air
E14 The service effect of A/C is poor
conditioner
E15 Poor A/C refrigeration Poor refrigerating effect of air conditioning system
Abnormal A/C alarm E11 -- Internal air
sensor open circuit
Abnormal A/C alarm E12 -- Internal air
sensor short circuit
Abnormal A/C alarm E15 -- Water
temperature sensor open circuit
Abnormal A/C alarm E16 -- Water
temperature sensor short circuit
Abnormal A/C alarm E18 -- solar sensor
short circuit
6-12
6.3 Classification of Faults September 15, 2020
CLG920E/922E/923E
Fault SN Fault symptom Consequence

Abnormal A/C alarm E43 -- Air blowing
valve abnormal
Abnormal A/C alarm E44 -- Abnormal air
mixing valve
Alarm system is faulty, causing potential safety
E23 Travel alarm unable to sound
hazard.
3. Faults of hydraulic mechanical system (for H series)
The Faults of Hydraulic System and Mechanical System mainly introduce the diagnosis methods for the
common faults in the hydraulic system.
The faults introduced in this chapter are shown in the table below
No. Fault symptom
H1 Excessive braking angle for slewing stop
H2 Abnormal noise from pump mounting position
H3 When the engine is started, all operations are unresponsive
H4 Hydraulic oil emulsification
H5 Abnormal hydraulic oil temperature rise
H6 Normal slewing cannot be achieved either in the left direction or in the right direction
H7 Unidirectional slewing operation is unresponsive
H8 Rotation cannot be stopped
H9 Unilateral travel mechanism fails to move completely
H10 Travel deviation
H11 Boom, arm or bucket moves slowly
H12 Weak actions of the boom, arm or bucket
H13 Significantly reduced engine speed or engine stalling
6-13
September 15, 2020 6.4 Diagnostic Trouble Code (DTC)
CLG920E/922E/923E 6.4.1 DTC 101001 Extremely Low Battery Voltage
6.4 Diagnostic Trouble Code (DTC)
6.4.1 DTC 101001 Extremely Low Battery Voltage
DTC Description Consequence

Extremely low battery voltage (The controller
101001 detects the battery voltage is extremely low — It is difficult to start the engine.
(below 16V).)
System description
When the alternator does not work or generates a low voltage, the battery supplies power to the
electrical equipment. When the engine starts, the battery supplies power to the starter motor. After the
machine is started, the battery is charged by the alternator. When the electrical equipment needs more
power simultaneously and the alternator is overloaded, the battery assists the alternator to supply power.
The battery has a rated voltage of 12V. The complete machine is powered by two batteries in series.
6-14
6.4 Diagnostic Trouble Code (DTC) September 15, 2020
6.4.1 DTC 101001 Extremely Low Battery Voltage CLG920E/922E/923E
For controller CM3620

6-15
For controller C101-D1
P29E00137
6-16
Component location
Front
Battery
Fault diagnosis and troubleshooting steps
Step 1 Check the battery terminals for looseness or rust
Be sure to turn off the electric lock before checking whether the battery cables are
secured reliably.
Inspection method
Turn the battery terminals by hand or with the tools, and check them for looseness;
Visually check the terminals for rust.
Whether the battery terminals become loose or rusty?
Yes No
Tighten or derust
Go to Step 6 Go to Step 2
6-17
Step 2 Check whether the battery voltage is too low
Make sure the ignition switch is at the OFF position before assembling and removing the
battery cables. When assembling, install the positive terminals before the negative terminals.
Removal is the reverse of installation. This can avoid damage to the battery terminals and the
wrench due to short-circuit spark.
During the detection period, turn the start key switch to the OFF position
Inspection method
There are three possible causes for low battery voltage:

1. Long time uncharged battery
2. Battery damage
3. Feed
Check the battery in the following procedures:
1. Check the battery hydrometer. If the hydrometer becomes black, the battery needs to be charged.
If the hydrometer becomes white, the battery has been damaged. If the hydrometer is in the green
status, the battery is good.
2. Measure the battery voltage with the multimeter: Turn the multimeter to its DC voltage function
(200V), and connect the red probe to the positive battery terminal and the black probe to the
negative battery terminal. The schematic diagram for detection is as follows:
Black probe
Red probe
Is the battery voltage too low?
Yes No
Charge or replace the battery

6-18
Step 3 Check the charging harness for open-circuit (check whether the coupling ends become
loose)
Pay special attention to the followings when conduct the measurement with running
engine:
Hot engine block can scald you seriously.
Prevent the harnesses, clothing and others from being drawn into the belts and the flywheel.
The complete machine is prohibited to act.
Correctly tie up harness and wire:
Avoid folding or bending the harness forcibly.
It shall be kept away from moving components as far as possible to prevent tensile failure and
wear.
Avoid friction with sharp metal edges.
Keep away from oil and water as far as possible.
Keep away from high temperature parts (e.g. cylinder body) as far as possible.
Inspection method
1. Check the battery charging harness (# 120) for wear and its terminals for looseness
2. Check the charging harness for open-circuit with the multimeter:
Method A: Turn the start switch to the OFF position. Turn the multimeter to its resistance function
(200Ω), and measure the resistance of the battery charging harness (# 120) (normally, <10Ω). For the
alternator location and the starter motor location, see the attached drawing
Start motor Alternator

Connect the multimeter probes to both
ends of the charging harness
LG922E930E06004
6-19
Method B: Turn the ignition switch to the ON position and turn the multimeter to its voltage function,
and then measure the voltage between the alternator terminal B and the grounding (normally, the
battery voltage should be 25 ± 0.5V.).
Connect the red probe to Connect the black

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

Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Alternator is faulty
1. Stop the engine and check whether the alternator belt becomes loose.
2. Start the engine, and measure the voltage between the alternator terminal B and the grounding
with the multimeter (normally, higher than the battery voltage)
Whether the alternator fails or its output voltage is low?
Yes No
6-20
1. Tighten or replace the drive belt

2. Contact local LiuGong dealer or authorized
service center.
Go to Step 6
Go to Step 5
Step 5 Check whether the controller power voltage is too low
Inspection method
1. Check the controller power line for wear and the coupling ends for looseness
2. For controller CM3620, turn the multimeter to its DC voltage function (200V), and measure the
voltage between the controller power terminal (J1-2, J1-3, J1-4, J1-5, J1-6) and the grounding,
respectively.
3. For controller C101-D1, turn the multimeter to its DC voltage function (200V), and measure the
voltage between the controller power terminal (J1,J1-27,J1-42) and the grounding, respectively.
Connect
Connect thethe black
black
probe
probe to groun
to the ground
Connect the red probe

To the red probe
Whether the controller power voltage is too low?

Yes No
6-21
Step 6: Check whether this fault is eliminated.
Inspection method
Turn the start switch to the ON position and re-check the DTC.
Has this fault been eliminated?
Yes No
Troubleshoot again the faults according to the
Maintenance is over steps or contact the local LiuGong dealers and
authorized service centers.
Attached drawing
Alternator
Start motor
6-22
6.4.2 DTC 101003 High Battery Voltage CLG920E/922E/923E
6.4.2 DTC 101003 High Battery Voltage

High battery voltage (the battery voltage detected
101003 by the controller is extremely high (higher than The engine may shut down
30V).)
System description
6-23
CLG920E/922E/923E 6.4.2 DTC 101003 High Battery Voltage

6-24
P29E00137
6-25
Component location
Front
Battery
Step 1 Check the battery voltage for fault
Inspection method:
Measure the battery voltage with the multimeter: Turn the multimeter to its DC voltage function (200V),
and connect the red probe to the positive battery terminal and the black probe to the negative battery
terminal. The schematic diagram for detection is as follows:
Black probe
Red probe
Normally, the battery (2 packs) voltage should be 25±0.5V.

Whether the battery voltage is abnormal or not?
Yes No
Repair or replace the battery
6-26
Step 2 Check the alternator for faults
engine:
Hot engine block can scald you seriously
Prevent the harnesses, clothing and others from being drawn into the belts and the flywheel
The complete machine is prohibited to act

Inspection method:
Start the engine and measure the voltage (normally no more than 30V) between the alternator
terminal B+ and the grounding, by using a multimeter switching to the DC voltage position (200V), with
connecting the red probe to the alternator terminal B+ while the black probe to the grounding. For the
alternator location, see the figure

Whether the alternator fails?

Yes No
Contact local LiuGong dealer or authorized
service center.
Step 3 Check whether this fault is eliminated
Inspection method
Yes No
6-27
Attached drawing
Alternator
6-28
6.4.3 DTC 101017 Low Battery Voltage CLG920E/922E/923E
6.4.3 DTC 101017 Low Battery Voltage

Low battery voltage (The controller detects the
101017 battery voltage is low ——lower than 16V higher It is difficult to start the engine.
than 18V.)
System description
6-29
CLG920E/922E/923E 6.4.3 DTC 101017 Low Battery Voltage

6-30
P29E00137
6-31
Component location
Front
Battery
Step 1 Check the battery terminals for looseness or rust
Be sure to turn off the electric lock before checking whether the battery cables are
secured reliably.
Inspection method
Turn the battery terminals by hand or with the tools, and check them for looseness;
Visually check the terminals for rust.
Whether the battery terminals become loose or rusty?
Yes No
Tighten or derust
6-32
Step 2 Check whether the battery voltage is too low
Make sure the ignition switch is at the OFF position before assembling and removing the
battery cables. When assembling, install the positive terminals before the negative terminals.
Removal is the reverse of installation. This can avoid damage to the battery terminals and the
wrench due to short-circuit spark.
Inspection method
There are three possible causes for low battery voltage:

1. Long time uncharged battery
2. Battery damage
3. Feed
1. Check the battery hydrometer. If the hydrometer becomes black, the battery needs to be charged.
If the hydrometer becomes white, the battery has been damaged. If the hydrometer is in the green
status, the battery is good.
Black probe
Red probe
If the voltage below 18V, this indicates the battery voltage is too low.
Is the battery voltage too low?
Yes No
Charge or replace the battery
6-33
Step 3 Check the charging harness for open-circuit (check whether the coupling ends become
loose)
engine:
wear.
6-34
Inspection method
1. Check the battery charging harness (# 120) for wear and its terminals for looseness
2. Check the charging harness for open-circuit with the multimeter:
Method A: Turn the start switch to the OFF position. Turn the multimeter to its resistance function
(200Ω), and measure the resistance of the battery charging harness (# 120) (normally, <10Ω). For the
alternator location and the starter motor location, see the attached drawing
Start motor Alternator

Connect the multimeter probes to both
ends of the charging harness
LG922E930E06004
Method B: Turn the ignition switch to the ON position and turn the multimeter to its voltage function,
and then measure the voltage between the alternator terminal B and the grounding (normally, the
battery voltage should be 25 ± 0.5V.).

Whether the charging harness is open-circuit or not (the coupling ends become loose)?
Yes No
6-35
Step 4 Check whether the alternator fails or the output voltage is low‘
engine:

Inspection method
After the complete machine is started, there are two possible causes for the alternator fault:
1. The belt is too loose.
2. Alternator is faulty
2. Start the engine, and measure the voltage between the alternator terminal B and the grounding
with the multimeter (normally, higher than the battery voltage)
Whether the alternator fails or its output voltage is low?
Yes No
1. Tighten or replace the drive belt
2. Contact local LiuGong dealer or authorized
service center.
6-36
Step 5 Check whether the controller power voltage is too low
Inspection method
1. Check the controller power line for wear and the coupling ends for looseness
2. For controller CM3620, turn the multimeter to its DC voltage function (200V), and measure the
voltage between the controller power terminal (J1-2, J1-3, J1-4, J1-5, J1-6) and the grounding,
respectively.
3. For controller C101-D1, turn the multimeter to its DC voltage function (200V), and measure the
voltage between the controller power terminal (J1-1,J1-27,J1-42) and the grounding, respectively.
Connect the black

probe to ground
To the red probe
If the voltage below 18V, this indicates the battery voltage is too low.
Whether the controller power voltage is too low?
Yes No
Inspection method
Yes No
6-37
Attached drawing
Alternator
Start motor
6-38
6.4.4 DTC 111001 System Charging Fault CLG920E/922E/923E
6.4.4 DTC 111001 System Charging Fault

System charging fault (controller detects that the
111001 voltage at the J2-28 end is 0.); and for controller Battery power loss.
C101-D1, system charging fault (controller detects
that the voltage at J1-9 end is 0V).
System description
The alternator is accompanied with the engine, and the silicon rectifier circuit and voltage regulator with
the frequency output are installed in the alternator. After the engine is started, the alternator driven by the
drive belt starts generating (nominal voltage 28V). The current from the generating terminal (B+) flows
through the # 120 and #108 wires and the battery relay to the battery to charge it. For the controller
CM3620, the charging indicator signal end (P) is connected to the controller J2-28 via the wire (# 928);
for the controller C101-D1, the charging indicator signal end (P) is connected to the controller J1-9 via
the wire (# 928), the controller checks whether the alternator is working properly through the signal end.
Controller J2(White)
Alternator
Battery charging
indicator switch
Start moter
GND
6-39
CLG920E/922E/923E 6.4.4 DTC 111001 System Charging Fault
P29E00132
Component location
Alternator
Front
6-40
6.4.4 DTC 111001 System Charging Fault CLG920E/922E/923E
Step 1 Check the alternator terminal P for electrical signal output (whether the alternator fails)
Inspection method
2. Start the engine and turn the multimeter to its voltage function, and then measure the voltage
between the alternator terminal P and ground (Normally, 14±0.5V).
Whether the alternator terminal P has no electrical signal output (the alternator fails)?
Yes No
Tighten or replace the belt
Contact your local LiuGong dealers and
Step 2 Check the harness for open-circuit
wear.
Inspection method

1. Check the # 928 harness (between the alternator terminal P and the J2-28 port) for wear.
2. Disconnect the connectors from the terminal P and the controller and check the harness for open-
circuit. Turn the multimeter to its resistance function, and measure the resistance of the harness (#
928) between the controller port J2-28 and the terminal P (normally, <10Ω).
1. Check the # 928 harness (between the alternator terminal P and the J1-9 port) for wear.
2. Disconnect the connectors from the terminal P and the controller and check the harness for open-
circuit. Turn the multimeter to its resistance function, and measure the resistance of the harness (#
928) between the controller port J1-9 and the terminal P (normally, <10Ω).
6-41
CLG920E/922E/923E 6.4.4 DTC 111001 System Charging Fault
Is the harness open-circuit?

Yes No
Connect the harness again and wrap the
harness.
Inspection method
Turn the start switch to the ON position and re-check for fault.
Yes No
6-42
6.4.5 DTC 121015 Oil Pressure Switch Disconnected CLG920E/922E/923E
6.4.5 DTC 121015 Oil Pressure Switch Disconnected

The display shows the oil pressure
121015 Oil pressure switch disconnected.
abnormally.
System description
The oil pressure switch is used for detecting the engine oil pressure. Normally, the pressure switch
contact is closed. When the pressure reaches 0.07MPa or more, the contact is open, resulting in a safety
overpressure less than 3.5MPa. Under normal circumstances, when the engine is started, the engine oil
pressure is greater than 0.07MPa, and the pressure switch contact should be open. The controller
detects the pressure switch signal. Then, if the engine oil pressure is lower than 0.07MPa, the controller
will give alarm information via the display.
Controller J2(White) Oil Pressure SW

Engine oil
pressure switch
6-43
CLG920E/922E/923E 6.4.5 DTC 121015 Oil Pressure Switch Disconnected
Component location
Engine oil
pressure switch
Front
Step 1 Check the oil pressure switch for fault.
When replacing the components, please be sure to use LiuGong parts.

Inspection method
Turn the start switch to the OFF position, and disconnect the oil pressure switch connector:
1. Check the connector pins for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function, and measure the resistance between the oil
pressure switch connector terminals 1 and 2 (normally, <10Ω).
Whether the oil pressure switch fails?
Yes No
Repair or replace the oil pressure switch.
6-44
6.4.5 DTC 121015 Oil Pressure Switch Disconnected CLG920E/922E/923E
wear.
Inspection method
1. Check the harness (# 902) and the grounding wire (# 283) between the controller (J2-02) and the
oil pressure switch for wear.
2. Disconnect the oil pressure switch connector and the controller connector, and check the harness
for open-circuit:
a. Turn the multimeter to its resistance function, and measure the resistance between the
grounding wire (#283) switch terminal and the grounding (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance of the harness
between the connector (C2-02) connected to the controller J2-02 and the switch (normally,
<10Ω).
Yes No
harness.
6-45
CLG920E/922E/923E 6.4.5 DTC 121015 Oil Pressure Switch Disconnected
Step 3 Check the connector for fault

Inspection method
Connect the oil pressure switch connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the connector C2-02
connecting to the controller port J2-02 and the grounding (normally, <10Ω).
When the resistance is abnormal, this indicates the connector is poorly contacted.
Whether the connector is faulty?
Yes No
Replace the connector.
Inspection method
Yes No
6-46
6.4.6 DTC 121018 Low Oil Pressure CLG920E/922E/923E
6.4.6 DTC 121018 Low Oil Pressure

Low oil pressure - when the engine is running, the
If the excavator is operated as usual, the
121018 signal circuit of the oil pressure switch detects a
engine can be damaged.
low oil pressure (the sensor contact is open).
System description
The oil pressure switch is used for detecting the engine oil pressure. Normally, the pressure switch
contact is closed. When the pressure reaches 0.07MPa or more, the contact is open, resulting in a safety
overpressure less than 3.5MPa. Under normal circumstances, when the engine is started, the engine oil
pressure is greater than 0.07MPa, and the pressure switch contact should be open. The controller
detects the pressure switch signal. Then, if the engine oil pressure is lower than 0.07MPa, the controller
will give alarm information via the display.
Controller J2(White) Oil Pressure SW

Engine oil
pressure switch
6-47
CLG920E/922E/923E 6.4.6 DTC 121018 Low Oil Pressure
Component location
Engine oil
pressure switch
Front
Step 1
Inspection method
1. Pull out the oil dipstick, and check whether the oil level on the dipstick is below the MIN scale.
2. Check whether the oil pump is functioning properly.
3. Remove the oil pressure switch, and measure whether the oil pressure is too low with the pressure
gauge.
Whether the oil pressure is low or not?
Yes No
Troubleshoot and restore the oil pressure.
6-48
6.4.6 DTC 121018 Low Oil Pressure CLG920E/922E/923E
Step 2

Inspection method
When the oil pressure is normal, check the oil pressure detection circuit or the oil pressure switch for
fault in accordance with the fault diagnosis of the 121015- Oil Pressure Fault
Whether the oil pressure monitoring system fails?
Yes No
Repair the oil pressure detection circuit or replace
the oil pressure switch.
Step 3
Inspection method
Yes No
6-49
CLG920E/922E/923E 6.4.7 DTC 121305 Handle Pressure Switch OFF
6.4.7 DTC 121305 Handle Pressure Switch OFF

121305 The handle pressure switch is turned off. No automatic idling.
System description
The hand pilot pressure switch is used to detect the hand pilot line pressure and the logic signal input for
the automatic idling function. After the engine is started, open the pilot shut-off valve. Then, when the
hand pilot control lever is not operated, the pressure switch contact should be closed. When the hand
pilot control lever is operated, the pressure switch contact should be open. The automatic idling function
can be achieved only when the controller detects simultaneously the hand pilot switch and foot pilot
switch signals, that is, when one or two pilot pressure switches are unplugged, the automatic idling
function will be invalid.
J1 (Black)
Controller
Hand pilot
pressure switch Hand pilot
pressure switch
J2(White)
Foot pedal
pressure switch
Foot pilot
pressure switch
LG922E930E06013
P29E00138
6-50
6.4.7 DTC 121305 Handle Pressure Switch OFF CLG920E/922E/923E
Component location
Front
Foot pilot
pressure switch
Hand pilot
pressure switch
Step 1 Check the hand pilot pressure switch for fault.

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the hand pilot pressure
switch:
2. Turn the multimeter to its resistance function, and measure the resistance between the hand pilot
pressure switch connector terminals 1 and 2 (normally, <10Ω).
Connect the multimeter probes to

two pins of the hand pilot
pressure switch, respectively.
Whether the hand pilot pressure switch fails?

Yes No
Repair or replace the hand pilot pressure switch.
6-51
wear.
Inspection method
1. For controller CM3620, check the harness (# 808) and the grounding wire (# 240) between the
controller (J1-8) and the hand pilot pressure switch for wear; and for controller C101-D1, check the
harness (# 808) and the grounding wire (# 240) between the controller (J2-61) and the hand pilot
pressure switch for wear?
2. Disconnect the hand pilot pressure switch connector and the controller connector, and check the
harness for open-circuit:
a. For controller CM3620,turn the multimeter to its resistance function, and measure the resistance
between the grounding wire (#240) hand pilot pressure switch end and the grounding (normally,
<10Ω); for controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance between the grounding wire (#240) hand pilot pressure switch end and the grounding
(normally, <10Ω).
Black probe
Gray
wire
Red probe
6-52
6.4.7 DTC 121305 Handle Pressure Switch OFF CLG920E/922E/923E
b. For the controller CM3620, turn the multimeter to its resistance function, and measure the
resistance between the controller port J1-8 and hand pilot pressure switch harness (normally,
<10Ω); and for the controller C101-D1, turn the multimeter to its resistance function, and
measure the resistance between the controller port J2-61 and hand pilot pressure switch
harness (normally, <10Ω).
To the black probe

To the red
probe
White wire

Yes No
harness.
6-53

Inspection method
For the controller CM3620: Connect the hand pilot pressure switch connector and disconnect the
controller connector. Turn the multimeter to its resistance function, and measure the resistance
between the harness at the controller port J1-8 and the grounding (normally, <10Ω).
For the controller C101-D1, connect the hand pilot pressure switch connector and disconnect the
between the harness at the controller port J2-61 and the grounding (normally, <10Ω).
To the black probe
To the red probe
Yes No
Inspection method
Yes No
6-54
6.4.8 DTC 121405 Pedal Pressure Switch Disconnected CLG920E/922E/923E
6.4.8 DTC 121405 Pedal Pressure Switch Disconnected

121405 The pedal pressure switch is disconnected. No automatic idling.
System description
The foot pilot pressure switch is used for detecting the foot pilot line pressure and the logic signal input
for automatic idling function. After the engine is started, open the pilot shut-off valve. When the foot pilot
control lever is not operated, the pressure switch contact should be closed. When the foot pilot control
lever is operated, the pressure switch contact should be open. The automatic idling function can be
achieved only when the controller detects simultaneously the foot pilot switch and hand pilot switch
signals, that is, when one or two pilot pressure switches are unplugged, the automatic idling function will
be invalid.
J1 (Black)
Controller
Hand pilot
pressure switch Hand pilot
pressure switch
J2(White)
Foot pedal
pressure switch
Foot pilot
pressure switch
P29E00138
6-55
CLG920E/922E/923E 6.4.8 DTC 121405 Pedal Pressure Switch Disconnected
Component location
Front
Foot pilot
pressure switch
Hand pilot
pressure switch
Step 1 Check the foot pilot pressure switch for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the foot pilot pressure switch connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the hand foot
pilot pressure switch connector terminals 1 and 2 (normally, <10Ω).
Connect the multimeter probes

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

Yes No
Repair or replace the foot pilot pressure switch.
6-56
wear.
Inspection method
1. For the controller CM3620, check the harness (# 913) and the grounding wire (# 240) between the
controller (J2-13) and the foot pilot pressure switch for wear; and for controller C101-D1, check the
harness (# 913) and the grounding wire (# 254) between the controller (J2-73) and the foot pilot
pressure switch for wear.
2. Disconnect the foot pilot pressure switch connector and the controller connector and check the
a. For controller CM3620,turn the multimeter to its resistance function, and measure the resistance
between the grounding wire (#240) foot pilot pressure switch end and the grounding (normally,
<10Ω); for controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance between the grounding wire (#240) foot pilot pressure switch end and the grounding
(normally, <10Ω).
Black probe
Gray
Red probe
wire
6-57
CLG920E/922E/923E 6.4.8 DTC 121405 Pedal Pressure Switch Disconnected
b. For the controller CM3620, turn the multimeter to its resistance function, and measure the
resistance between the controller port J2-13 and foot pilot pressure switch harness (normally,
measure the resistance between the controller port J2-73 and foot pilot pressure switch harness
(normally, <10Ω).
White
wire
To the red probe

To the black probe

Yes No
harness.
6-58

Inspection method
For the controller CM3620, connect the foot pilot pressure switch connector and disconnect the
between the harness at the controller port J2-13 and the grounding (normally, <10Ω); and for the
controller C101-D1, connect the foot pilot pressure switch connector and disconnect the controller
connector. Turn the multimeter to its resistance function, and measure the resistance between the
harness at the controller port J2-73 and the grounding (normally, <10Ω).
To the black probe

To the red probe
Yes No
Inspection method
Yes No
6-59
CLG920E/922E/923E 6.4.9 DTC 121604 Air Filter Switch Shorted to Ground
6.4.9 DTC 121604 Air Filter Switch Shorted to Ground

121604 Air filter switch shorted to ground
engine can be damaged
System description
The air prefilter is used to filter the dust and large impurities in the air before entering the air filter. The air
filter mounted on the inside of the left door of the complete machine is used to filter further the air from
the prefilter, and keep the air clean and dry through the main filter element and safety filter element
before entering into the engine cylinders for combustion. When the airflow through the air filter is blocked
and the air filter is needed to work, then if the engine is running, a high vacuum between the air filter and
the engine will produce. The vacuum can activate the electronic indicator (air filter switch) to generate
ground which is transmitted to the controller. The display will show the current situation to alert the
operator.
J2(White)
Controller
Intake air Filter alarm SW
filter alarm
P29E00139
6-60
6.4.9 DTC 121604 Air Filter Switch Shorted to Ground CLG920E/922E/923E
Component location
Front
Air filter
switch
Step 1 Check the air filter switch for fault
When replacing, LiuGong genuine parts must be used.

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the air filter switch:
1. Check the connector inside for moisture, oil dirt and other.
2. Turn the multimeter to its resistance function, and measure the resistance between the air filter
switch terminals (normally, >100K).
Whether the air filter switch fails?
Yes No
Repair or replace the air filter switch.
6-61
CLG920E/922E/923E 6.4.9 DTC 121604 Air Filter Switch Shorted to Ground
Step 2 Check whether the harness is shorted to ground
wear.
Inspection method
1. For the controller CM3620, check the harness (# 927) between the controller (J2-27) and the air
filter switch for wear;and for the controller C101-D1, check the harness (# 927) between the
controller (J2-53) and the air filter switch for wear.
2. Disconnect the air filter switch connector and the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 927) switch terminal and
the grounding (normally, >100K).
Whether the harness is shorted to ground or not?
Yes No
harness.
6-62
6.4.9 DTC 121604 Air Filter Switch Shorted to Ground CLG920E/922E/923E

Inspection method
For the controller CM3620, connect the air filter switch connector and disconnect the controller
controller port J2-27 and the grounding (normally, >100K); and for the controller C101-D1, connect the
air filter switch connector and disconnect the controller connector. Turn the multimeter to its resistance
function, and measure the resistance between the controller port J2-53 and the grounding (normally,
>100K).
When the resistance is abnormal, this indicates there is an insulation fault in the connector.
Yes No
Inspection method
Yes No
6-63
CLG920E/922E/923E 6.4.10 DTC 121615 Air Filter Clogging
6.4.10 DTC 121615 Air Filter Clogging

Air filter clogging - when the engine is running, the
121615 signal circuit of the air filter switch detects the air
filter is clogged (the sensor contact is closed).
System description
The air pre-filter is used to filter the dust and large impurities in the air before entering the air filter. The
air filter mounted on the inside of the left door of the complete machine is used to filter further the air from
the prefilter, and keep the air clean and dry through the main filter element and safety filter element
before entering into the engine cylinders for combustion. When the airflow through the air filter is blocked
and the air filter is needed to work, then if the engine is running, a high vacuum between the air filter and
the engine will produce. The vacuum can activate the electronic indicator (air filter switch) to generate
ground which is transmitted to the controller. The display will show the current situation to alert the
operator.
J2(White)
Controller
Intake air Filter alarm SW
filter alarm
LG922E930E06023
P29E00139
6-64
6.4.10 DTC 121615 Air Filter Clogging CLG920E/922E/923E
Component location
Front
Air filter
switch
Step 1 Check whether the air filter is clogged
Inspection method
Check whether the air filter is clogged

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

Inspection method
If the air filter is normal, check the air filter detection circuit or air filter alarm switch for fault in
accordance with the fault diagnosis of the 121604- Air Filter Switch Shorted to Ground.
Whether the air filter monitoring system fails?
Yes No
Repair the air filter detection circuit or replace the
air filter alarm switch.
6-65
CLG920E/922E/923E 6.4.10 DTC 121615 Air Filter Clogging
Inspection method
Yes No
6-66
6.4.11 DTC 131000 High Engine Speed CLG920E/922E/923E
6.4.11 DTC 131000 High Engine Speed

High engine speed - When the engine is running,
131000 the signal circuit of the speed sensor detects the
engine speed is too high.
System description
The speed sensor is used for detecting the engine speed which can be read on the display. The speed
sensor is an electromagnetic induction sensor, which is mounted on the diesel engine flywheel housing.
The diesel engine flywheel cuts the magnetic field lines, resulting in an EMF and output current. After
starting the engine, let it run at 1000 ~ 2270r/min, and then turn the multimeter to its AC voltage function,
and measure the speed sensor output voltage of 3~28V.
J1(Black)
Controller
Engine speed
J2(White)
Speed sensor
Sensor to ground
6-67
CLG920E/922E/923E 6.4.11 DTC 131000 High Engine Speed
Component location
Speed sensor
Front
Step 1 Check whether the operating method is incorrect

Inspection method
Check whether the operator’s operating method is correct.

Whether the operating method is incorrect or not?
Yes No
Tell the operator about the correct operating
method.
Step 2 Check whether the fuel is used properly.
Be careful! Hot engine block and hydraulic oil can cause serious scald.
Inspection method
Check whether the fuel being used is the specified one.

Whether the fuel is used improperly or not?
Yes No
Replace the fuel
6-68
6.4.11 DTC 131000 High Engine Speed CLG920E/922E/923E
Step 3 Check the detection circuit or speed sensor for fault

Inspection method
Check the speed detection circuit or speed sensor for fault in accordance with the fault diagnosis of
the 131005- Engine Speed Sensor Fault.
Whether the detection circuit speed sensor is faulty?
Yes No
Repair the detection circuit or replace the speed
sensor.
Inspection method
Yes No
6-69
CLG920E/922E/923E 6.4.12 DTC 131005 Engine Speed Sensor Fault
6.4.12 DTC 131005 Engine Speed Sensor Fault

An abnormal speed appears on the
Engine speed sensor fault (There is a fault in the
131005 display.
speed sensor circuit.)
The speed calibration is unsuccessful.
System description
Used to detect the engine speed which can be displayed on the display. The speed sensor is an
electromagnetic induction sensor, which is mounted on the diesel engine flywheel housing. The diesel
engine flywheel cuts the magnetic field lines, resulting in an EMF and output current. After starting the
engine, let it run at 1000 ~ 2270r/min, and then turn the multimeter to its AC voltage function, and
measure the speed sensor output voltage of 3~28V.
J1(Black)
Controller
Engine speed
J2(White)
Speed sensor
Sensor to ground
Component location
Speed sensor
Front
6-70
6.4.12 DTC 131005 Engine Speed Sensor Fault CLG920E/922E/923E
Step 1 Check the speed sensor for fault
Inspection method
1. Check the sensor for looseness.

2. Disconnect the speed sensor connector:
a. Check the connector pins for looseness, rust, bending and damage. Check the connector inside
for moisture, oil dirt and other.
b. Start the engine and turn the knob to increase the accelerator gradually. Turn the multimeter to
its AC voltage function, and measure the voltage on the sensor output ports (normally, when the
engine speed at 1000~2270r/min, the speed sensor outputs an AC voltage between 3~28V).
Whether the speed sensor is faulty?
Yes No
Tighten or repair, or replace the speed sensor.
Step 2 Check the harness for open-circuit and short-circuit
wear.
Inspection method
1. Check the harnesses (# 830 and # 922) between the controller (J1-30 and J2-22) and the speed
sensor for wear, respectively.
2. Disconnect the speed sensor connector and the controller connector and check the harnesses for
open-circuit: Turn the multimeter to its resistance function, and measure the resistance of the
harness (# 830 and # 922) between the controller (J1-30 and J2-22) and the speed sensor,
respectively (normally, <10Ω).
3. Disconnect the speed sensor connector and the controller connector and check whether the
harnesses is shorted to the ground. Turn the multimeter to its resistance function, and measure
the resistance between the harness (# 830 and # 922) sensor terminal and the grounding,
respectively (normally, >100K).
6-71
CLG920E/922E/923E 6.4.12 DTC 131005 Engine Speed Sensor Fault
Is the harness open or short circuit ?

Yes No
harness.

Inspection method
Connect the speed sensor connector and disconnect the controller connector. Start the engine and
turn the knob to increase the accelerator gradually. Turn the multimeter to its AC voltage function, and
measure the voltage between the controller ports J1-30 and J2-22 (normally, when the engine speed
at 1000~2270r/min, the speed sensor outputs an AC voltage between 3~28V.).
An abnormal voltage indicates that there is fault in the connector.
Yes No
Inspection method
Yes No
6-72
6.4.13 DTC 131100 Extremely High Coolant Temperature CLG920E/922E/923E
6.4.13 DTC 131100 Extremely High Coolant Temperature

Extremely-high coolant temperature - When the
engine is running, the signal circuit of the engine If the excavator is operated as usual, this
131100
coolant temperature sensor detects that the can cause the scuffing of cylinder bore.
engine coolant is overheating (108 °C).
System description
The temperature sensor is made of NTC temperature sensing material and is used for detecting cooling
water temperature and dedicated for the Cummins engine. The temperature sensor is a negative
temperature coefficient thermistor type, i.e., the lower the temperature, the larger the resistance.
Therefore, the temperature change is converted into a resistance voltage signal output to the controller
which detects the temperature of the cooling water. The temperature of the cooling water appears on the
connected display instrument. When the water temperature is higher than a certain value, an alarm
signal is sent.
Temperature sensor
Controller
Coolant temperature
Sensor to ground
6-73
CLG920E/922E/923E 6.4.13 DTC 131100 Extremely High Coolant Temperature
Component location
Coolant
temperature
sensor
Front
Step 1 Check the engine coolant for overheating.
Be careful! Hot engine block and coolant can scald you seriously.
Inspection method
Check the engine coolant for overheating with a thermometer.

Whether the engine coolant overheating or not?
Yes No
Look for the cause for the engine coolant
overheating.
Step 2 Check the engine coolant temperature monitoring system for fault

Inspection method
If the coolant temperature is normal, check the coolant temperature detection circuit or coolant
temperature sensor for fault in accordance with the fault diagnosis of 131103- Coolant Temperature
Sensor Voltage Outside the Range Value.
Whether the engine coolant temperature monitoring system fails or not?
Yes No
Repair the coolant temperature detection circuit
or replace the coolant temperature sensor.
6-74
6.4.13 DTC 131100 Extremely High Coolant Temperature CLG920E/922E/923E
Inspection method
Yes No
6-75
CLG920E/922E/923E 6.4.14 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value
6.4.14 DTC 131103 Coolant Temperature Sensor Voltage Above the

Range Value

The controller detects the coolant temperature
If the excavator is operated as usual, this
131103 sensor voltage is higher than the range value, that
can cause the scuffing of cylinder bore.
is, the detected voltage is above 4.9V.
System description
signal is sent.
Temperature sensor
Controller
Coolant temperature
Sensor to ground
Coolant temperature sensor parameter table
Coolant temperature (°C)
Resistance (Ω)
6-76
6.4.14 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value CLG920E/922E/923E
Component location
Coolant
temperature
sensor
Front
Step 1 Check the coolant temperature sensor for fault.
Inspection method
Turn the knob switch to the OFF position, and disconnect the sensor connector:
1. Check the connector for looseness, rust, bending and damage.
2. Turn the multimeter to its resistance function (20KΩ), measure the resistance between the sensor
connector terminals 1 and 2, and compare the result with the parameter table (normally, <4K).
Whether a fault developing in the coolant temperature sensor or not?
Yes No
Repair or replace the sensor.
wear.
6-77
CLG920E/922E/923E 6.4.14 DTC 131103 Coolant Temperature Sensor Voltage Above the Range Value
Inspection method
1. Check the harnesses (# 819 and # 922) between the controller (J1-19 and J2-22) and the coolant
temperature sensor for wear, respectively.
2. Disconnect the coolant temperature sensor connector and the controller connector: Turn the
multimeter to its resistance function, and measure the resistance of the harness (# 819 and # 922)
between the controller (J1-19 and J2-22) and the sensor, respectively (normally, <10Ω).
Yes No
harness.

Inspection method
Connect the coolant temperature sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the controller port J1-19
and J2-22, comparing the result with the parameter table (normally, <4K).
An abnormal resistance indicates that there is poor contact in the connector
Yes No
Inspection method
Yes No
6-78
6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value CLG920E/922E/923E
6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the

Range Value

Coolant temperature sensor voltage below the
range value (When the engine is running, the
131104 signal circuit of the engine coolant temperature
can cause the engine power down.
sensor detects that the engine coolant
temperature is too high —(above 150°C).)
System description
water (hydraulic oil) temperature and dedicated for the Cummins engine. The temperature sensor is a
negative temperature coefficient thermistor type, i.e., the lower the temperature, the larger the
resistance. Therefore, the temperature change is converted into a resistance voltage signal output to the
controller which detects the temperature of the cooling water (hydraulic oil). The temperature of the
cooling water (hydraulic oil) appears on the connected display instrument. When the cooling water
(hydraulic oil) temperature is higher than a certain value, an alarm signal is sent.
J1(Black)
Controller
Coolant
temperature
Hydraulic oil
temperature Temperature sensor
J2(White)
Sensor to ground
Hyd temperature
sensor
LG922E930E06029
Coolant temperature sensor parameter table

Resistance (Ω)
6-79
CLG920E/922E/923E 6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value
Component location
Coolant
temperature
sensor
Front
Step 1 Check the coolant temperature sensor for fault.

Inspection method
1. Check the connector for moisture, oil dirt and other
connector terminals 1 and 2, and compare the result with the parameter table (normally, >10Ω).
Whether a fault developing in the coolant temperature sensor or not?
Yes No
6-80
6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value CLG920E/922E/923E
wear.
Inspection method
1. Check the harnesses (# 819 and # 922) between the controller (J1-19 and J2-22) and the coolant
temperature sensor for wear, respectively.
2. Disconnect the coolant temperature sensor connector and the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness (# 819 and
# 922) sensor terminal and the grounding, respectively (normally, >100K).
Yes No
harness.

Inspection method
Connect the coolant temperature sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, measure the resistance between the controller port J1-19 and J2-
22, and compare the result with the parameter table (normally, >10Ω)
When the resistance is abnormal, this indicates there is an insulation fault in the connector
Yes No
6-81
CLG920E/922E/923E 6.4.15 DTC 131104 Coolant Temperature Sensor Voltage Below the Range Value
Inspection method
Yes No
6-82
6.4.16 DTC 131115 High Coolant Temperature CLG920E/922E/923E
6.4.16 DTC 131115 High Coolant Temperature

High coolant temperature—— When the engine is
running, the signal circuit of the engine coolant If the excavator is operated as usual, this
131115
temperature sensor detects that the engine can cause the scuffing of cylinder bore.
coolant is overheating (102°C).
System description
signal is sent.
Temperature sensor
Controller
Coolant temperature
Sensor to ground
6-83
CLG920E/922E/923E 6.4.16 DTC 131115 High Coolant Temperature
Component location
Coolant
temperature
sensor
Front
Step 1 Check whether the engine coolant temperature is too high.
Inspection method
Check whether the engine coolant temperature is too high with a thermometer.
Whether the engine coolant temperature is high or not?
Yes No
Look for the cause for high coolant temperature.

Inspection method
Sensor Voltage Above the Range Value.
Yes No
6-84
Inspection method
Yes No
6-85
6.4.17 DTC 131116 High Coolant Temperature

High coolant temperature - When the engine is
running, the signal circuit of the engine coolant If the excavator is operated as usual, this
131116
temperature sensor detects that the engine can cause the scuffing of cylinder bore.
coolant is overheating (105?).
System description
signal is sent.
Temperature sensor
Controller
Coolant temperature
Sensor to ground
6-86
Component location
Coolant
temperature
sensor
Front
Step 1 Check whether the engine coolant temperature is too high.
Inspection method
Check whether the engine coolant temperature is too high with a thermometer.
Whether the engine coolant temperature is high or not?
Yes No
Look for the cause for overhigh coolant
temperature.

Inspection method
Sensor Voltage Outside the Range Value.
Yes No
6-87
Inspection method
Yes No
6-88
6.4.18 DTC 1131200 Extremely High Hydraulic Oil Temperature CLG920E/922E/923E
6.4.18 DTC 1131200 Extremely High Hydraulic Oil Temperature

Extremely high hydraulic oil temperature - when
the engine is running, the signal circuit of the
131200 can cause damage to the hydraulic
hydraulic oil temperature sensor detects the
components.
hydraulic oil temperature is extremely high (95?).
System description
The temperature sensor is made of NTC temperature sensing material and is used for detecting
hydraulic oil (cooling water) temperature and dedicated for the Cummins engine. The temperature
sensor is a negative temperature coefficient thermistor type, i.e., the lower the temperature, the larger
the resistance. Therefore, the temperature change is converted into a resistance voltage signal output to
the controller which detects the temperature of the hydraulic oil (cooling water). The temperature of the
hydraulic oil (cooling water) appears on the connected display instrument. When the water temperature
is higher than a certain value, an alarm signal is sent.
Hyd temperature sensor

Controller
Sensor to ground
6-89
CLG920E/922E/923E 6.4.18 DTC 1131200 Extremely High Hydraulic Oil Temperature
Component location
Front
Hydraulic
oil
temperature
sensor
Step 1 Check whether the hydraulic oil temperature is extremely high
Be careful! Hot engine block and hydraulic oil can cause serious scald
Inspection method
Check whether the hydraulic oil is overheating with a thermometer.

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

Inspection method
If the hydraulic oil temperature is normal, check the hydraulic oil temperature detection circuit or
hydraulic oil temperature sensor for fault in accordance with the fault diagnosis of 131203- Hydraulic
Oil Temperature Sensor Voltage Above the Range Value.
Whether the hydraulic oil temperature monitoring system fails?
Yes No
Repair the hydraulic oil temperature detection
circuit or replace the hydraulic oil temperature
sensor.
6-90
Inspection method
Yes No
6-91
CLG920E/922E/923E6.4.19 DTC 131203 Hydraulic Oil Temperature Sensor Voltage Above the Range Value
6.4.19 DTC 131203 Hydraulic Oil Temperature Sensor Voltage Above the
Range Value

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

Controller
Sensor to ground
Hydraulic oil temperature sensor parameter table

Resistance (Ω)
6-92
6.4.19 DTC 131203 Hydraulic Oil Temperature Sensor Voltage Above the Range Value CLG920E/922E/
Component location
Front
Hydraulic
oil
temperature
sensor
Step 1 Check the hydraulic oil temperature sensor for fault
Inspection method
Whether the hydraulic oil temperature sensor fails?
Yes No
Repair or replace the hydraulic oil temperature
sensor.
wear.
6-93
CLG920E/922E/923E6.4.19 DTC 131203 Hydraulic Oil Temperature Sensor Voltage Above the Range Value
Inspection method
1. Check the harnesses (# 831 and # 922) between the controller (J1-31 and J2-22) and the
hydraulic oil temperature sensor for wear.
2. Disconnect the connectors from the hydraulic oil temperature sensor and the controller. Turn the
multimeter to its resistance function, and measure the resistance of the harness (# 831/# 922)
between the controller (J1-31/J2-22) and the hydraulic oil temperature sensor, respectively
(normally, <10Ω)
Yes No
harness.

Inspection method
Connect the hydraulic oil temperature sensor connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller port J1-31
and J2-22, comparing the result with the parameter table (normally, <4K).
An abnormal resistance indicates that there is poor contact in the connector
Yes No
Inspection method
Yes No
6-94
6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the Range Value CLG920E/922E/923E
6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the
Range Value

The hydraulic oil temperature sensor voltage is
below the range valve.
pipeline.
System description

Controller
Sensor to ground

Resistance (Ω)
6-95
CLG920E/922E/923E 6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the Range Value
Component location
Front
Hydraulic
oil
temperature
sensor
Step 1 Check the hydraulic oil temperature sensor for fault

Inspection method
connector terminals 1 and 2, and compare the result with the parameter table(normally, >10Ω).
Whether the hydraulic oil temperature sensor fails?
Yes No
6-96
6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the Range Value CLG920E/922E/923E
wear.
Inspection method
1. Check the harnesses (# 831 and # 922) between the controller (J1-31 and J2-22) and the
hydraulic oil temperature sensor for wear.
2. Disconnect the connectors from the hydraulic oil temperature sensor and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harness (# 831/#
922) sensor terminal and the grounding, respectively (normally, >100K).
Yes No
harness.

Inspection method
Connect the hydraulic oil temperature sensor connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the controller port J1-31
and J2-22, comparing the result with the parameter table (normally, >10Ω).
Yes No
6-97
CLG920E/922E/923E 6.4.20 DTC 131204 Hydraulic Oil Temperature Sensor Voltage below the Range Value
Inspection method
Yes No
6-98
6.4.21 DTC 131215 High Hydraulic Oil Temperature CLG920E/922E/923E
6.4.21 DTC 131215 High Hydraulic Oil Temperature

High hydraulic oil temperature - When the engine
is running, the signal circuit of the hydraulic oil
temperature sensor detects the hydraulic oil
components.
temperature is high (86°C).
System description

Controller
Sensor to ground
6-99
CLG920E/922E/923E 6.4.21 DTC 131215 High Hydraulic Oil Temperature
Component location
Front
Hydraulic
oil
temperature
sensor
Step 1 Check whether the hydraulic oil temperature is too high
Inspection method
Check the hydraulic oil temperature is high by using a thermometer.

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

Inspection method
Yes No
sensor.
6-100
6.4.21 DTC 131215 High Hydraulic Oil Temperature CLG920E/922E/923E
Inspection method
Yes No
6-101
6.4.22 DTC 131216 Extremely High Hydraulic Oil Temperature

Extremely high hydraulic oil temperature - when
the engine is running, the signal circuit of the
hydraulic oil temperature sensor detects the
components.
hydraulic oil temperature is high (88?).
System description

Controller
Sensor to ground
6-102
Component location
Front
Hydraulic
oil
temperature
sensor
Step 1 Check whether the hydraulic oil temperature is extremely high
Inspection method
Check whether the hydraulic oil temperature is extremely high with a thermometer.
Whether the hydraulic oil temperature is extremely high or not?
Yes No

Inspection method
Yes No
sensor.
6-103
Inspection method
Yes No
6-104
6.4.23 DTC 131303 Fuel Level Sensor Voltage Above the Range Value CLG920E/922E/923E
6.4.23 DTC 131303 Fuel Level Sensor Voltage Above the Range Value

131303 Fuel level sensor voltage above the range value
can cause the engine shuts down.
System description
The fuel level sensor is a reed pipe type. The magnetic floater density is lower than the working medium
(diesel) density, so the fuel level sensor floats on the surface of the working medium and can slide up
and down on the reed pipe. When the floater moves on the reed pipe, the on-off of the internal circuit of
the reed pipe is controlled by a magnetic field to allow the resistance between the two output leads of the
connector to change. Therefore, the fuel level change is converted into a resistance signal output, and
through connecting to the controller the fuel level in the tank is detected, and through connecting to the
display instrument the fuel level is displayed.
Fuel level
Fuel level sensor
LG922E930E06032
P29E00140
Fuel level sensor parameter table (for the details, see the attached drawing)
6-105
CLG920E/922E/923E 6.4.23 DTC 131303 Fuel Level Sensor Voltage Above the Range Value
Component location
Front
Fuel level sensor
Step 1 Check the fuel level sensor for fault.
High temperature and high pressure oil or water can cause personal injury! When
replacing the sensor, please shut down the engine first and wait until the engine and gearbox
housing are sufficiently cooled.
To install the fuel level sensor into the fuel tank, wipe off its water and keep it clean.
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level
sensor connector terminals 1 and 2 (normally, <2K, for the specific resistance, see the figure.).
6-106
Whether the fuel level sensor fails?

Yes No
Repair or replace the fuel level sensor.
wear.
Inspection method
1. For the controller CM3620, check the harness (# 930) and the grounding wire (#227) between the
controller (J2-30) and fuel level sensor for wear; and for the controller C101-D1, check the harness
(# 930) and the grounding wire (#255) between the controller (J1-8) and fuel level sensor for wear
2. Disconnect the fuel level sensor connector and the controller connector. Check the harness for
open-circuit:
a. For the controller CM3620, turn the multimeter to its resistance function, and measure the
resistance between the grounding wire (#227) sensor end and the grounding (normally, <10Ω);
and for the controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance between the grounding wire (#255) sensor end and the grounding (normally, <10Ω).
Gray wire
6-107
b. For the controller CM3620,turn the multimeter to its resistance function, and measure the
resistance of harness between the connector port J2-30 and sensor (normally, <10Ω); and for
the controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance of harness between the connector port J1-8 and sensor (normally, <10Ω).
White wire
To the
black probe
To the red probe

Yes No
harness.
6-108

Inspection method
Connect the fuel level sensor connector and disconnect the controller connector; for the controller
CM3620, turn the multimeter to its resistance function, and measure the resistance between the
harness at the controller port J2-30 and the grounding (normally, <2 kΩ, for the specific resistance,
see the attached drawing); and for the controller C101-D1, turn the multimeter to its resistance function,
and measure the resistance between the harness at the controller port J2-30 and the grounding (normally,
<2 kΩ, for the specific resistance, see the attached drawing).
Connect the black

probe to ground
Connect the red

probe to Pin 30
Yes No
Inspection method
Yes No
6-109
Attached drawing: Fuel level sensor parameter table
Floater position (be subject to 17.5mm) Output resistance (Ω)

Below L1 1100±11
L1-L2 1050±10.5
L2-L3 1000 10
L3-L4 950±9.5
L4-L5 900±9
L5-L6 850±8.5
L6-L7 800±8
L7-L8 750±7.5
L8-L9 700±7
L9-L10 650±6.5
L10-L11 600±6
L11-L12 550±5.5
L12-L13 500±5
L13-L14 450±4.5
L14-L15 400±4
L15-L16 350±3.5
L16-L17 300±3
L17-L18 250±2.5
L18-L19 200±2
L19-L20 150±1.5
L20-L21 100±1
6-110
Oil level
6-111
CLG920E/922E/923E 6.4.24 DTC 131304 Fuel Level Sensor Shorted to Ground
6.4.24 DTC 131304 Fuel Level Sensor Shorted to Ground

131304 The fuel level sensor is shorted to ground
can cause the engine shuts down.
System description
Fuel level
Fuel level sensor
LG922E930E06032
P29E00140
6-112
6.4.24 DTC 131304 Fuel Level Sensor Shorted to Ground CLG920E/922E/923E
Component location
Front
Fuel level sensor
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor
2. Turn the multimeter to its resistance function (2K), and measure the resistance between the fuel
level sensor terminals 1 and 2 (normally, >10Ω, for the details, see the attached drawing).
6-113

Yes No

wear.
Inspection method
1. For the controller CM3620,check the harness (# 930) between the controller (J2-30) and fuel level
sensor for wear; and for the controller C101-D1, check the harness (# 930) between the controller
(J1-8) and fuel level sensor for wear.
2. Disconnect the connectors from the fuel level sensor and the controller. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 930) sensor terminal and
the grounding (normally, >100K).
White wire

Yes No
harness.
6-114
6.4.24 DTC 131304 Fuel Level Sensor Shorted to Ground CLG920E/922E/923E

Inspection method
Connect the sensor connector and disconnect the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the J2-30 port and the grounding (normally,
>10Ω).
Yes No
Inspection method
Yes No

Below L1 1100±11
L1-L2 1050±10.5
L2-L3 1000 10
L3-L4 950±9.5
L4-L5 900±9
L5-L6 850±8.5
L6-L7 800±8
L7-L8 750±7.5
L8-L9 700±7
L9-L10 650±6.5
L10-L11 600±6
L11-L12 550±5.5
6-115

L12-L13 500±5
L13-L14 450±4.5
L14-L15 400±4
L15-L16 350±3.5
L16-L17 300±3
L17-L18 250±2.5
L18-L19 200±2
L19-L20 150±1.5
L20-L21 100±1
Oil level
6-116
6.4.25 DTC 131317 Low Fuel Level CLG920E/922E/923E
6.4.25 DTC 131317 Low Fuel Level

Low fuel level - When the start switch is turned to
the ON position (without starting the engine), the If the excavator is operated as usual, this
131317
signal circuit of the fuel level sensor detects that can cause the engine shuts down.
the fuel level is low (below 10%).
System description
connector to change. Therefore, the fuel level change is converted into a resistance signal output , and
Fuel level
Fuel level sensor
P29E00140
6-117
CLG920E/922E/923E 6.4.25 DTC 131317 Low Fuel Level
Component location
Front
Front
Fuel
Fuellevel
levelsensor
sensor
Step 1 Check whether the fuel level is low.
Inspection method
Check the fuel level.

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

Inspection method
If the fuel level is normal, check the fuel level monitoring system in accordance with the fault diagnosis
in the 131304- Fuel Level below the Lower Limit.
Whether the fuel level monitoring system fails?
Yes No
6-118
6.4.25 DTC 131317 Low Fuel Level CLG920E/922E/923E
Inspection method
Yes No

Below L1 1100±11
L1-L2 1050±10.5
L2-L3 1000 10
L3-L4 950±9.5
L4-L5 900±9
L5-L6 850±8.5
L6-L7 800±8
L7-L8 750±7.5
L8-L9 700±7
L9-L10 650±6.5
L10-L11 600±6
L11-L12 550±5.5
L12-L13 500±5
L13-L14 450±4.5
L14-L15 400±4
L15-L16 350±3.5
L16-L17 300±3
L17-L18 250±2.5
L18-L19 200±2
L19-L20 150±1.5
L20-L21 100±1
6-119
CLG920E/922E/923E 6.4.25 DTC 131317 Low Fuel Level
Oil level
6-120
6.4.26 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value CLG920E/922E/923E
6.4.26 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value

The water-in-fuel sensor voltage is higher than the
range value. The signal circuit of the water-in-fuel
131603 sensor detects the voltage is too high (more than
The engine can not be started.
4.3V)
System description
The water-in-fuel sensor is used to detect water content in the fuel. The more the water in the fuel, the
smaller the resistance. Therefore, the change in water content is converted into the resistance voltage
signal output, and through connecting to the controller the water content in the fuel is detected, and an
alarm signal is sent.
Water-in-fuel
sensor
Water-in-fuel sensor
LG922E930E06040
Component location
Front
Fuel-in-water
sensor
6-121
CLG920E/922E/923E 6.4.26 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value
Step 1 Check the water-in-fuel sensor for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
2. Turn the multimeter to its resistance function, and measure the resistance between the water-in-
fuel sensor connector terminals 1 and 2 (normally, <4.6M/306.5K).
Whether the water-in-fuel sensor fails?
Yes No
Repair or replace the water-in-fuel sensor.
wear.
Inspection method
water-in-fuel sensor for wear.
2. Disconnect the connectors from the water-in-fuel sensor and the controller. Check the harness for
open-circuit:
grounding wire (#254) sensor terminal and the grounding (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance of harness between
the connector terminals J2-21 and sensor (normally, <10Ω).
Yes No
6-122
6.4.26 DTC 131603 Water-in-Fuel Sensor Voltage Above the Range Value CLG920E/922E/923E

harness.

Inspection method
Connect the water-in-fuel sensor connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness at the
controller port J2-21 and the grounding (normally, <4.6M/306.5K).
Yes No
Inspection method
Yes No
6-123
CLG920E/922E/923E 6.4.27 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value
6.4.27 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value

The water-in-fuel sensor voltage is below the
range value. The signal circuit of the water-in-fuel
131604 There is white smoke from the engine
sensor detects the power voltage is too low (below
0.25V)
System description
Water-in-fuel
sensor
LG922E930E06040
Component location
Front
Fuel-in-water
sensor
6-124
6.4.27 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value CLG920E/922E/923E

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor
fuel sensor connector terminals 1 and 2 (normally, >2.62K).
Yes No
wear.
Inspection method
1. Check the harness (# 921) between the controller (J2-21) and the water in fuel sensor for wear.
2. Disconnect the connectors from the water in fuel sensor and the controller, respectively. Turn the
multimeter to its resistance function, and measure the resistance between the harness (# 921)
sensor terminal and the grounding (normally, >100K).
Yes No
harness.
6-125
CLG920E/922E/923E 6.4.27 DTC 131604 Water-in-Fuel Sensor Voltage Below the Range Value

Inspection method
and the grounding (normally, >2.62K).
Yes No
Inspection method
Yes No
6-126
6.4.28 DTC 131605 Water-in-Fuel Sensor Open-Circuited CLG920E/922E/923E
6.4.28 DTC 131605 Water-in-Fuel Sensor Open-Circuited

The water-in-fuel sensor is open-circuit (The
131605 signal circuit of the water-in-fuel sensor is open-
circuit)
System description
Water-in-fuel
sensor
LG922E930E06040
Component location
Front
Fuel-in-water
sensor
6-127
CLG920E/922E/923E 6.4.28 DTC 131605 Water-in-Fuel Sensor Open-Circuited

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the water-in-fuel sensor:
fuel sensor connector terminals 1 and 2 (normally, <4.6M).
Yes No
wear.
Inspection method
water-in-fuel sensor for wear.
2. Disconnect the connectors from the water-in-fuel sensor and the controller. Check the harness for
open-circuit:
grounding wire (#254) sensor terminal and the grounding (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance of harness between
the connector terminals J2-21 and sensor (normally, <10Ω).
Yes No
6-128
6.4.28 DTC 131605 Water-in-Fuel Sensor Open-Circuited CLG920E/922E/923E

harness.

Inspection method
controller port J2-21 and the grounding (normally, <4.6M).
Yes No
Inspection method
Yes No
6-129
CLG920E/922E/923E 6.4.29 DTC 131615 Water in Fuel
6.4.29 DTC 131615 Water in Fuel

Water-in-fuel——When the start switch is turned
to the ON position (without starting the engine), If the excavator is operated as usual, the
131615
the signal circuit of the water-in-fuel sensor engine power will reduce.
detects there is water in the fuel.
System description
Water-in-fuel
sensor
LG922E930E06040
Component location
Front
Fuel-in-water
sensor
6-130
6.4.29 DTC 131615 Water in Fuel CLG920E/922E/923E
Step 1 Check the fuel for water.
Inspection method
Check the fuel-water separator for water.

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

Inspection method
If the fuel is normal, check the water-in-fuel detection circuit or the water-in-fuel sensor for fault in
accordance with the fault diagnosis in the 131604- Water-in-Fuel Sensor Voltage below the Range
Value or 131603- Water-in-Fuel Sensor Voltage above the Range Value.
Whether the water-in-fuel monitoring system fails?
Yes No
Repair the water-in-fuel detection circuit or
replace the water-in-fuel sensor.
Inspection method
Yes No
6-131
CLG920E/922E/923E 6.4.30 DTC 131703 Sensor Power (5V) Shorted to Battery
6.4.30 DTC 131703 Sensor Power (5V) Shorted to Battery

The accelerator actuator cannot function
131703 The sensor power (5V) is shorted to the battery.
properly.
System description
The accelerator control system mainly consists of the accelerator potentiometer (accelerator knob),
controller and accelerator actuator. The schematic diagram is shown below: #907 and #904 are drive
control lines. The controller is driven by 2 pins. If either pin is open-circuit, this can cause the accelerator
system fault. The accelerator potentiometer is used to control the engine speed. As shown in the figure,
Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is connected to the controller-sensor
ground and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator actuator
controls the engine accelerator opening through the flexible shaft to control the engine speed. The
terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), Pin 5 is
grounded, Pin 2 is used for the accelerator feedback signal, Pin 1 is used to control the accelerator
motor’s positive rotation and Pin 4 is used to control the accelerator motor’s negative rotation.
Accelerator knob
Controller J1 (Black)
Accelerator motor 2 (ls ac2)
5V power supply
12-position throttle
potentiometer Accelerator actuator
J2(White)
Accelerator motor 2 (hs ac2)

Accelerator motor position
feedback
Sensor to ground
6-132
6.4.30 DTC 131703 Sensor Power (5V) Shorted to Battery CLG920E/922E/923E
Component location
Front
Accelerator
actuator
Step 1 Check the 5V sensor power is shorted to the battery.
wear.
Inspection method
Turn the start switch to the ON position and disconnect the controller connector to switch on the
switches of all electrical equipment, and then measure the voltage between the J1-28 port (# 828) and
ground (normally, 0V).
Whether the sensor power (5V) is shorted to the battery or not?
Yes No
Re-connect the harness and wrap it or replace
the connector.
6-133
CLG920E/922E/923E 6.4.30 DTC 131703 Sensor Power (5V) Shorted to Battery
Inspection method
Yes No
6-134
6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground CLG920E/922E/923E
6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground

The accelerator actuator cannot function
131704 The sensor power (5V) is shorted to ground
properly.
System description
ground terminal and Pin 3 is connected to the accelerator signal feedback terminal. The accelerator
actuator controls the engine accelerator opening through the flexible shaft to control the engine speed.
The terminals are shown in the figure. Pin 3 of the M1 connector is the controller power (5V), pin 5 is
grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used to control the accelerator
motor’s forward rotation and pin 4 is used to control the accelerator motor’s reverse rotation.
Accelerator knob
Controller J1 (Black)
5V power supply
potentiometer Accelerator actuator
J2(White)

feedback
Sensor to ground
6-135
CLG920E/922E/923E 6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground
Component location
Front
Accelerator
actuator
Step 1 Check the accelerator knob or actuator for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the connectors from the accelerator knob and
actuator:
2. Turn the multimeter to its resistance function, and measure the resistance between the accelerator
knob connector terminals 1 and 2 (normally, >10Ω).
3. Measure the resistance between the terminals 3 and 5 of the accelerator actuator connector
(normally, >10Ω).
Whether the accelerator knob or actuator fails?
Yes No
Repair or replace the accelerator knob and the
accelerator actuator.
6-136
6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground CLG920E/922E/923E
wear.
Inspection method
1. Check the harnesses (# 828 and # 922) between the controllers (J1-28 and J2-22) and the
accelerator knob or actuator for wear, respectively.
2. Disconnect the accelerator knob, the accelerator actuator connector and the controller connector.
Turn the multimeter to its resistance function, and measure the resistance between the terminal
opposite to the harness (# 828,# 922) controller and the grounding, respectively (normally,
>100K).
Yes No
harness.
6-137
CLG920E/922E/923E 6.4.31 DTC 131704 Sensor Power (5V) Shorted to Ground

Inspection method
1. Connect the accelerator knob connector and disconnect the accelerator actuator and the controller
controller ports J1-28 and J2-22 (normally, >10Ω).
2. Connect the accelerator actuator connector and disconnect the accelerator knob and the controller
controller port J1-28 and J2-22 (normally, >10Ω).
When the resistance in any step above is abnormal, this indicates an insulation fault develops in the
connector.
Yes No
Inspection method
Yes No
6-138
6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-Circuited CLG920E/922E/923E
6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-

Circuited

Pump proportional solenoid valve feedback open-
141005 The complete machine moves slowly.
circuit
System description
The pilot pump provides oil to the electromagnetic proportional pressure-reducing valve on the main
pump directly. The electromagnetic proportional pressure-reducing valve regulates the displacement of
the main pump based on various operating conditions.
Pump proprtional
solenoid valve
Pump solenoid valve
current feedback
P29E00133
6-139
CLG920E/922E/923E 6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-Circuited
Component location
Front
Pump
proportional solenoid valve
Step 1 Check the pump proportional solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the pump proportional solenoid valve
connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the pump
proportional solenoid valve connector terminals 1 and 2 (normally, 16~40Ω).
Whether the pump proportional solenoid valve fails?
Yes No
Repair or replace the pump proportional solenoid
valve.
6-140
6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-Circuited CLG920E/922E/923E
wear.
Inspection method
1. Check the harness (No. 905/No. 901) between the controller and the pump proportional solenoid
valve for wear.
2. Disconnect the connectors from the pump proportional solenoid valve and the controller,
respectively. Turn the multimeter to its resistance function, and measure the resistance of the
harness (# 905/# 901) between the controller and the solenoid valve, respectively (normally,
<10Ω).
Yes No
harness.
6-141
CLG920E/922E/923E 6.4.32 DTC 141005 Pump Proportional Solenoid Valve Feedback Open-Circuited

Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector; for
the controller CM3620,
turn the multimeter to its resistance function, and measure the resistance between the controller ports
J2-01 and J2-05 (normally, 16~40Ω); and for the controller C101-D1, turn the multimeter to its
resistance function, and measure the resistance between the controller ports J1-31 and J2-56
(normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-142
6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent CLG920E/922E/923E
6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback

Overcurrent

Pump proportional solenoid valve feedback The engine gets stuck or even shuts down
141006
overcurrent in a low gear.
System description
Pump proprtional
solenoid valve
Pump solenoid valve
current feedback
P29E00133
6-143
CLG920E/922E/923E 6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent
Component location
Front
Pump

Inspection method
connector
Yes No
valve.
6-144
6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent CLG920E/922E/923E
Step 2 Check the harness for short-circuit
wear.
Inspection method
1. For the controller CM3620, check the harnesses (# 901 and # 905) between the controller (J2-01
and J2-05) and the pump proportional solenoid valve for wear; and for the controller C101-D1,
check the harnesses (# 901 and # 905) between the controller (J-31 and J2-56) and the pump
proportional solenoid valve for wear. Disconnect both the controller and the solenoid valve
2. Check the two harnesses for short-circuit: Turn the multimeter to its resistance function, and
measure the resistance of the harness (# 901/905) between the solenoid valve terminals
(normally, >100K)
3. Check whether the harness is shorted to the battery. Turn the start switch to the ON position and
switch on the switches of all electrical equipment, and then measure the voltage between the
harness (# 901/# 905) solenoid valve terminal and the grounding (normally, 0V).
Is the harness short-circuit?
Yes No
harness.
6-145
CLG920E/922E/923E 6.4.33 DTC 141006 Pump Proportional Solenoid Valve Feedback Overcurrent

Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector, for
the controller CM3620, turn the multimeter to its resistance function, and measure the resistance
between the controller ports J2-01 and J2-05 (normally, 16~40Ω); and for the controller C101-
D1,check the resistance between the controller ports J-31 and J2-56 (normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-146
6.4.34 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground CLG920E/922E/923E
6.4.34 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground

Pump proportional solenoid valve shorted to
141104 Works slowly
ground
System description
Pump proprtional
solenoid valve
Pump solenoid valve
current feedback
LG922E930E06044
P29E00133
Component location
Front
Pump
6-147
CLG920E/922E/923E 6.4.34 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground

Inspection method
connector
Yes No
valve.
wear.
Inspection method
1. For the controller CM3620, check the harnesses (# 901 and # 905) between the controller (J2-01
and J2-05) and the pump proportional solenoid valve for wear; and for the controller C101-D1,
check the harnesses (# 901 and # 905) between the controller (J1-31 and J2-56) and the pump
proportional solenoid valve for wear.
2. Disconnect the connectors from the pump proportional solenoid and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harnesses (# 904
and # 905) the solenoid valve terminal and the grounding, respectively (normally, >100K).
Yes No
6-148
6.4.34 DTC 141104 Pump Proportional Solenoid Valve Shorted to Ground CLG920E/922E/923E

harness.

Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector, for
between the controller port J2-01 and the grounding (normally 16~40Ω); and for the controller C101-
D1,turn the multimeter to its resistance function, and measure the resistance between the controller
port J2-56 and the grounding (normally 16~40Ω)
Yes No
Inspection method
Yes No
6-149
CLG920E/922E/923E 6.4.35 DTC 141105 Pump Proportional Solenoid Valve Open-Circuited or Shorted to

Shorted to Battery

Pump proportional solenoid valve open-circuited
141105 The engine gets stuck
or shorted to the battery
System description
Pump proprtional
solenoid valve
Pump solenoid valve
current feedback
LG922E930E06044
P29E00133
Component location
Front
Pump
6-150
6.4.35 DTC 141105 Pump Proportional Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/

Inspection method
connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the solenoid
valve connector terminals 1 and 2 (normally, <100K).
Yes No
valve.
Step 2 Check whether the harness is open-circuited or shorted to the battery.
wear.
Inspection method
1. Check the harness (No. 905/No. 901) between the controller and the pump proportional solenoid
valve for wear.
Disconnect the connectors from the pump proportional solenoid valve and the controller.
3. Check the harnesses for open-circuit. Turn the multimeter to its resistance function, and measure
the resistance of the harnesses (#905 and #901) between the controller and the solenoid valve,
respectively (normally,<10Ω).
6-151
CLG920E/922E/923E 6.4.35 DTC 141105 Pump Proportional Solenoid Valve Open-Circuited or Shorted to
Whether the harness open-circuited or shorted to the battery or not?

Yes No
harness.

Inspection method
Connect the pump proportional solenoid valve connector and disconnect the controller connector; for
between the controller ports J2-01 and J2-05 (normally, 16~40Ω); and for the controller C101-D1, turn
the multimeter to its resistance function, and measure the resistance between the controller ports J1-
31 and J2-56 (normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-152
6.4.36 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground CLG920E/922E/923E
6.4.36 DTC 151004 Attachment Confluence Solenoid Valve Shorted to

Ground

Attachment confluence solenoid valve shorted to
151004 There is no hydraulic shear function
ground
System description
The attachment confluence solenoid valve (hydraulic shear function solenoid valve, ATT function
solenoid valve) (optional) is used to control realization of hydraulic shear function.
Shear function solenoid (option)
Controller
ATT solenoid valve
Component location
Front
Attachment
confluent
solenoid valve (position)
6-153
CLG920E/922E/923E 6.4.36 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground
Step 1 Check the attachment confluence solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluence solenoid valve
connector
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluence solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluence solenoid valve fails?
Yes No
Repair or replace the attachment confluence
solenoid valve.
wear.
Inspection method
1. Check the harness (No. 912) between the controller (J2-12) and the attachment confluent solenoid
valve for wear.
2. Disconnect the connectors from the attachment confluent solenoid valve and the controller. Turn
the multimeter to its resistance function, and measure the resistance between the harness (# 912)
solenoid valve terminal and the grounding (normally, >100K).
Yes No
6-154
6.4.36 DTC 151004 Attachment Confluence Solenoid Valve Shorted to Ground CLG920E/922E/923E

harness.

Inspection method
Connect the attachment confluent solenoid valve connector and disconnect the controller connector.
Turn the multimeter to its resistance function, and measure the resistance between the controller port
J2-12 and the grounding (normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-155
CLG920E/922E/923E6.4.37 DTC 151005 Attachment Confluent Solenoid Valve Open-Circuited or Shorted to
6.4.37 DTC 151005 Attachment Confluent Solenoid Valve Open-Circuited

or Shorted to Battery

Attachment confluent solenoid valve
151005 open-circuited or shorted to the There is no hydraulic shear function
battery
System description
The attachment confluence solenoid valve (hydraulic shear function solenoid valve, ATT function
solenoid valve) (optional) is used to control realization of hydraulic shear function.
Shear function solenoid (option)
Controller
ATT solenoid valve
Component location
Front
Attachment
confluent
solenoid valve (position)
6-156
6.4.37 DTC 151005 Attachment Confluent Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/
Step 1 Check the attachment confluence solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the attachment confluence solenoid valve
connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the attachment
confluence solenoid connector terminals 1 and 2 (normally, 16~40Ω).
Whether the attachment confluence solenoid valve fails?
Yes No
Repair or replace the attachment confluence
solenoid valve.
wear.
Inspection method
1. Check the harness (No. 912) or the grounding wire (No. 252) between the controller and the
attachment confluent solenoid valve for wear. Disconnect the attachment confluence solenoid
valve connector and the controller connector.
turn on all switches of the electrical equipment, and then measure the voltage between the
harness (No.912) solenoid valve terminal and the grounding (normally, 0V)
3. Check the harness for open-circuit. Turn the multimeter to its resistance function, and measure the
resistance of the harness (No.912) between the controller and the solenoid valve and that of the
harness (No. 252) between the solenoid valve and the grounding (normally, <10Ω).
6-157
CLG920E/922E/923E6.4.37 DTC 151005 Attachment Confluent Solenoid Valve Open-Circuited or Shorted to

Yes No
harness.

Inspection method
Connect the attachment confluent solenoid valve connector and disconnect the controller connector.
Turn the multimeter to its resistance function, and measure the resistance between the harness at
controller port J2-12 and the grounding (normally, 16~40Ω).
Yes No
Inspection method
Yes No
6-158
6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground CLG920E/922E/923E
6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground

The travel shift solenoid valve is shorted to
151204 There is no travel shift function.
ground.
System description
The controller outputs a signal to the travel shift solenoid valve through the harness (# 910 wire) to open
the valve port.
Controller
Controller
Travel speed solenoid valve (valve A2)
A2 Travel speed
solenoid valve
LG922E930E06048
P29E00127
Component location
A2-marked
Front
solenoid
valve can be
located.
6-159
CLG920E/922E/923E 6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground
Step 1 Check the travel speed solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the valve connector from the travel shift
solenoid valve.
1. Check the pins for moisture, oil dirt and other.
2. Measure the resistance between both ends of the travel shift solenoid valve. The resistance
should be 16~40Ω.
Whether the travel shift solenoid valve fails?
Yes No
Repair or replace the travel lifting solenoid valve.
Step 2 Check whether the power harness of the travel speed solenoid valve is shorted to ground.
Shutdown operation is needed

Inspection method
1. Turn the start switch to the OFF position for fault diagnosis.
2. Disconnect the connectors from the controller (in the figure) and travel speed solenoid, and
measure the resistance between the power line (No. 910) of travel speed solenoid and the
grounding. The resistance should be infinite
Whether the power harness of the travel shift solenoid valve is shorted to ground or not?
Yes No
Re-connect the harness, and wrap it.
6-160
6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground CLG920E/922E/923E
Step 3 Check the connectors for fault

Inspection method
Connect the travel shift solenoid valve connector and disconnect the controller connector; for the
controller CM3620, turn the multimeter to its resistance function, and measure the resistance between
the harness at the controller port J2-10 and the grounding (normally, 16~40Ω), and for the controller
C101-D1, turn the multimeter to its resistance function, and measure the resistance between the
harness at the controller port J1-5 and the grounding (normally, 16~40Ω). When the resistance is
abnormal, this indicates that there is a fault in the connector.
Definition of
connector pin
serial number
Whether the connector fails?

Yes No
Inspection method
Turn the start switch to the ON position and re-check the DTC
Yes No
6-161
CLG920E/922E/923E 6.4.38 DTC 151204 A2 Travel Speed Solenoid Shorted to Ground
Attached drawing
Controller
Controller connector
Front
6-162
6.4.39 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/
6.4.39 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or

Shorted to Battery

A2 travel speed solenoid valve is There is no travel shift function or the
151205 open-circuited or shorted to the travel shift solenoid valve is
battery. uncontrolled by the controller.
System description
The controller outputs a signal to the travel shift solenoid valve through the harness (# 910 wire) to open
the valve port.
Controller
Travel speed solenoid valve (valve A2)
A2 Travel speed
solenoid valve
LG922E930E06048
P29E00127
6-163
CLG920E/922E/923E6.4.39 DTC 151205 A2 Travel Shift Solenoid Valve Open-Circuited or Shorted to Battery
Component location
A2-marked
Front
solenoid
valve can be
located.
Step 1 Check the travel speed solenoid valve for fault.

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

wear.
6-164
Inspection method
1. For the controller CM3620,check the harness (# 910) and the grounding wire (# 221) between the
controller (J2-10) (in the figure) and the travel speed solenoid valve for wear; and for the controller
C101-D1, check the harness (#910) and the grounding wire (#221) between the controller (J1-5)
and the travel speed solenoid valve for wear.
2. Disconnect the travel shift solenoid valve connector and controller connector and check whether
the harness is open-circuited:
resistance of harness between the controller port J2-10 and travel speed solenoid valve
(normally, <10Ω); and for the controller C101-D1, turn the multimeter to its resistance function,
and measure the resistance of harness between the controller port J1-5 and travel speed
solenoid valve (normally, <10Ω).
b. Turn the multimeter to its resistance function, and measure the resistance between the
grounding wire (#222) travel speed solenoid valve valve terminal and the grounding (normally,
<10Ω).
Definition of
connector pin
serial number

Yes No
harness.
6-165

Inspection method
Connect the travel speed solenoid valve connector and disconnect the controller connector, for the
the harness (wire 910) at the controller port J2-10 and the grounding (normally, 16-40Ω); and for the
controller C101-D1, turn the multimeter to its resistance function, and measure the resistance
between the harness (wire 910) at the controller port J1-5 and the grounding (normally, 16-40Ω).When
the resistance is abnormal, it indicates that there is a fault in the connector.
Yes No
Repair or replace the connector.
Step 4 Check whether the travel speed solenoid valve is shorted to the battery.
Inspection method
Turn the start switch to the ON position for fault diagnosis.

Disconnect the connectors from the controller and A2 travel shift solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A2 travel shift
solenoid valve. The voltage should be 0.
Whether the travel speed solenoid valve is shorted to the battery or not?
Yes No
Find out the short circuit position and re-connect
the harness and wrap it.
6-166
Inspection method
Yes No
Attached drawing
Controller
Front
6-167
CLG920E/922E/923E 6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground
6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground

151304 Flattening solenoid valve shorted to ground. There is no flattening function.
System description
The controller outputs a signal to the flattening solenoid valve through the harness (# 827) to open the
valve port.
ControllerController
Flattening solenoid valve (valve A3) A3 arm speed
2nd gear proportional
solenoid valve
LG922E930E06052
P29E00131
Component location
Front A3-marked
solenoid valve
can be located.
6-168
6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground CLG920E/922E/923E
Step 1 Check the flattening solenoid valve for fault.

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

Inspection method
Turn the start switch to the OFF position for fault diagnosis
Disconnect the connectors from the controller (in the figure) and the flattening solenoid valve, and
measure the resistance between the power line(No. 827) of the flattening solenoid valve and the
grounding. The resistance should be infinite
Whether the power line of the flattening solenoid valve is shorted to ground or not?
Yes No
6-169
CLG920E/922E/923E 6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground

Inspection method
Connect the flattening solenoid valve connector and disconnect the controller connector, for the
the harness (wire 827) at the controller port J1-27 and the grounding (normally, 16-40Ω); and for the
between the harness (wire 827) at the controller port J2-72 and the grounding (normally, 16-
40Ω).When the resistance is abnormal, it indicates that there is a fault in the connector.
Definition of
connector pin
serial number

Yes No
Inspection method
Yes No
6-170
6.4.40 DTC 151304 A3 Flattening Solenoid Salve Shorted to Ground CLG920E/922E/923E
Attached drawing
Controller
Front
6-171
6.4.41 DTC 151305 A3 Travel Shift Solenoid Valve Open-Circuited or

Shorted to Battery

There is no flattening function or the
A3 Flattening solenoid valve is open-circuited or
151305 flattening solenoid valve is uncontrolled by
shorted to the battery.
the controller.
System description
The controller outputs a signal to the flattening solenoid valve through the harness (# 827) to open the
valve port.
ControllerController
Flattening solenoid valve (valve A3) A3 arm speed
2nd gear proportional
solenoid valve
LG922E930E06052
P29E00140
Component location
Front A3-marked
solenoid valve
can be located.
6-172
Step 1 Check the flattening solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position, and disconnect the travel shift solenoid valve connector
2. Measure the resistance between the both ends of the flattening solenoid valve. The resistance
should be 16~40Ω.
Whether the flattening solenoid valve fails?
Yes No
Repair or replace the flattening solenoid valve.
wear.
6-173
Inspection method
controller (J1-27) and the flattening solenoid valve for wear; and for the controller C101-D1, check
the harness (# 827) and the grounding wire (#222) between the controller (J2-72) and the
flattening solenoid valve for wear.
2. Disconnect the connectors from the flattening solenoid valve and the controller. Check the harness
for open-circuit:
resistance of harness between the controller port J1-27 and flattening solenoid valve (normally,
<10Ω); and for the controller C101-D1, check the resistance of harness between the controller
port J2-72 and flattening solenoid valve (normally, <10Ω).
grounding wire (# 222) flattening solenoid valve valve terminal and the grounding (normally,
<10Ω).
Definition of
connector pin
serial number

Yes No
harness.
6-174

Inspection method
Connect the flattening solenoid valve connector and disconnect the controller connector; for the
the harness at the controller port J1-27 and the grounding (normally, 16-40Ω); and for the controller
harness at the controller port J1-27 and the grounding (normally, 16-40Ω). When the resistance is
abnormal, it indicates that there is a fault in the connector.
Yes No
Step 4 Check whether the flattening solenoid valve is shorted to the battery
Inspection method

Disconnect the connectors from the controller and A3 flattening solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A3 flattening
solenoid valve. The voltage should be 0
Whether the flattening solenoid valve is shorted to the battery or not?
Yes No
Inspection method
Yes No
6-175
Attached drawing
Controller
Front
6-176
6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground CLG920E/922E/923E
6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground

151404 The digging solenoid valve is shorted to ground. There is no digging function.
System description
The controller outputs a signal to the digging solenoid valve A8 through the harness (# 825) to open the
valve port.
Controller
Digging solenoid valve (valve A8)
A8 Digging
solenoid valve
LG922E930E06054
P29E00130
Component location
Front A8-marked
solenoid valve
can be located.
6-177
CLG920E/922E/923E 6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground
Step 1 Check the digging solenoid valve for fault

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

Inspection method
1. Turn the start switch to the OFF position for fault diagnosis
2. Disconnect the connectors from the controller (attached drawing) and the digging solenoid valve,
and measure the resistance between the power line (# 825) of the trenching solenoid valve and
the grounding. The resistance should be infinite.
Whether the power harness of the digging solenoid valve is shorted to ground or not?
Yes No
6-178
6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground CLG920E/922E/923E

Inspection method
Connect the digging solenoid valve connector and disconnect the controller connector; for the
the harness (#825) at the controller port J1-25 and the grounding (normally, 16-40Ω); and for the
between the harness (#825) at the controller port J1-6 and the grounding (normally, 16-40Ω). When
the resistance is abnormal, it indicates that there is a fault in the connector.
Definition of
connector pin
serial number

Yes No
Inspection method
Yes No
6-179
CLG920E/922E/923E 6.4.42 DTC 151404 A8 Trenching Solenoid Valve Shorted to Ground
Attached drawing
Controller
Front
6-180
6.4.43 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/923E
6.4.43 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or

Shorted to Battery

The trenching solenoid valve is open-circuited or The trenching solenoid valve is open-
151405
shorted to the battery. circuited or in the digging function state.
System description
The controller outputs a signal to the digging solenoid valve A8 through the harness (# 825) to open the
valve port.
Controller Controller
Digging solenoid valve (valve A8)
A8 Digging
solenoid valve
LG922E930E06054
P29E00130
Component location
Front A8-marked
solenoid valve
can be located.
6-181
CLG920E/922E/923E 6.4.43 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to Battery
Step 1 Check the digging solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the digging solenoid
valve.
2. Measure the resistance between both ends of the digging solenoid valve. The resistance should
be 16~40Ω.
Whether the digging solenoid valve fails?
Yes No
Repair or replace the digging solenoid valve.
wear.
6-182
Inspection method
1. Check the connecting harness (No.825) and the earthing wire (No. 225) between the controller
(J1-25) (in the figure) and the trenching solenoid valve for wear.
2. Disconnect the connectors from the digging solenoid valve and the controller, and check the
resistance of harness between the controller port J1-25 and digging solenoid valve (normally,
measure the resistance of harness between the controller port J1-6 and digging solenoid valve
(normally, <10Ω).
grounding wire (#225) trenching solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
connector pin
serial number

Yes No
harness.
6-183
CLG920E/922E/923E 6.4.43 DTC 151405 A8 Trenching Solenoid Valve Open-Circuited or Shorted to Battery
When replacing, LiuGong genuine parts must be used

Inspection method
Connect the digging solenoid valve connector and disconnect the controller connector; for the
Yes No
Step 4 Check whether the trenching function solenoid valve is shorted to the battery.
Inspection method

Disconnect the connectors from the controller and A8 trenching solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A8 trenching
function solenoid valve. The voltage should be 0
Whether the trenching solenoid valve is shorted to the battery or not?
Yes No
Step 5
Inspection method
Yes No
6-184
Attached drawing
Controller
Controller
Front Controller connector
Front
6-185
CLG920E/922E/923E 6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground
6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground

151504 A5 flow adjusting solenoid is shorted to ground. There is no flow adjusting function.
System description
The controller outputs a signal to the flow adjusting solenoid valve through the harness (No. 908) which
feeds back the valve port opening through the harness (No. 924). The controller performs logical
judgement and then adjusts the signal to control the valve port opening through the harness (No. 908).
Controller
Accessory adjusting solenoid 2 valve A5

A5 Flow adjusting
Pql & PQ2 flow adjusting (valve A6 & A5) solenoid valve 2
LG922E930E06056
P29E00141
Component location
Front A5-marked
solenoid valve
can be located.
6-186
6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground CLG920E/922E/923E
Step 1 Check the flow adjusting solenoid for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the flow adjusting
solenoid valve.
2. Measure the resistance between both ends of the flow adjusting solenoid valve. The resistance
should be 16-40Ω
Whether the flow adjusting valve fails?
Yes No
Repair or replace the flow adjusting solenoid
valve.
Step 2 Check whether the harness of A5 flow adjusting solenoid valve is shorted to ground.

Inspection method
2. Disconnect the connectors from the controller (attached drawing) and the A5 flow adjusting
solenoid valve, for the controller CM3620,
measure the resistance between the power harness (#908) of the A5 flow adjusting solenoid valve J2-
8 and the grounding; and for the controller C101-D1, measure the resistance between the power line
(# 908) of the A5 flow adjusting solenoid valve J1-4 and the grounding. The resistance should be
infinite.
6-187
CLG920E/922E/923E 6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground
Definition of
connector pin
serial number
Whether the harness of A5 flow adjusting solenoid valve is shorted to ground or not?
Yes No

Inspection method
Connect the flow adjusting solenoid valve connector and disconnect the controller connector; for the
Yes No
6-188
6.4.44 DTC 151504 A5 Flow Adjusting Solenoid Shorted to Ground CLG920E/922E/923E
Inspection method
Yes No
Attached drawing
Controller
Front
6-189
CLG920E/922E/923E 6.4.45 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to
6.4.45 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or

Shorted to Battery

A5 flow adjusting solenoid valve is open-circuited
151505 There is no flow adjusting function.
or shorted to the battery.
System description
Controller
Accessory adjusting solenoid 2 valve A5

A5 Flow adjusting
Pql & PQ2 flow adjusting (valve A6 & A5) solenoid valve 2
LG922E930E06056
P29E00141
Component location
Front A5-marked
solenoid valve
can be located.
6-190
6.4.45 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/

Inspection method
solenoid valve.
should be 16-40Ω.
Yes No
valve.
wear.
6-191
Inspection method
1. For the controller CM3620, check the harness (# 908) and the feedback wire (# 924) between the
controller (J2-8) (attached drawing) and the flow adjusting solenoid valve for wear; and for the
controller C101-D1, check the harness (# 908) and the feedback wire (#924) between the
controller (J1-4) and the flow adjusting solenoid valve for wear.
2. Disconnect the connectors from flow adjusting solenoid valve and the controller. Check the
resistance of harness between the controller port J2-8 and flow adjusting solenoid valve
(normally, <10Ω); and for the controller C101-D1, check the resistance of harness between the
controller port J1-4 and flow adjusting solenoid valve (normally, <10Ω).
feedback wire (#924) flow adjusting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
Definition of
connector pin
connector pin
serial
serialnumber
number

Yes No
harness.
6-192
6.4.45 DTC 151505 A5 Flow Adjusting Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/

Inspection method
Yes No
Step 4 Check whether the flow adjusting solenoid valve is shorted to the battery
Inspection method

Disconnect the connectors from the controller and A5 flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A5 flow adjusting
Whether the flow adjusting solenoid valve is shorted to the battery or not?
Yes No
Inspection method
Yes No
6-193
Attached drawing
Controller
Front
6-194
6.4.46 DTC 151605 A6 Flow Adjusting Solenoid Open-Circuited or Shorted to Battery CLG920E/922E/923E
6.4.46 DTC 151605 A6 Flow Adjusting Solenoid Open-Circuited or

Shorted to Battery

A6 flow adjusting solenoid valve is open-circuited
151605 There is no flow adjusting function.
or shorted to the battery.
System description
Controller
Accessory adjusting solenoid valve 1(valve A6)

A6 Flow adjusting
Pq1 & PQ2 flow adjusting (valve A6 & A5) solenoid valve 1
LG922E930E06058
P29E00142
Component location
Front A6-marked
solenoid valve
can be located.
6-195
CLG920E/922E/923E 6.4.46 DTC 151605 A6 Flow Adjusting Solenoid Open-Circuited or Shorted to Battery

Inspection method
solenoid valve.
should be 16-40Ω.
Yes No
valve.
wear.
6-196
Inspection method
controller (J2-9) (attached drawing) and the flow adjusting solenoid valve for wear; and for the
controller C101-D1, check the harness (# 909) and the feedback wire (#924) between the
controller (J1-16) and the flow adjusting solenoid valve for wear.
2. Disconnect the connectors from flow adjusting solenoid valve and the controller. Check the
resistance of harness between the controller port J2-9 and flow adjusting solenoid valve
(normally, <10Ω); and for the controller C101-D1, check the resistance of harness between the
controller port J1-16 and flow adjusting solenoid valve (normally, <10Ω).
feedback wire (#924) flow adjusting solenoid valve terminal and the grounding (normally, <10Ω).
Definition of
Definition of
connector pin
connector pin
serial number
serial number

Yes No
harness.
6-197
CLG920E/922E/923E 6.4.46 DTC 151605 A6 Flow Adjusting Solenoid Open-Circuited or Shorted to Battery

Inspection method
the harness at the controller port J2-9 and the grounding (normally, <10Ω); and for the controller
C101-D1, check the resistance between the harness at the controller port J1-16 and the grounding
(normally, <10Ω). When the resistance is abnormal, it indicates that there is a fault in the connector.
Yes No
Step 4 Check whether the flow adjusting solenoid valve is shorted to the battery
Inspection method

Disconnect the connectors from the controller and A6 flow adjusting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A6 flow adjusting
Whether the flow adjusting solenoid valve is shorted to the battery or not?
Yes No
Inspection method
Yes No
6-198
Attached drawing
Controller
Front
6-199
CLG920E/922E/923E 6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground
6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground

The transient power boosting solenoid valve is
151704 No transient power boosting function.
shorted to ground.
System description
Sends a power boosting signal automatically or manually to control on-off of the solenoid valve port to
achieve the power boosting.
Controller
Transient power bossting solenoid valve valve A7
A7 Transient power
boosting solenoid
valve
LG922E930E06060
Component location
Front A7-marked
solenoid valve
can be located.
6-200
6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground CLG920E/922E/923E
Step 1 Check the transient power boosting solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
2. Measure the resistance between both ends of the transient power boosting solenoid valve. The
resistance should be 29-32Ω
Whether the transient power boosting solenoid valve fails?
Yes No
Repair or replace the transient power boosting
solenoid valve.
Step 2 Check whether the power line of the transient power boosting solenoid valve is shorted to
ground.

Inspection method
2. Disconnect the connectors from the controller (in the figure) and transient power boosting solenoid
valve, and measure the resistance between the power line (# 813) of the transient power boosting
solenoid valve and the grounding. The resistance should be infinite.
Whether the power harness of the transient power boosting solenoid valve is shorted to
ground or not?
Yes No
6-201
CLG920E/922E/923E 6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground

Inspection method
Connect the power boosting solenoid valve connector and disconnect the controller connector. Turn
the multimeter to its resistance function, and measure the resistance between the harness at the
controller port J1-13 and the grounding (normally, <10Ω). When the resistance is abnormal, this
indicates there is a fault in the connector.
Definition of
connector pin
serial number

Yes No
Inspection method
Yes No
6-202
6.4.47 DTC 151704 A7 Power Boosting Solenoid Valve Shorted to Ground CLG920E/922E/923E
Attached drawing
Controller
Front
6-203
CLG920E/922E/923E 6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or

Shorted to Battery

The power boosting solenoid valve is open- There is no transient power boosting or the
151705
circuited or shorted to the battery. power boosting is kept.
System description
Sends a power boosting signal automatically or manually to control on-off of the solenoid valve port to
achieve the power boosting
Controller
Transient power bossting solenoid valve valve A7
A7 Transient power
boosting solenoid
valve
LG922E930E06060
P29E00143
Component location
Front A7-marked
solenoid valve
can be located.
6-204
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/
Step 1 Check the transient power boosting solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the connector of the
transient power boosting solenoid valve.
2. Measure the resistance between both ends of the transient power boosting solenoid valve. The
resistance should be 16-40Ω.
Whether the transient power boosting solenoid valve fails?
Yes No
Repair or replace the transient power boosting
solenoid valve.
wear.
6-205
Inspection method
controller (J1-13) (attached drawing) and the transient power boosting solenoid valve for wear;
and for the controller C101-D1, check the harness (# 813) and the feedback wire (#224) between
the controller (J1-15) and the transient power boosting solenoid valve for wear.
2. Disconnect the connectors from the power boosting solenoid valve and the controller, and check
the harness for open-circuit:
resistance of harness between the controller port J1-13 and instantaneous power boosting
solenoid valve (normally, <10Ω); and for the controller C101-D1, check the resistance of
harness between the controller port J1-15 and instantaneous power boosting solenoid valve
(normally, <10Ω).
grounding wire (#224) power boosting solenoid valve terminal and the grounding (normally,
<10Ω).
Definition of
connector pin
serial number

Yes No
harness.
6-206
6.4.48 DTC 151705 A7 Power Boosting Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/

Inspection method
Connect the instantaneous power boosting solenoid valve connector and disconnect the controller
connector; for the controller CM3620, turn the multimeter to its resistance function, and measure the
resistance between the harness at the controller port J1-13 and the grounding (normally, 16-40Ω); and
for the controller C101-D1, turn the multimeter to its resistance function, and measure the resistance
between the harness at the controller port J1-15 and the grounding (normally, 16-40Ω). When the
resistance is abnormal, it indicates that there is a fault in the connector.
Yes No
Step 4 Check whether the power boosting solenoid valve is shorted to the battery
Inspection method

Disconnect the connectors from the controller and A7 power boosting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A7 power
boosting solenoid valve. The voltage should be 0
Whether the power boosting solenoid valve is shorted to the battery?
Yes No
Inspection method
Yes No
6-207
Attached drawing
Controller
Front
6-208
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground CLG920E/922E/923E
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground

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

A4 Travel lifting
solenoid valve
LG922E930E06062
Component location
Front A4-marked
solenoid valve
can be located.
6-209
CLG920E/922E/923E 6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground
Step 1 Check the travel lifting solenoid valve for fault.

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

Inspection method
2. Disconnect the connectors from the controller (in the figure) and the travel lifting solenoid valve,
and measure the resistance between the power line (# 826) of the travel lifting solenoid valve and
the grounding. The resistance should be infinite
Whether the power harness of the travel lifting solenoid valve is shorted to ground?
Yes No
6-210
6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground CLG920E/922E/923E

Inspection method
Connect the travel lifting solenoid valve connector and disconnect the controller connector. Turn the
controller port J1-26 and the grounding (normally, 16~40Ω). When the resistance is abnormal, this
indicates that there is a fault in the connector.
Definition of
connector pin
serial number

Yes No
Inspection method
Yes No
6-211
CLG920E/922E/923E 6.4.49 DTC 151804 A4 Travel Lifting Solenoid Valve Shorted to Ground
Attached drawing
Controller
Front
6-212
6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to Battery CLG920E/922E/
6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or

Shorted to Battery

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

A4 Travel lifting
solenoid valve
LG922E930E06062
6-213
CLG920E/922E/923E 6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to
Component location
Front A4-marked
solenoid valve
can be located.
Step 1 Check the travel lifting solenoid valve for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the travel lifting solenoid
valve.
2. Measure the resistance between both ends of the travel lifting solenoid valve. The resistance
should be 16~40Ω.
Whether the travel lifting solenoid valve fails?
Yes No
6-214
wear.
Inspection method
1. Check the harness (#826) and the grounding wire (# 223) between the controller J1-26 (attached
drawing) and the travel lifting solenoid valve for wear.
2. Disconnect the connectors from the travel lifting solenoid valve and the controller, and check the
controller port J1-26 and travel speed solenoid valve harness (normally, <10Ω).
grounding wire (# 223) travel lifting solenoid valve terminal and the grounding (normally, <10Ω).
Definitionofof
Definition
connector pin
connector pin
serial number
serial number

Yes No
harness.
6-215
CLG920E/922E/923E 6.4.50 DTC 151805 A4 Travel Lifting Solenoid Valve Open-Circuited or Shorted to

Inspection method
Connect the travel lifting solenoid valve connector and disconnect the controller connector. Turn the
multimeter to its resistance function, and measure the resistance between the harness (#826) at the
controller port J1-26 and the grounding (normally, 16~40Ω). When the resistance is abnormal, this
indicates that there is a fault in the connector.
Yes No
Step 4 Check whether the travel lifting solenoid valve is shorted to the battery.
Inspection method

Disconnect the connectors from the controller and A4 travel lifting solenoid valve to switch on the
switches of all electrical equipment, and then measure the voltage of the harness of A4 travel lifting
solenoid valve. The voltage should be 0.
Whether the travel lifting solenoid valve is shorted to the battery or not?
Yes No
Inspection method
Yes No
6-216
Attached drawing
Controller
Front
6-217
CLG920E/922E/923E 6.4.51 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited
6.4.51 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited

A5 or A6 flow adjusting solenoid valve is open
151905 The flow cannot be adjusted.
circuit.
System description
The controller sends a signal through which A5 or A6 adjusts the hydraulic flow.
Controller
Accesspry adjusting solenoid valve 2 valve A5
Accesspry adjusting solenoid valve 1 (valve A6)
Pq1 & PQ2 flow adjusting solenoid valve (valve A6 & A5)
A5 Flow adjusting
solenoid valve 2
A1 Flow adjusting
solenoid valve1
6-218
6.4.51 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited CLG920E/922E/923E
P29E00129
6-219
Component location
assembly. Both
A5-marked
solenoid and
A6-marked
solenoid can be
located
Front
Correctly tie up harness and wire
Keep away from high temperature parts (e.g. engine block) as far as possible
Inspection method
Turn the start switch to the OFF position,

Disconnect the connectors from the controller (attached drawing), A5, A6 flow adjusting solenoid valve,
for the controller CM3620,
measure the resistance between the J2-24 wire and the A5/A6 flow adjusting solenoid valve
connector; and for the controller C101-D1, measure the resistance between the J1-17 wire and the
A5/A6 flow adjusting solenoid valve connector. The maximum resistance should be 10Ω.
6-220
6.4.51 DTC 151905 A5 or A6 Solenoid Valve Feedback Open-Circuited CLG920E/922E/923E
Definition of
Definition of
connector pin
connector pin
serial number
serial number

Yes No
Re-connect the harness and wrap it.

Inspection method
Check the connectors between the A5/A6 flow adjusting solenoid valve and the controller for
looseness and their pins for rust, bending and damage one by one manually.
Disconnect the controller connector and connect the connector of the A5/A6 flow adjusting solenoid
valve, for the controller CM3620,measure the resistance between the controller connector ports J2-
8,J2-9 and J2-24; and for the controller C101-D1, measure the resistance between the controller
connector ports J1-4, J1-16 and J1-17, the resistance should be 16-40Ω. Otherwise, there is a fault in
the connector.
Yes No
Adjust or replace the connector.
6-221
Inspection method
Yes No
Attached drawing
Controller
Front
6-222
6.4.52 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent CLG920E/922E/923E
6.4.52 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent

151906 A5 or A6 solenoid valve feedback overcurrent. The flow cannot be adjusted.
System description
The controller sends a signal through which A5 or A6 adjusts the hydraulic flow.
Controller
Accesspry adjusting solenoid valve 2 valve A5
Accesspry adjusting solenoid valve 1 (valve A6)
Pq1 & PQ2 flow adjusting solenoid valve (valve A6 & A5)
A5 Flow adjusting
solenoid valve 2
A1 Flow adjusting
solenoid valve1
6-223
CLG920E/922E/923E 6.4.52 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent
P29E00129
6-224
Component location
assembly. Both
A5-marked
solenoid and
A6-marked
solenoid can be
located
Front
Step 1 Check the pump proportional solenoid valve for fault

Inspection method
Turn the start switch to the OFF position, and check the pins for moisture, oil dirt and other.
Measure the resistance of A5 or A6 flow adjusting solenoid valve. The resistance should be 16-40Ω.
Yes No
Replace the solenoid valve.
6-225
CLG920E/922E/923E 6.4.52 DTC 151906 A5 or A6 Solenoid Valve Feedback Overcurrent
Step 2 Check whether the harness is shorted to the battery

Inspection method
Disconnect the connectors from the controller, A5 and A6 solenoid valves, respectively
For the controller CM3620, measure the voltage between the controller (attached drawing) connector
terminal J2-24 and the ground by using the voltmeter (200V); and for the controller C101-D1, measure
the voltage between the controller connector terminal J1-17 and ground by using the voltmeter
(200V), the voltage should be 0V.
Definition of
connector pin
Definition of
serial number
connector pin
serial number
Whether the harness is shorted to the battery or not?

Yes No

Inspection method
Check the connectors between the A5/A6 flow adjusting solenoid valve and the controller for
looseness and their pins for rust, bending and damage one by one manually.
Yes No
Repair or replace the connector
6-226
Inspection method
Yes No
Attached drawing
Controller
Front
6-227
CLG920E/922E/923E 6.4.53 DTC 171004 Battery Relay Shorted to Ground
6.4.53 DTC 171004 Battery Relay Shorted to Ground

The alternator’s load dump may burn
171004 Battery relay shorted to ground electronic components and electrical
equipment.
System description

When the B or L terminal is connected to the positive pole of the power (24V) and the E terminal to the
negative pole, the energized coil generates a magnetic field suction to move the armature to pull in the
contact, so that the controlled circuit is switched on.
Battery
IPC Controller
Power supply relay
Battery relay
6-228
6.4.53 DTC 171004 Battery Relay Shorted to Ground CLG920E/922E/923E

When the positive of battery relay is connected to the positive of the power supply (24V) and the
negative to that of the power supply, the energized coil generates a magnetic field suction to move the
armature to pull in the contact, so that the controlled circuit is switched on.
P29E00144
Component location
Front
Battery relay
6-229
CLG920E/922E/923E 6.4.53 DTC 171004 Battery Relay Shorted to Ground
Step 1 Check the battery relay for fault

Inspection method
Turn the start switch to the OFF position and for the controller CM3620, turn the multimeter to its
resistance function (200Ω), and then measure the resistance between the relay terminals L and E
(normally, >10Ω, about 50Ω); and for the controller C101-D1, turn the multimeter to its resistance
function (200Ω), and then measure the resistance between the relay positive and negative (normally,
>10Ω, about 50Ω).
Whether the battery relay fails?
Yes No
Replace the battery relay.
Shutdown operation is needed.

Inspection method
1. For the controller CM3620, check the harness (# 824) between the controller (J1-24) and the
battery relay for wear; and for the controller C101-D1, check the harness (# 824) between the
controller (J2-76) and the battery relay for wear.
2. Disconnect the relay connector and the controller connector. Turn the multimeter to its resistance
function, and measure the resistance between the harness (# 824) relay terminal and the ground
(normally, >100K).
Yes No
harness.
6-230
6.4.53 DTC 171004 Battery Relay Shorted to Ground CLG920E/922E/923E
Inspection method
Yes No
6-231
CLG920E/922E/923E 6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground
6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground

171104 The auto preheating relay is shorted to ground. The auto preheating function fails.
System description
The controller needs to be preheated before logical judgment. If the harness (No. 911) is energized, the
automatic preheater K9 is energized and the harness (No. 123) is connected to the harness (No. 190),
then the harness (No. 190) is energized. As a result, the preheating relay is energized, so that the
harness (No. 104) is connected to the harness (No. 185) which connects the heater for heating.
Ignition switch
Auto
Electric lock preheating 10A Auto preheating
power supply relay K9
Battery
Preheating relay K3
Controller
Preheating relay
6-232
6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground CLG920E/922E/923E
Component location
Open the fuse box.
K9 auto preheating
relay. It can be pulled
out during detection
6-233
CLG920E/922E/923E 6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground
Step 1 Check whether the harness connecting the controller port J2-11 is shorted to ground

Inspection method
Turn the start switch to the OFF position for fault diagnosis.
Disconnect the connector from the controller (in the figure) and pull out the auto preheating relay, and
then measure the resistance between the harness (# 911) at the J2-11 port and the grounding. The
resistance should be infinite
Definition of
connector pin
serial number
Check whether the harness connecting the controller port J2-11 is shorted to ground.
Yes No

Inspection method
Check manually the connectors between the automatic preheating relay and the controller one by one
for moisture, oil dirt and other failures which may cause electric leakage.
Yes No
6-234
6.4.54 DTC 171104 Auto Preheating Relay Shorted to Ground CLG920E/922E/923E
Inspection method
Yes No
Attached drawing
Controller
Front
6-235
CLG920E/922E/923E 6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to Battery
6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to

Battery

Auto preheating relay is open-circuited or shorted
171105 The auto preheating function fails.
to the battery.
System description
The controller needs to be preheated before logical judgment. If the harness (No. 911) is energized, the
automatic preheater K9 is energized and the harness (No. 123) is connected to the harness (No. 190),
then the harness (No. 190) is energized. As a result, the preheating relay is energized, so that the
harness (No. 104) is connected to the harness (No. 185) which connects the heater for heating.
Ignition switch
Auto
Electric lock preheating 10A Auto preheating
power supply relay K9
Battery
Preheating relay K3
Controller
Preheating relay
6-236
6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to Battery CLG920E/922E/923E
Component location
Open the fuse box.
K9 auto preheating
out during detection
Step 1 Check the auto preheating relay for fault.

Inspection method
Open the fuse box, and pull out the auto preheating relay.
Measure the resistance between the ports 85 and 86 of the auto preheating relay coil. The resistance
should be 350-360Ω
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87 by turning
the multimeter to its on-off function. The relay should switch on.
Whether the auto preheating relay fails?
Yes No
Replace the auto preheating relay.
6-237
CLG920E/922E/923E 6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to Battery
Avoid folding or bending the harness forcibly
Try to keep far way from oil and water
Inspection method
Disconnect the connector from the controller (in the figure) and pull out the auto preheating relay, and
then measure the resistance between the harness (No. 911) at the J2-11 port and the auto preheating
relay. The maximum resistance should be 10Ω
Measure the resistance between the 85 port in the fuse box and the ground. The maximum resistance
should be 10Ω
Definition of
connector pin
serial number

Yes No
6-238
6.4.55 DTC 171105 Auto Preheating Relay Open-Circuited or Shorted to Battery CLG920E/922E/923E

Inspection method
Insert the auto preheating relay into the fuse box properly and disconnect the controller connector,
and then turn the multimeter to its resistance function and measure the resistance between the
harness at the controller port J2-11 and the grounding. The resistance should be between 345-360Ω.
Otherwise, check the connector:
a. Check the connector at the grounding of the auto preheating relay for poor contact
b. Check the connector of the auto preheating relay for looseness or damage.
Yes No
Inspection method
Yes No
Attached drawing
Controller
Front
6-239
CLG920E/922E/923E 6.4.56 DTC 171204 Start Cut-off Relay Shorted to Ground
6.4.56 DTC 171204 Start Cut-off Relay Shorted to Ground

The start cut-off relay is not controlled by
171204 Start cut-off valve relay is shorted to ground.
the controller.
System description
For the controller CM3620, after the controller port 23 is energized, the harness (# 923) is energized, so
that the ports 30 and 87A of the start cut-off relay K8 are switched off.
Controller
Start cutoff relay
Controller control start relay K8

Pilot control start relay K7
6-240
6.4.56 DTC 171204 Start Cut-off Relay Shorted to Ground CLG920E/922E/923E
For the controller C101-D1, after the controller port 71 is energized, the harness (# 923) is energized, so
P29E00145
6-241
Component location
Open the fuse box.
Start cut-off relay K8
Step 1 Check whether there is a fault in the start cut-off relay.

Inspection method
1. Turn the start switch to the OFF position for troubleshooting;

Open the fuse box, and pull out the auto preheating relay.;
2. Measure the resistance between the ports 85 and 86 of the start cut-off relay coil. The resistance
should be 320-350Ω;
3. Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87A by
turning the multimeter to its on-off function. The relay should switch on.
Whether the start cut-off relay fails?
Yes No
Replace the start cut-off relay.
6-242
6.4.56 DTC 171204 Start Cut-off Relay Shorted to Ground CLG920E/922E/923E
Step 2 Check whether the power line of the start cut-off relay is shorted to ground.

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

Inspection method
Connect the connector of the start cut-off relay and disconnect the controller connector, and for the
controller CM3620,then turn the multimeter to its resistance function and measure the resistance
between the harness at the controller port J2-23 and the grounding (normally, 320-360Ω). If the
resistance is abnormal, it indicates that there is a fault in the connector.
Definition of
connector pin
serial number

Yes No
6-243
Inspection method
Yes No
Attached drawing
Controller
Front
6-244
6.4.57 DTC 171205 Start Cut-Off Output Open-Circuited or Shorted to Battery CLG920E/922E/923E
6.4.57 DTC 171205 Start Cut-Off Output Open-Circuited or Shorted to

Battery

The start cut-off output is open-circuited or The start cut-off relay is not controlled by
171205
shorted to the battery. the controller.
System description
For the controller CM3620, after the controller port 23 is energized, the harness (# 911) is energized, so
Controller
Start cutoff relay
Controller control start relay K8

Pilot control start relay K7
6-245
CLG920E/922E/923E 6.4.57 DTC 171205 Start Cut-Off Output Open-Circuited or Shorted to Battery
For the controller C101-D1, after the controller port 71 is energized, the harness (# 923) is energized, so
P29E00145
6-246
Component location
Open the fuse box.
Start cut-off relay K8
Step 1 Check whether there is a fault in the start cut-off relay.

Inspection method
1. Turn the start switch to the OFF position for fault diagnosis
2. Open the fuse box, and pull out the start cut-off relay.
3. Measure the resistance between the ports 85 and 86 of the start cut-off relay coil. The resistance
should be 320-360Ω.
4. Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87 by
turning the multimeter to its on-off function. The relay should switch on.
Whether the start cut-off relay fails?
Yes No
Replace the start cut-off relay.
6-247
Avoid folding or bending the harness forcibly
Try to keep far way from oil and water
Inspection method
1. Turn the start switch to the OFF position for troubleshooting;

2. Disconnect the connector from the controller (attached drawing) and pull out the start cut-off relay;
for the controller CM3620, measure the resistance between the harness (# 923) at the J2-23 port
and the start cut-off relay; and for the controller C101-D1, measure the resistance between the
harness (# 923) at the J2-71 port and the start cut-off relay, normally, the resistance should be less
than 10Ω;
Measure the resistance between the 85 port in the fuse box and the ground. The maximum resistance
should be 10Ω
Definition of
connector pin
serial number

Yes No
6-248

Inspection method
Insert the start cut-off relay into the fuse box properly and disconnect the controller connector,for the
controller CM3620,
turn the multimeter to its resistance function, and measure the resistance between the harness (#923)
at the controller port J2-23 and the grounding; and for the controller C101-D1, turn the multimeter to its
resistance function, and measure the resistance between the harness (#923) at the controller port J2-
71 and the grounding, and normally it should be 320-360Ω. When the resistance is abnormal,please
check the connector.
1. Check the connector at the grounding of the start cut-off relay for poor contact
2. Check the connector of the start cut-off relay for looseness or damage.
Yes No
Step 4 Check whether the start cut-off relay is shorted to the battery

Inspection method

Disconnect the connectors from the controller and the start cut-off relay and turn on the switches of all
electrical equipment, and then measure the voltage of the harness connecting the start cut-off relay.
The voltage should be 0.
Whether the start cut-off relay is shorted to the battery or not?
Yes No
6-249
Inspection method
Yes No
Attached drawing
Controller
Front
6-250
6.4.58 DTC 201004 Travel Alarm Shorted to Ground CLG920E/922E/923E
6.4.58 DTC 201004 Travel Alarm Shorted to Ground

201004 Travel alarm is shorted to ground Travel alarm fails to work
System description
The travel alarm is used to beep for warning when the machine is moving, as shown in the figure. One
pin of the travel alarm is connected to the controller directly and the other pin is grounded. When the
machine is moving, the controller receives the traveling signal and allows the travel alarm to be
energized through its internal logic program.
(Black)
Travel alarm buzzer
Controller
Travel alarm (optional)
P29E00146
6-251
CLG920E/922E/923E 6.4.58 DTC 201004 Travel Alarm Shorted to Ground
Component location
Front
Travel alarm
Step 1 Check the travel alarm for fault.

Inspection method
Turn the start switch to the OFF position, and disconnect the travel alarm connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the alarm
connector terminals 1 and 2 (normally, >10Ω).
Whether the travel alarm fails?
Yes No
6-252
6.4.58 DTC 201004 Travel Alarm Shorted to Ground CLG920E/922E/923E
wear.
Inspection method
Travel alarm for wear; and for the controller C101-D1, check the harness (# 801) between the
controller (J2-68) and the Travel alarm for wear.
2. Disconnect the traveling alarm connector and the controller connector. Turn the multimeter to its
resistance function, and measure the resistance between the harness (# 801) sensor terminal and
grounding (normally, >100K).
Yes No
harness.
6-253
CLG920E/922E/923E 6.4.58 DTC 201004 Travel Alarm Shorted to Ground

Inspection method
Connect the Travel alarm connector and disconnect the controller connector; for the controller
controller port J1-01 port and the grounding (normally, >10Ω); and for the controller C101-D1,check
the resistance between the controller port (J2-68) and the grounding (normally, >10Ω).
Yes No
Inspection method
Yes No
6-254
6.4.59 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value CLG920E/922E/923E
6.4.59 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range
Value

The P1 pump pressure sensor voltage is out of the
range value. (When the left/right joystick is Operating the excavator as usual can
211003 operated, the voltage detected in the signal circuit cause the engine gets stuck or even shuts
of the P1 pump pressure sensor is higher than the down.
normal value.)
System description
The pressure sensor (pressure transmitter) converts the detected hydraulic oil pressure parameter into
the current signal, which is input to the controller, then the controller detects the hydraulic oil pressure
value which is displayed on the display instrument.
Controller
5V power supply - :+ :+ 3
:+
- *<
P1 pump pressure - :+ P1 pump pressure sensor
Sensor to earthing - *<
%$5
a
LG925E4F06169
P29E00147
Pressure sensor parameters:

Output voltage: 0.5-4.5V
Working voltage: 5Vdc
Pressure range: 0-500bar
6-255
CLG920E/922E/923E 6.4.59 DTC 211003 P1 Pump Pressure Sensor Voltage Above the Range Value
Component location
P1 pressure sensor
3⌫ু࣑Ֆ᝕ಞ
P2 pressure sensor
3⌫ু࣑Ֆ᝕ಞ
ࢃ Front
LG925E4F06170

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

Yes No
Step 2 Check the harness for shorted to power supply
wear.
6-256
Inspection method
pump pressure sensor for wear; and for the controller C101-D1, check the harness (# 931)
between the controller (J1-37) and the pump pressure sensor for wear.
2. Turn the start switch to the ON position and disconnect the connectors from the pump pressure
sensor and the controller. Measure the voltage between the harness (# 931) sensor terminal and
the grounding using voltage band of the multimeter (normally, 0V).
Whether the harness is shorted to the power supply?
Yes No
harness.
Step 3 Check whether the sensor power supply is normal.
wear.
Inspection method
1. For the controller CM3620, check the harness (# 828) between the controller (J-28) and the pump
pressure sensor for wear;and for the controller C101-D1, check the harness (# 828) between the
controller (J-28) and the pump pressure sensor for wear.
2. Turn the start switch to the ON position and disconnect the pump pressure sensor connector. Turn
the multimeter to its voltage function and measure the voltage between the harness (# 828) sensor
power supply terminal and the grounding (normally, 5V).
Whether the pump pressure sensor fails?
Yes No
Replace the pump pressure sensor.
6-257
Step 4 Check the pump pressure sensor for fault

Inspection method
Turn the start switch to the OFF position and connect the controller connector, and then disconnect
the pump pressure sensor connector and measure the voltage in the pump pressure sensor signal;
For the controller CM3620, start the engine, and with the boom lifted, turn the multimeter to its voltage
function, and measure the voltage between the sensor signal J2-31 (#931) and grounding (normally,
0.5-4.5V); and for the controller C101-D1, start the engine, and with the boom lifted, turn the
multimeter to its voltage function, and measure the voltage between the sensor signal J1-37 (#931)
and grounding (normally, 0.5-4.5V).
Yes No
Replace the pump pressure sensor
Inspection method
Yes No
6-258
6.4.60 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value CLG920E/922E/923E
6.4.60 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range
Value

The P1 pump pressure sensor voltage is lower
than the range value (When the left/right joystick is
Some hydraulic actions cannot be
211004 operated, the voltage detected in the signal circuit
achieved.
of the P1 pump pressure pressure too low---less
than 0.5V)
System description
Controller
5V power supply
P1 Pump pressure
Sensor to ground P1 pump pressure sensor
P29E00147

Output voltage: 0.5 -4.5
6-259
CLG920E/922E/923E 6.4.60 DTC 211004 P1 Pump Pressure Sensor Voltage Below the Range Value
Component location
P1 Pump
pressure
sensor
P2Pump
pressure
sensor
Front
LG925E4F06170

Inspection method
1. Check the connector at the sensor grounding for poor contact

2. Check whether the connector becomes loose.
3. Check the connector pins for rust, bending or damage.
Yes No
6-260
Step 2 Check the harness for open-circuit or shorted to ground.
wear.
Inspection method
pump pressure sensor and the power supply line for wear; and for the controller C101-D1, check
the harness (# 931) between the controller (J1-37) and the pump pressure sensor and the power
supply line for wear.
Turn the start switch to the ON position, and disconnect the connectors from the pump pressure
sensor and the controller, respectively.
2. Check the harness for open-circuit:
a. Measure the voltage between the sensor power connecting end and the sensor grounding using
voltage band of the multimeter (normally, 5V).
b. Turn the start switch to OFF position. Measure the resistance of the harness (# 931) between
the controller and the sensor using resistance band of the multimeter(normally, <10Ω)
3. Check whether the harness is shorted to ground:
Measure the resistance between the harness (# 931) sensor terminal and the grounding (normally,
>100K).
Whether the harness open-circuit or shorted to ground?
Yes No
harness.
6-261
Step 3 Check the pump pressure sensor for fault.

Inspection method
Yes No
Inspection method
Yes No
6-262
Value

The P2 pump pressure sensor voltage is higher
than the range value (When the left/right joystick is If the machine is operated as usual, the
211103
operated, the voltage detected in the signal circuit engine will get stuck or even shut down.
of the P2 pump pressure sensor is high (>4.5V))
System description
P2
Controller J1
5V power supply J1-28 28 828WH 828WH 2 P
932WH 4
J2 922GY 1
P2 pump pressure J2-32 32 932WH P2 pump pressure sensor
Sensor to earthing J2-22 22 922GY
0~500BAR
LG925E4F06173
P29E00148

Output current: 0.5-4.5V
6-263
Component location
P1 pump
pressure
sensor
P2 pump
pressure
sensor
Front

Inspection method

33Yes No
6-264
Step 2 Check the harness for shorted to battery
wear.
Inspection method
Whether the harness is shorted to the battery.
Yes No
harness.
6-265

Inspection method
Yes No
Inspection method
Yes No
6-266
6.4.62 DTC 211104 P2 Pump Pressure Sensor Voltage Below the Range
Value

The P2 pump pressure sensor voltage is lower
than the range value. (When the left/right joystick
211104 is operated, the voltage detected in the signal No special response.
circuit of the P2 pump pressure sensor is less than
0.5V)
System description
P2
Controller J1
932WH 4
J2 922GY 1
0~500BAR
LG925E4F06173
P29E00148
6-267

Component location
Front
N1 Negative flow pressure sensor (position)

Inspection method

Yes No
6-268
wear.
Inspection method
pump pressure sensor and the power supply line (#828) for wear; and for the controller C101-D1,
check the harness (# 932) between the controller (J1-48) and the pump pressure sensor and the
power supply line (#828) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the pump pressure
sensor and the controller, respectively.
a. Measure the voltage between sensor power connecting end and the grounding using voltage
band of the multimeter (normally, 5V).
b. Turn the start switch to OFF position. Turn the multimeter to its resistance band, and measure
the resistance of the harness (# 932) between the controller and the sensor (normally, <10Ω).
>100K).
Yes No
harness.
6-269

Inspection method
the pump pressure sensor connector and measure the voltage in the pump pressure sensor signal:
Yes No
Inspection method
Yes No
6-270
6.4.63 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the Range Value CLG920E/922E/
Range Value

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

6-271
CLG920E/922E/923E6.4.63 DTC 211203 N1 Negative Flow Pressure Sensor Voltage Above the Range Value
Component location
Front

Inspection method

Yes No
wear.
6-272
Inspection method
1. Check the harness (# 919) between the controller (J2-19) and the N1 negative flow pressure
sensor for wear.
Yes No
harness.
Step 3 Check the N1 negative flow pressure sensor for fault.

Inspection method
the N1 negative flow pressure sensor connector and measure the current in the sensor signal circuit:
Start the engine, and with the boom lifted, turn the multimeter to its voltage band, and measure the
voltage between the sensor signal J2-19 (#919) and grounding (normally, 0.5-4.5V).
Whether the N1 Negative Flow Pressure Sensor Fails?
Yes No
Replace the N1 negative flow pressure sensor.
Inspection method
Yes No
6-273
CLG920E/922E/923E6.4.64 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the Range Value
Range Value

lower than the range value (The voltage in the Abnormal hydraulic oil temperature rise
211204
signal circuit of the N1 negative flow pressure under no load.
sensor is too low (<0.5V)).
System description
Controller
5V power supply
N1 Negative flow pressure
N1 negative flow pressure sensor.

Sensor to ground

6-274
6.4.64 DTC 211204 N1 Negative Flow Pressure Sensor Voltage Below the Range Value CLG920E/922E/
Component location
Front

Inspection method

Yes No
6-275
wear.
Inspection method
sensor and the power line (# 121) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the N1 negative flow
pressure sensor and the controller.
a. Turn the multimeter to its voltage function, and measure the voltage between the power line (#
121) sensor terminal and the grounding (normally, 25±0.5V (battery voltage)).
b. Turn the multimeter to its resistance function, and measure the resistance of the harness (#
919) between the controller and the sensor (normally, <10Ω)
>100K).
Yes No
harness.
6-276
Step 3 Check the N1 negative flow pressure sensor for fault.

Inspection method
the N1 negative flow pressure sensor connector and measure the voltage in the sensor signal circuit:
Whether the N1 Negative Flow Pressure Sensor Fails?
Yes No
Inspection method
Yes No
6-277
Range Value

higher than the range value (The voltage in the
sensor is too high (>4.5V)).
System description
P3
Controller J1
933WH 4
J2 922GY 1
N2 Negative flow
pressure J2-33 33 933WH
Sensor to earthing J2-22 22 922GY N2 negative flow pressure sensor
0~60BAR
LG925E4F06181

6-278
Component location
Front

Inspection method

Yes No
wear.
6-279
Inspection method
sensor for wear.
2. Turn the start switch to the ON position and disconnect the connectors from N2 negative flow
pressure sensor and the controller, and turn the multimeter to its voltage function, then measure
the voltage between the harness (# 933) sensor terminal and the grounding (normally, 0V).
Yes No
harness.
Step 3 Check the N2 negative flow pressure sensor for fault

Inspection method
Whether the N2 negative flow pressure sensor fails?
Yes No
Inspection method
Yes No
6-280
Range Value

lower than the range value (The voltage in the Abnormal hydraulic oil temperature rise
211304
signal circuit of the N2 negative flow pressure under no load.
sensor is too low (<0.5V)).
System description
Controller
5V power supply
Sensor to ground N2 negative flow pressure sensor.

6-281
Component location
Front
N Negative flow pressure sensor (position)

Inspection method

Yes No
6-282
wear.
Inspection method
sensor and the power line (# 121) for wear.
Turn the start switch to the ON position, and disconnect the connectors from the N2 negative flow
pressure sensor and the controller.
a. Measure the voltage between the sensor power end and the sensor using voltage band of the
multimeter (normally, 5V).
b. Turn the Start switch to OFF position. Turn the multimeter to its resistance band, and measure
the resistance of the harness (# 933) between the controller and the sensor (normally, <10Ω).
>100KΩ).
Yes No
harness.
6-283
Step 3 Check the N2 negative flow pressure sensor for fault

Inspection method
Whether the N2 negative flow pressure sensor fails?
Yes No
Inspection method
Yes No
6-284
6.4.67 DTC 211316 High N2 Negative Flow Pressure CLG920E/922E/923E
6.4.67 DTC 211316 High N2 Negative Flow Pressure

High N2 negative flow pressure - When the
machine is operated, the pressure detected in the
sensor is high (more than 4.2MPa).
System description
Controller
5V power supply
Sensor to ground N2 negative flow pressure sensor.
LG925E4F06185

Component location
Front
N Negative flow pressure

sensor (position)
6-285
CLG920E/922E/923E 6.4.67 DTC 211316 High N2 Negative Flow Pressure
Step 1 Check whether the N2 negative flow pressure is high
Inspection method
Using the manometer, check whether the N2 negative flow pressure is too high.
Whether the N2 negative flow pressure is high?
Yes No
Troubleshoot the high pump pressure.
Step 2 Check the N2 negative flow pressure monitoring system for fault

Inspection method
When the pressure is normal, check the N2 negative flow pressure detection circuit or pressure
sensor for fault, referring to the troubleshooting in the 211303-N2 Negative Flow Pressure Sensor
Voltage Above the Range Value.
Whether the N2 negative flow pressure monitoring system fails?
Yes No
Check and repair N2 negative flow pressure
detection circuit or replace the pressure sensor.
Inspection method
Yes No
6-286
Value

The P2 pump pressure sensor voltage is higher
than the range value (When the left/right joystick is
If the machine is operated as usual, the
211103 operated, the voltage detected in the signal circuit
engine will get stuck or even shut down.
of the P2 pump pressure sensor is too high
(>4.5V)).
System description
P2
Controller J1
932WH 4
J2 922GY 1
0~500BAR
LG925E4F06173
P29E00148

6-287
Component location
P1 pump
pressure
sensor
P2 pump
pressure
sensor
Front

Inspection method

Yes No
wear.
6-288
Inspection method
reducing valve pressure sensor and the controller. Measure the voltage between the harness (#
932) sensor terminal and the grounding using voltage band of the multimeter (normally, 0V).
Yes No
harness.
Step 3 Check the pump pressure-reducing valve sensor for fault.

Inspection method
the pump pressure sensor connector and measure the voltage in the sensor signal circuit;
Whether a fault developing in the pump pressure-reducing valve sensor?
Yes No
Replace the pump pressure-reducing valve
sensor.
Step 4 Check whether this fault is eliminated-
Inspection method
Yes No
6-289
CLG920E/922E/923E 6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage Below the Range
6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage

Below the Range Value

The pump pressure-reducing valve sensor voltage
is below the range value. The detected current in
211404 The engine gets stuck or even shuts down.
the signal circuit of the pump proportional valve
pressure sensor is too low —(less than 4mA).
System description
Pump valve pressure
Pump valve pressure transmitter
transmitter
LG922E930E06085

Output current: 4-20mA
Component location
Front
Pressure sensor for pump proportional

6-290
6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage Below the Range Value CLG920E/

Inspection method

Yes No
wear.
Inspection method
1. Check the harness (# 920) and the power line (# 121) between the controller (J2-20) and the pump
pressure-reducing valve sensor for wear.
Turn the start switch to the ON position, and disconnect the connectors from the pump pressure-
reducing valve sensor and the controller, respectively.
a. Turn the multimeter to its voltage function, and measure the voltage between the power line (#
121) sensor terminal and the grounding (normally, 25-27 V (battery voltage)).
b. Turn the multimeter to its resistance function, and measure the resistance of the harness (#
920) between the controller and the sensor (normally, <10Ω)
6-291
CLG920E/922E/923E 6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage Below the Range
>100KΩ).
Yes No
harness.
Step 3 Check the pump pressure-reducing valve sensor for fault.

Inspection method
Turn the start switch to the OFF position and disconnect the connector from the pump pressure-
reducing valve sensor, and then connect the controller connector:
1. Connect the current detection circuit as shown in the schematic diagram:
Connector matching P5
Pump valve pressure transmitter
Pressure of pump proportional
Black probe Red probe
Multimeter
2. Turn the multimeter to its current function (200mA) and start the engine, and then with the boom
lifted, measure the current between the sensor connector male terminal and female terminal (Pin
1) (normally, 4-20mA).
Whether a fault developing in the pump pressure-reducing valve sensor?
Yes No
Replace the pump pressure-reducing valve
sensor.
6-292
6.4.69 DTC 211404 Pump Pressure-Reducing Valve Sensor Voltage Below the Range Value CLG920E/
Inspection method
Yes No
6-293
CLG920E/922E/923E 6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value
6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value

The actuator feedback voltage is lower than the
221001 range value, i.e., the detected voltage in the The accelerator actuator fails.
actuator feedback signal circuit is lower than 0.5V.
System description
Accelerator knob
(Black) (Black)
5V power supply
12-position accelerator
potentiometer
Accelerator actuator
(White)

feedback
Sensor to ground
6-294
6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value CLG920E/922E/923E
Component location
Front
Accelerator
actuator
Step 1 Check the accelerator actuator for fault

Inspection method
Disconnect the connectors from the accelerator actuator:

1. Check the connector pins for looseness, rust, bending and damage. Check the connector inside
2. Turn the multimeter to its resistance function (20kΩ) and measure the resistance between the
actuator connector pins 3 and 5 (normally, about 4-5kΩ), and then, using the multimeter, measure
the resistance between the pins 2 and 3 and that between the pins 2 and 5. The sum of the
resistance between the pins 2 and 3 and that between the pins 2 and 5 equals the resistance
between the pins 3 and 5.
Whether the accelerator actuator fails?
Yes No
Repair or replace the accelerator actuator.
6-295
CLG920E/922E/923E 6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value
Step 2 Check the harness for open-circuit and short-circuit
wear.
Inspection method
1. Check the harness (# 828,# 918) between the controller (J1-28,J1-18) and the accelerator
actuator for wear.
Disconnect the connectors from the accelerator actuator and the controller, respectively
Turn the multimeter to its resistance function, and measure the resistance of the harness (# 828/#
918) between the controller and the accelerator actuator, respectively, (normally, <10Ω).
3. Check whether the harness is short-circuited to ground:
Turn the multimeter to its resistance function, and measure the resistance between the (# 828/# 918)
harness’s actuator coupling end and the grounding (normally, >100K).
Is the harness open or short circuit ?
Yes No
harness.

Inspection method
Connect the actuator connector and disconnect the controller connector. Turn the multimeter to its
resistance function and measure the resistance between the controller port J1-28 and J2-18 (normally,
4~5kΩ), and then measure the resistance between the ports J1-28 and J2-22 and that between the
ports J2-28 and J2-22. The sum of the resistance between the pins 2 and 3 and that between the pins
2 and 5 equals the resistance between the pins 3 and 5.
An abnormal resistance indicates that there is fault in the connector.
6-296
6.4.70 DTC 221001 Actuator Feedback Voltage Below the Range Value CLG920E/922E/923E

Yes No
Step 4
Inspection method
Yes No
6-297
CLG920E/922E/923E 6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value
6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value

The actuator feedback voltage is higher than the
range value, i.e., the detected voltage in the
221003 The accelerator actuator fails.
actuator feedback signal circuit is higher than
4.5V.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-298
6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value CLG920E/922E/923E
Component location
Front
Accelerator
actuator

Inspection method
Disconnect the connectors from the accelerator actuator:

actuator connector pins 3 and 5 (normally, about 4.29kΩ), and then, using the multimeter, measure
Yes No
6-299
CLG920E/922E/923E 6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value
Step 2 Check the harness for short-circuit and open-circuit.
wear.
Inspection method
1. Check the harness between the controller and the accelerator actuator for wear.
2. Check whether the harness is shorted to the battery:
Turn the start switch to the ON position and turn on all switches of the electrical equipment, and then
measure the voltage between the harness (# 828/# 904) solenoid valve terminal and the grounding
(normally, 0V), respectively.
Turn the multimeter to its resistance function, and measure the resistance of the harness (# 922)
between the controller port (J2-22) and the solenoid valve (normally, <10Ω).
Is the harness short-circuit or open-circuit?
Yes No
harness.

Inspection method
Connect the actuator connector and disconnect the controller connector. Turn the multimeter to its
resistance function and measure the resistance between the controller port J1-28 and J2-18 (normally,
4~5kΩ), and then measure the resistance between the ports J1-28 and J2-22 and that between the
ports J2-28 and J2-22. The sum of the resistance between the pins 2 and 3 and that between the pins
2 and 5 equals the resistance between the pins 3 and 5.
6-300
6.4.71 DTC 221003 Actuator Feedback Voltage Above the Range Value CLG920E/922E/923E

Yes No
Step 4
Inspection method
Yes No
6-301
CLG920E/922E/923E 6.4.72 DTC 221007 Actuator GettingStuck
6.4.72 DTC 221007 Actuator GettingStuck

221007 The actuator gets stuck. The accelerator actuator fails.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-302
6.4.72 DTC 221007 Actuator GettingStuck CLG920E/922E/923E
Component location
Front
Accelerator
actuator
Step 1 Check the harness connector for fault.

Inspection method
Check the harness connector for looseness.

Check the harness connector pins for rust, bending and damage.
There is moisture, oil dirt or insulation fault in the connector.
Whether a fault developing in the connector or not?
Yes No
Re-connect or replace the connector.
6-303
CLG920E/922E/923E 6.4.72 DTC 221007 Actuator GettingStuck
Step 2 Check whether the accelerator actuator gets stuck.

Inspection method
Turn the start switch to the OFF position, and visually check whether the engine accelerator flexible
shaft (including its mounting plate) becomes loose
Start the excavator and turn the accelerator knob, and then check whether the accelerator flexible
shaft is operating properly.
Whether the accelerator actuator gets stuck?
Yes No
Inspection method
Yes No
6-304
6.4.73 DTC 221013 Actuator Outside Calibrated Range CLG920E/922E/923E
6.4.73 DTC 221013 Actuator Outside Calibrated Range

221013 Actuator outside the calibrated range The accelerator actuator fails.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-305
CLG920E/922E/923E 6.4.73 DTC 221013 Actuator Outside Calibrated Range
Component location
Front
Accelerator
actuator
Step 1 Check whether the number of teeth of the flywheel is correct.

Inspection method
Check whether the number of teeth of the flywheel is correct in the control parameter.
Whether the number of teeth of the flywheel is correct or not?
Yes No
Re-adjust the number of teeth of the flywheel in
the control parameter.
6-306
Step 2 Check the speed sensor for fault

Inspection method
1. Check the sensor for looseness.

2. Disconnect the speed sensor connector:
a. Check the connector pins for looseness, rust, bending and damage. Check the connector inside
b. Start the engine and turn the knob to increase the accelerator gradually. Turn the multimeter to
its AC voltage function, and measure the voltage on the sensor output ports (normally, when the
engine speed at 1000~2270r/min, the speed sensor outputs an AC voltage between 3~28V).
Whether the speed sensor is faulty?
Yes No
Tighten or repair, or replace the speed sensor.
wear.
Inspection method
1. Check the harness (# 918) between the controller (J2-18)and the accelerator actuator for wear.
2. Disconnect the connectors from the accelerator actuator and the controller, respectively. Turn the
multimeter to its resistance function, and then measure the resistance between the harness (#
918) actuator terminal and the grounding (normally, >100K).
Yes No
harness.
6-307
CLG920E/922E/923E 6.4.73 DTC 221013 Actuator Outside Calibrated Range
Step 4 Check whether the harness is open-circuited or shorted to the battery
wear.
Inspection method
1. Check the harness for open-circuit: Turn the multimeter to its resistance function, and measure the
resistance of the harness (# 918) between the controller and the actuator (normally, <10Ω).
harness (#918) actuator terminal and the grounding (normally, 0V).
Yes No
harness.
Step 5 Check whether the harness is wrong.
wear.
6-308
Inspection method
According to the accelerator control system schematics, check whether the sequence of the
harnesses between the actuator and the controller is correct.
Whether the harness is wrong or not.
Yes No
harness.
Inspection method
Yes No
6-309
CLG920E/922E/923E 6.4.74 DTC 221104 Actuator AC1 Shorted to Ground
6.4.74 DTC 221104 Actuator AC1 Shorted to Ground

The actuator fails to work, so the revolving
221104 AC1 end of actuator short circuit to ground
speed cannot be governed.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-310
6.4.74 DTC 221104 Actuator AC1 Shorted to Ground CLG920E/922E/923E
Component location
Front
Accelerator
actuator

Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors
2. Turn the multimeter to its resistance function, and measure the resistance between the actuator
connector terminal 4 and the grounding (normally, >100KΩ)
Yes No
6-311
wear.
Inspection method
1. Check the harness (#907) between the controller (J2-07) and the accelerator actuator for wear.
Yes No
harness.

Inspection method
Connect the accelerator actuator connector and disconnect the controller connector. Turn the
and the grounding (normally, >100K).
Yes No
6-312
Inspection method
Yes No
6-313
6.4.75 DTC 221204 Actuator AC2 Shorted to Ground

221204 AC2 end of actuator short circuit to ground
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-314
Component location
Front
Accelerator
actuator

Inspection method
Turn the start switch to the OFF position and disconnect the accelerator actuator connectors:
2. Turn the multimeter to its resistance function, and measure the resistance between the actuator
connector terminal 1 and the grounding (normally, >100KΩ)
Yes No
6-315
wear.
Inspection method
1. Check the harness (#904) between the controller (J2-04) and the accelerator actuator for wear.
Yes No
harness.

Inspection method
and the grounding (normally, >100K).
Yes No
6-316
Inspection method
Yes No
6-317
CLG920E/922E/923E 6.4.76 DTC 221305 Actuator AC1 Open-Circuited
6.4.76 DTC 221305 Actuator AC1 Open-Circuited

221305 AC1 end of actuator open circuit The actuator fails to work.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-318
6.4.76 DTC 221305 Actuator AC1 Open-Circuited CLG920E/922E/923E
Component location
Front
Accelerator
actuator

Inspection method
actuator connector terminals 1 and 4 (normally, <100K)
Yes No
6-319
CLG920E/922E/923E 6.4.76 DTC 221305 Actuator AC1 Open-Circuited
wear.
Inspection method
1. Check the connecting harness (#907/904) between the controller and the accelerator actuator for
wear.
2. Disconnect the connectors from the accelerator actuator and the controller, respectively. Measure
the resistance value of the connecting harness (#907/904) between the controller and the actuator
using multimeter resistance function (normally, <10Ω).
Yes No
harness.

Inspection method
harness and J2-04 (normally, <100K).
Yes No
6-320
6.4.76 DTC 221305 Actuator AC1 Open-Circuited CLG920E/922E/923E
Inspection method
Yes No
6-321
CLG920E/922E/923E 6.4.77 DTC 221306 Actuator AC1 Overcurrent
6.4.77 DTC 221306 Actuator AC1 Overcurrent

Actuator AC1 overcurrent (actuator AC1 terminal
221306 is shorted to the battery, with a 3Ω circuit
connected in series.)
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-322
6.4.77 DTC 221306 Actuator AC1 Overcurrent CLG920E/922E/923E
Component location
Front
Accelerator
actuator

Inspection method
actuator connector terminals 1 and 4 (normally, >10Ω).
Yes No
6-323
Step 2 Check whether the harness is shorted to the battery.
wear.
Inspection method
1. Check the harness (#907/#904) between the controller (J2-07,J7-04)and the accelerator actuator
for wear respectively.
Disconnect both the controller and the solenoid valve
measure the resistance of the harness (#907/#904) between the actuator terminals (normally,
>100K).
switch off the switches of all electrical equipment, and then measure the voltage between the
harness (#907/#904) actuator connecting terminal and the grounding (normally, 0V).
Yes No
harness.
6-324

Inspection method
and J2-04 (normally, >10Ω).
Yes No
Inspection method
Yes No
6-325
CLG920E/922E/923E 6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited
6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited

221405 AC2 end of actuator open circuit The actuator fails to work.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-326
6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited CLG920E/922E/923E
Component location
Front
Accelerator
actuator

Inspection method
actuator connector terminals 1 and 4 (normally, <100K)
Yes No
6-327
CLG920E/922E/923E 6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited
wear.
Inspection method
1. Check the connecting harness (#907/904) between the controller and the accelerator actuator for
wear.
2. Disconnect the connectors from the accelerator actuator and the controller, respectively. Measure
the resistance value of the connecting harness (#907/904) between the controller and the actuator
using multimeter resistance function (normally, <10Ω).
Yes No
harness.

Inspection method
harness and J2-04 (normally, <100K).
Yes No
6-328
6.4.78 DTC 221405 Actuator AC2 Terminal Open-Circuited CLG920E/922E/923E
Inspection method
Yes No
6-329
6.4.79 DTC 221406 Actuator AC2 Overcurrent

Actuator AC2 overcurrent (actuator AC2 terminal The actuator fails to work, so the revolving
221406
is shorted to the battery). speed cannot be governed.
System description
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
6-330
Component location
Front
Accelerator
actuator

Inspection method
actuator connector terminals 1 and 4 (normally, >10Ω)
Yes No
6-331
Step 2 Check whether the harness is shorted to the battery.
wear.
Inspection method
1. Check the harness (#907/#904) between the controller (J2-07 ,J7-04)and the accelerator actuator
for wear respectively.
measure the resistance of the harness (#907/#904) between the actuator terminals (normally,
>100K).
switch off the switches of all electrical equipment, and then measure the voltage between the
harness (#907/#904) actuator connecting terminal and the grounding (normally, 0V).
Yes No
harness.
6-332

Inspection method
and J2-04 (normally, >10Ω).
Yes No
Inspection method
Yes No
6-333
CLG920E/922E/923E 6.4.80 DTC 231012 Abnormal Controller Heartbeat
6.4.80 DTC 231012 Abnormal Controller Heartbeat

231012 Abnormal controller heartbeat. The machine fails to work.
System description
The controller is the core part of the excavator’s electrical control system and is responsible for the
complete machine operation mode and status, information processing, and various electronic control
functions.
Tracker (optional)
Electric lock ON
Power -
Power +
Electric lock
Ground
Controller (Black)
CAN 1/2 shield
CAN 1 low
CAN 1 high
Travel alarm buzzer Controller, Display 30A

Power
6-334
6.4.80 DTC 231012 Abnormal Controller Heartbeat CLG920E/922E/923E
P29E00149
Component location
Controller
Front
6-335
CLG920E/922E/923E 6.4.80 DTC 231012 Abnormal Controller Heartbeat
Step 1 Check the controller connector J1 for looseness.
Inspection method
Manually check whether the controller connector for looseness or fall-off.

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

For the controller CM3620, turn the multimeter to its voltage function, and measure the voltage
between ports 2, 3, 4, 5 & 6 of J1 and the ground, respectively. The voltage should be about 24V,
otherwise, the controller power fails;and for the controller C101-D1, turn the multimeter to its voltage
function, and measure the voltage between ports 1,27,42 of J1 and the ground, respectively. The
voltage should be about 24V, otherwise, the controller power fails.
Definition of
connector pin
serial number
Whether there is no power to the controller?

Yes No
Check the harness (# 111) for open-circuit, and
re-connect it.
6-336
6.4.80 DTC 231012 Abnormal Controller Heartbeat CLG920E/922E/923E
Inspection method
Yes No
6-337
CLG920E/922E/923E 6.4.81 DTC 231014 CAN Bus Communication Error
6.4.81 DTC 231014 CAN Bus Communication Error

231014 CAN bus communication error. The machine cannot operate properly.
System description
The CAN bus can achieve real-time data exchange of various control units of the excavator.
Monitor
Battery power
Battery power
Electric lock
Ground
Ground
supply
supply
ON
Power 12V Socket (Option)
Tracker (optional)
Electric lock ON
Power -
Power +
Electric lock
Ground
6-338
6.4.81 DTC 231014 CAN Bus Communication Error CLG920E/922E/923E
P29E00150
Component location
GPS antenna
Display
GPS
6-339
CLG920E/922E/923E 6.4.81 DTC 231014 CAN Bus Communication Error
Step 1 Check the display connector for fault
Inspection method
Manually check the controller connector for looseness or fall-off, and check the pins for bending.
Whether the display connector fails?
Yes No
Repair or tighten the connector.
Step 2 Check the harness of display for fault.
Inspection method
Dismantle the display connector C4 and the GPS connector C3.

Turn the multimeter to its on-off function, and check the harness (#751wire and # 752 wire) between
the port 5 (C3) and the port 1 (C4)/between the port 8 (C3) and the port 8 (C4) for open-circuit.
Whether the display harness fails?
Yes No
Re-connect the harness.
Inspection method
Yes No
6-340
6.4.82 DTC 241014 Accelerator Knob Outside Measurement Range CLG920E/922E/923E
6.4.82 DTC 241014 Accelerator Knob Outside Measurement Range

241014 Accelerator knob outside the measurement range The gear positions display abnormally.
System description
For the controller CM3620: the accelerator control system mainly consists of the accelerator
potentiometer (accelerator knob), controller and accelerator actuator. The schematic diagram is shown
below: #907 and #904 are drive control lines. The controller is driven by 2 pins. If either pin is open-
circuit, this can cause the accelerator system fault. The accelerator potentiometer is used to control the
engine speed. As shown in the figure, Pin 1 of the R1 connector is connected to the 5V power, Pin 2 is
connected to the controller-sensor ground terminal and Pin 3 is connected to the accelerator signal
feedback terminal. The accelerator actuator controls the engine accelerator opening through the flexible
shaft to control the engine speed. The terminals are shown in the figure. Pin 3 of the M1 connector is the
controller power (5V), pin 5 is grounded, pin 2 is used for the accelerator feedback signal, pin 1 is used
to control the accelerator motor’s forward rotation and pin 4 is used to control the accelerator motor’s
reverse rotation.
For the controller C101-D1, the accelerator knob with ten gears have five pins, among which D is
ground. Pins A, F, B, E have two states: state one: connecting to the ground (connecting to D) and
represented by 1; state two: hanging (disconnecting to D) and represented by 0. When the accelerator
signal detected by controller doesn't belong to states listed in following table, the DTC will appear on the
display.
A F B E D
1st gear 1 0 0 0 1
2nd gear 0 1 0 0 1
3rd gear 1 1 0 0 1
4th gear 0 0 1 0 1
5th gear 1 0 1 0 1
6th gear 0 1 1 0 1
7th gear 1 1 1 0 1
8th gear 0 0 0 1 1
9th gear 1 0 0 1 1
10th gear 0 1 0 1 1
11th gear 1 1 0 1 1
12th gear 0 0 1 1 1
6-341
CLG920E/922E/923E 6.4.82 DTC 241014 Accelerator Knob Outside Measurement Range
Accelerator knob
(Black) (Black)
5V power supply
potentiometer
(White)

feedback
Sensor to ground
P29E00151
Component location
Throttle
Potentiometer
Controller
6-342

Inspection method
For the controller CM3620, disconnect the connectors from the accelerator actuator:
actuator connector pins 3 and 5 (normally, about 4-5kΩ), and then, using the multimeter, measure
For the controller C101-D1, disconnect the accelerator knob connector:
2. Turn the multimeter to its resistance function, and measure the connecting or disconnecting status
of connector pins of accelerator knob 1-12 gears one by one, and whether the connecting or
disconnecting status of 1(A), 2(F), 3(B), 4(E) pins with 5(D) pin conforms to the listed status in the
table above.
Yes No
Step 2 Check the harness for short-circuit and open-circuit.
wear.
6-343
CLG920E/922E/923E 6.4.82 DTC 241014 Accelerator Knob Outside Measurement Range
Inspection method

1. Check the harness (#828/#829) between the controller (J1-28/J1-29) and the accelerator actuator
and the grounding wire (#922) for wear.
2. Check whether the harness is shorted to the battery: disconnect the connectors from the
accelerator actuator and the controller. Turn the multimeter to its voltage function, and measure
the voltage between the harness (#828/#829) and the grounding, respectively (normally, 0V).
3. Check the harness for open-circuit: turn the multimeter to its resistance function, and measure the
resistance between the harness (No. 922) of actuator connecting terminal and the grounding
(normally, <100kΩ).
1. Check the harnesses (# 922,802,803,804,805) between the controllers (J1-49, J1-44, J1-18, J1-
10, J1-11) and the accelerator knob for wear.
2. Check whether the harness is shorted to the positive battery terminal: disconnect the accelerator
knob connector and the controller connector. Turn the multimeter to its voltage function, and
measure the voltage respectively between the harness #922, #802, #803, #804, #805 and the
grounding (normally 0V).
3. Check the harness for open-circuit: disconnect the connectors from the accelerator knob and the
controller. Turn the multimeter to its resistance function, and measure the resistance value of the
connecting harness (#922, #802, #803, #804, #805) between the controllers (J1-49, J1-44, J1-18,
J1-10, J1-11) and the accelerator knob (normally, <10Ω).
Is the harness short-circuit or open-circuit?
Yes No
harness.
6-344

Inspection method
For the controller CM3620,connect the actuator connector and disconnect the controller connector:
1. Turn the multimeter to its resistance function, and measure the resistance between the controller
port J1-28 and the grounding (normally, 4-5kΩ).
2. Turn the multimeter to its resistance function, and measure the resistance between the controller
ports J1-28 and J1-29 (normally, >10Ω).
For the controller C101-D1, connect the accelerator knob connector and disconnect the controller
connector:
Turn the multimeter to its resistance function, and measure the connecting or disconnecting status of
connector pins of accelerator knob 1st-12th gears one by one at controller connector end, and
whether the connecting or disconnecting status of J1-44(A), J1-18(F), J1-10(B), J1-11(E) pins with J1-
49(D) pin conforms to the listed status in the table above.
Yes No
Inspection method
Yes No
6-345
CLG920E/922E/923E 6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground
6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground

The refueling pump automatically stops
251004 Fuel pump relay shorted to ground
and refueling function fails
System description
Power on the electric lock to energize the battery relay, the harness (#133) and the harness (#320), so
that the refueling pump can operate. If the controller port gives the 24V signal and the harness (#906) is
energized, then the refueling pump relay is energized, so that the harnesses (#133 and #320) are open-
circuit and the refueling pump automatically stops.
Controller
Fuel pump relay
Fuel pump (option)
Ignition switch
Electric lock Fuel pump fuse 20A (optional)

Fuel pump relay K11 power 20A
Battery
6-346
6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground CLG920E/922E/923E
P29E00152
Component location
Open the fuse box.
K11 auto preheating

out during detection.
6-347
CLG920E/922E/923E 6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground
Step 1 Check whether the harness connecting the controller port is shorted to ground

Inspection method
For the controller CM3620, disconnect the connector from the controller (attached figure) and pull out
the fuel refueling pump relay, and then measure the resistance between the harness (#906) at the J2-
6 port and the grounding. The resistance should be infinite.
Definition of
connector pin
serial number
For the controller C101-D1, disconnect the connector from the controller and pull out the fuel refueling
pump relay, and then measure the resistance between the harness (#906) at the J2-75 port and the
grounding. The resistance should be infinite.
Whether the harness connecting the controller port is shorted to ground?
Yes No
6-348
6.4.83 DTC 251004 Fuel Pump Relay Shorted to Ground CLG920E/922E/923E

Inspection method
Check manually the connectors between the automatic preheating relay and the controller one by one
for moisture, oil dirt and other failures which may cause electric leakage.
Yes No
Inspection method
Yes No
Attached drawing
Controller
Front
6-349
CLG920E/922E/923E 6.4.84 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to Battery
6.4.84 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to

Battery

Fuel refueling pump relay is open-circuited or The refueling pump automatically stops
251005
shorted to the battery. and refueling function fails.
System description
Power on the electric lock to energize the battery relay, the harness (#133) and the harness (#320), so
that the refueling pump can operate. If the controller port gives the 24V signal and the harness (#906) is
energized, then the refueling pump relay is energized, so that the harnesses (#133 and #320) are open-
circuit and the refueling pump automatically stops.
Controller
Fuel pump relay
Fuel pump (option)
Ignition switch
Electric lock Fuel pump fuse 20A (optional)

Fuel pump relay K11 power 20A
Battery
6-350
6.4.84 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to Battery CLG920E/922E/923E
P29E00152
Component location
Open the fuse box.
K11 auto preheating

out during detection.
6-351
Step 1 Check the fuel refueling pump relay for fault

Inspection method
Turn the multimeter to its resistance function and measure the resistance between the terminals 85
and 86 of the fuel refueling pump relay coil. The resistance should be between 320-360Ω.
Turn the multimeter to its on/off function, and measure the ports 30 and 87A of the relay. The relay
should switch on and sound.
Connect the ports 85 and 86 to the power supply (24V), and measure the ports 30 and 87A. The relay
should switch off and not sound.
Whether the fuel refueling pump relay fails?
Yes No
Replace the relay.
Inspection method
Turn the start switch to the OFF position for fault diagnosis.
For the controller CM3620, disconnect the connector from the controller (attached figure) and pull out
6 port and the grounding. The resistance should be 10Ω or less.
Measure the resistance between the 85 port in the fuse box and the ground. The resistance should be
less than 10Ω; for the controller C101-D1, disconnect the connector from the controller and pull out
75 port and the grounding. The resistance should be 10Ω or less.
6-352
6.4.84 DTC 251005 Fuel Pump Relay Open-Circuited or Shorted to Battery CLG920E/922E/923E
Definition of
connector pin
serial number

Yes No

Inspection method
Insert the fuel refueling pump relay into the fuse box properly and disconnect the controller
connector,for the controller CM3620,
turn the multimeter to its resistance function, and measure the resistance between the harness (#906)
at the controller port J2-6 and the grounding; and for the controller C101-D1, turn the multimeter to its
resistance function, and measure the resistance between the harness (#906) at the controller port J2-
75 and the grounding, and normally it should be 320-360Ω. When the resistance is abnormal,please
check the connector.
a. Check the connector at the grounding of the auto preheating relay for poor contact
b. Check the connector of the auto preheating relay for looseness or damage.
Yes No
6-353
Inspection method
Yes No
Attached drawing
Controller
Front
6-354
6.4.85 DTC 261011GPS Antenna Fault CLG920E/922E/923E
6.4.85 DTC 261011GPS Antenna Fault

The machine cannot be positioned and
261011 GPS antenna fails.
connected to the monitoring center.
System description
Use the GPS (Global Positioning System) to position the machine and use the GSM mobile
communication network to achieve the two-way data exchange with the central control center to realize
remote monitoring and control.
Component location
GPS antenna
Display
GPS
Step 1 Check the antenna connector for looseness and fall-off.
Inspection method
Manually check whether the antenna connector becomes loose or falls off.
Whether the antenna connector becomes loose or falls off?
Yes No
Tighten the antenna connector.
6-355
CLG920E/922E/923E 6.4.85 DTC 261011GPS Antenna Fault
Step 2 Check the antenna for damage
Inspection method
Remove the antenna, and re-install a new one to determine whether the antenna is damaged.
Whether the antenna is damaged or not?
Yes No
Replace the antenna.
Inspection method
Yes No
6-356
6.4.86 DTC 261111GPS Module Fault CLG920E/922E/923E
6.4.86 DTC 261111GPS Module Fault

261111 GPS module fault. GPS signals cannot be received.
System description
Component location
GPS antenna
Display
GPS
Step - Contact local LiuGong dealers and authorized service centers.

6-357
CLG920E/922E/923E 6.4.87 DTC 261211 GSM Signal Fault
6.4.87 DTC 261211 GSM Signal Fault

261211 GSM signal fault. GSM signal is weak.
System description
Component location
GPS and
GSM antenna
Display
GPS
Step 1 Check the antenna connector for looseness and fall-off.
Inspection method
Manually check whether the antenna connector becomes loose or falls off.
Whether the antenna connector becomes loose or falls off?
Yes No
Tighten the antenna connector.
6-358
6.4.87 DTC 261211 GSM Signal Fault CLG920E/922E/923E
Step 2 Check the antenna for damage
Inspection method
View the mobile signal strength. Compared with the GSM signal, if the mobile signal is stronger, the
antenna is faulty.
Whether the antenna is damaged or not?
Yes No
Replace the antenna.
Inspection method
Yes No
6-359
CLG920E/922E/923E 6.4.88 DTC 261311 GPRS Connection Fault
6.4.88 DTC 261311 GPRS Connection Fault

261311 GPRS connection fault. GPS cannot operate properly.
System description
GPRS is used to transmit information between GPS and mobile server.
Steps - Contact local LiuGong dealers and authorized service centers.
6.4.89 DTC 261411 SIM Card Read Fault

261411 SIM card read fault. GPS cannot operate properly.
System description
The GPS positioning information is transmitted to the monitoring center through the SIM card.
Component location
GPS and
GSM antenna
Display
GPS
(SIM card
inside GPS)
6-360
6.4.89 DTC 261411 SIM Card Read Fault CLG920E/922E/923E
Step 1 Check whether the SIM card becomes loose.
Inspection method
Turn the start switch to the OFF position, and manually check whether the SIM card becomes loose
If the SIM card becomes loose?
Yes No
Fix the SIM card.
Step 2: Check whether this fault is eliminated
Inspection method
Yes No
6-361
CLG920E/922E/923E 6.4.90 DTC 261512 Abnormal GPS Heartbeat
6.4.90 DTC 261512 Abnormal GPS Heartbeat

Over time, the machine is limited to be
261512 Abnormal GPS heartbeat.
used.
System description
Ignition switch
Tracker (optional)
Electric lock
ON
Power -
Power +
Electric lock
Ground
6-362
6.4.90 DTC 261512 Abnormal GPS Heartbeat CLG920E/922E/923E
Component location
GPSantenna
GPS antenna
Display
Display
GPS
GPS
Step 1 Check whether the GPS connector becomes loose and falls off.
Inspection method
Manually check the GPS connector for looseness or fall-off

Whether the GPS connector becomes loose and falls off?
Yes No
Tighten the GPS connector.
Step 2 Check the harness (No.149) for fault.
Inspection method
Turn the start switch to the ON position.

Dismantle the GPS connector C3. Make sure no pin of the connector is bent. Turn the multimeter to its
voltage function, and measure the voltage between the connector terminal 4 and the grounding. The
voltage should be 24V. Otherwise, a fault develops in the harness (#149).
Is there a fault in the harness (#149)?
Yes No
Rewire.
6-363
CLG920E/922E/923E 6.4.90 DTC 261512 Abnormal GPS Heartbeat
Inspection method
Yes No
6-364
6.4.91 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, Machine Is Limited for Use

Machine Is Limited for Use

Automatic locking level 1 abnormal GPS
261611 The machine is limited for use.
heartbeat, the machine is limited for use
System description
Ignition switch
Tracker (optional)
Electric lock
ON
Power -
Power +
Electric lock
Ground
6-365
CLG920E/922E/923E 6.4.91 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, Machine Is
Component location
GPS antenna
Display
GPS
Inspection method

Yes No
Inspection method

Yes No
Rewire.
6-366
6.4.91 DTC 261611 Automatic Locking Level 1 Abnormal GPS Heartbeat, Machine Is Limited for Use
Inspection method
Yes No
6-367
CLG920E/922E/923E 6.4.92 DTC 261614 Forced Locking Level 1 Payment Expired, Machine Is Limited for
6.4.92 DTC 261614 Forced Locking Level 1 Payment Expired, Machine Is

Limited for Use

Forced locking level 1 payment expired, and the
machine is prohibited for use.
System description

6-368
6.4.93 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the Machine is Prohibited for

and the Machine is Prohibited for Use
DTC Descriptions Consequence

Automatic locking level 2 abnormal GPS
261711 The machine is prohibited for use.
heartbeat, and the machine is prohibited for use.
System description
Ignition switch
Tracker (optional)
Electric lock
ON
Power -
Power +
Electric lock
Ground
6-369
CLG920E/922E/923E 6.4.93 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the
Component location
GPS antenna
Display
GPS
Inspection method

Yes No
Inspection method

Yes No
Rewire.
6-370
6.4.93 DTC 261711 Automatic Locking Level 2 Abnormal GPS Heartbeat, and the Machine is Prohibited for
Inspection method
Yes No
6-371
CLG920E/922E/923E 6.4.94 DTC 261714 Forced Locking Level 2 Overdue Payment, and the Machine is
6.4.94 DTC 261714 Forced Locking Level 2 Overdue Payment, and the
Machine is Prohibited for Use

Forced locking level 2 payment expired, and the
machine is prohibited for use.
System description
6.4.95 DTC 261814 Pay Due Loan Promptly

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

6-372
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to ground CLG920E/922E/923E
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to ground

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

Controller
Fan reversing solenoid valve
Component location
Front
Fan reversing
solenoid valve
6-373
CLG920E/922E/923E 6.4.96 DTC 271304 Fan reversing solenoid valve shorted to ground
Step 1 Check the fan reversing solenoid valve for fault

Inspection method
Turn the start switch to the OFF position, and disconnect the fan reversing solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the fan
reversing solenoid valve terminals 1 and 2 (normally, >16-40Ω).
Whether the fan reversing solenoid valve fails?
Yes No
Repair or replace the fan reversing solenoid
valve.

wear.
Inspection method
1. Check the harness (# 904) between the controller (J2-04) and the fan reversing solenoid valve for
wear.
2. Disconnect the connectors from the fan reversing solenoid valve and the controller. Turn the
multimeter to its resistance function, and measure the resistance between the harness (#904)
solenoid valve terminal and the grounding (normally, >100K)
Yes No
harness.
6-374
6.4.96 DTC 271304 Fan reversing solenoid valve shorted to ground CLG920E/922E/923E

Inspection method
Connect the fan reversing solenoid valve connector and disconnect the controller connector. Turn the
and the grounding (normally, >10Ω)
Yes No
Inspection method
Yes No
6-375
CLG920E/922E/923E 6.4.97 DTC 271305 Pump Proportional Solenoid Valve Open-Circuited or Short-

Short-Circuited to Battery

Fan reversing solenoid valve open-circuited or
271305 The fan cannot reverse
short-circuited to the battery
System description
The fan reversing solenoid valve (variable speed fan reversing solenoid valve) is used to control the
fan’s positive and negative rotation. To achieve that end, the controller receives the operation signal for
the fan’s positive and negative rotation from the instrument and controls the solenoid valve through the
J2-4 port.
Ignition switch
Tracker (optional)
Electric lock
ON
Power -
Power +
Electric lock
Ground
6-376
6.4.97 DTC 271305 Pump Proportional Solenoid Valve Open-Circuited or Short-Circuited to Battery
Component location
GPS antenna
Display
GPS
Step 1 Check the fan reversing solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the fan reversing solenoid valve connector:
2. Turn the multimeter to its resistance function, and measure the resistance between the fan
reversing solenoid valve terminals 1 and 2 (normally, 16-40Ω).
Whether the fan reversing solenoid valve fails?
Yes No
Repair or replace the fan reversing solenoid
valve.
6-377
CLG920E/922E/923E 6.4.97 DTC 271305 Pump Proportional Solenoid Valve Open-Circuited or Short-
wear.
Inspection method
1. Check the harness (#904) or grounding wire (#229) between the controller and the fan reversing
solenoid valve for wear.
Disconnect the connectors from the fan reversing solenoid valve and the controller,
harness (No.904) solenoid valve terminal and the grounding (normally, 0V).
3. Check the harness for open-circuit. Turn the multimeter to its resistance function, and measure the
resistance of the harness (#904) between the controller and the solenoid valve and that of the
harness (# 229) between the solenoid valve and the grounding (normally, <10Ω).
Yes No
harness.
6-378
6.4.97 DTC 271305 Pump Proportional Solenoid Valve Open-Circuited or Short-Circuited to Battery

Inspection method
Connect the fan reversing solenoid valve connector and disconnect the controller connector. Turn the
and the grounding (normally, 16-40Ω).
Yes No
Inspection method
Yes No
6-379
CLG920E/922E/923E 6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground

271404 Fan drive solenoid valve shorted to ground The fan speed cannot be controlled
System description
The fan drive solenoid valve (variable speed fan overflow solenoid valve) is used to control the fan
speed: the controller provides the current through Port J2-07 to control the relief valve which regulates
the hydraulic oil pressure to drive the fan, thereby changing the fan speed.
Controller
Fan relief solenoid valve 1 Fan relief

solenoid valve
Fan relief solenoid valve 2
Component location
Front
Fan drive
solenoid
valve
6-380
6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground CLG920E/922E/923E
Step 1 Check the fan drive solenoid valve for fault

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the terminals 1
and 2 of the fan drive solenoid valve (normally, 16-40Ω).
Whether the fan drive solenoid valve fails?
Yes No
Repair or replace the fan drive solenoid valve.
wear.
Inspection method
1. Check the harnesses (#907 and #835) between the controllers (J2-07 and J1-35) and the fan drive
solenoid valve for wear, respectively.
2. Disconnect the connectors from the fan drive solenoid valve and the controller. Turn the
multimeter to its resistance function, and measure between the harnesses (#907 and #835) the
solenoid valve terminal and the grounding, respectively (normally, >100K)
Yes No
harness.
6-381
CLG920E/922E/923E 6.4.98 DTC 271404 Fan drive solenoid valve shorted to the ground

Inspection method
Connect t he fan drive solenoid valve connector, disconnect the controller connector, and then turn the
(normally, 16-40Ω)
Yes No
Inspection method
Yes No
6-382
6.4.99 DTC 271405 Fan Drive Solenoid Valve Open-Circuited or Short to Battery CLG920E/922E/923E
6.4.99 DTC 271405 Fan Drive Solenoid Valve Open-Circuited or Short to

Battery

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

solenoid valve
Component location
Front
Fan drive
solenoid
valve
6-383
CLG920E/922E/923E 6.4.99 DTC 271405 Fan Drive Solenoid Valve Open-Circuited or Short to Battery

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector:
Yes No
wear.
Inspection method
1. Check the harness (#904 and #835) between the controller and the fan drive solenoid valve for
wear.
Disconnect the connectors from the fan drive solenoid valve and controller.
3. Check the harnesses for open-circuit. Turn the multimeter to its resistance function, and measure
the resistance of the harnesses (#904 and #835) between the controller and the solenoid valve,
respectively (normally,<10Ω).
6-384
6.4.99 DTC 271405 Fan Drive Solenoid Valve Open-Circuited or Short to Battery CLG920E/922E/923E
Yes No
harness.

Inspection method
Connect the fan drive solenoid valve connector, disconnect the controller connector, and then turn the
multimeter to its resistance function, and measure the resistance between the controller ports J2-04
and J1-35 (normally, 16-40Ω).
Yes No
Inspection method
Yes No
6-385
CLG920E/922E/923E 6.4.100 DTC 271505 Fan Drive Solenoid Valve Feedback Open-Circuited
6.4.100 DTC 271505 Fan Drive Solenoid Valve Feedback Open-Circuited

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

solenoid valve
Component location
Front
Fan drive
solenoid
valve
6-386
6.4.100 DTC 271505 Fan Drive Solenoid Valve Feedback Open-Circuited CLG920E/922E/923E

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector:
Yes No
wear.
Inspection method
1. Check the harness (#904 and #835) between the controller and the fan drive solenoid valve for
wear.
2. Disconnect the connectors from the fan drive solenoid valve and the controller. Turn the
multimeter to its resistance function, and measure the resistance of the harnesses (#904 and
#935) between controller and the solenoid valve (normally, <10Ω).
Yes No
harness.
6-387
CLG920E/922E/923E 6.4.100 DTC 271505 Fan Drive Solenoid Valve Feedback Open-Circuited

Inspection method
multimeter to its resistance function, and measure the resistance between the controller ports J2-04
and J1-35 (normally, 16-40Ω).
Yes No
Inspection method
Yes No
6-388
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent CLG920E/922E/923E
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent

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

solenoid valve
Component location
Front
Fan drive
solenoid
valve
6-389
CLG920E/922E/923E 6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent

Inspection method
Turn the start switch to the OFF position and disconnect the fan drive solenoid valve connector
2. Turn the multimeter to its resistance function, and measure the resistance between the fan drive
solenoid valve terminals 1 and 2 (normally, >16-40Ω).
Yes No
Step 2 Check the harness for short-circuit
wear.
Inspection method
1. Check the harnesses (#904/#835) between the controllers (J2-04 and J1-35) and the fan drive
solenoid valve for wear.
measure the resistance of the harness (# 904/835) between the solenoid valve terminals
(normally, >100K)
6-390
6.4.101 DTC 271505 Fan drive solenoid valve feedback overcurrent CLG920E/922E/923E
Yes No
harness.

Inspection method
multimeter to its resistance function, and measure the resistance Port between the controller ports J2-
04 Port and J1-35 (normally, 16-40Ω).
Yes No
Inspection method
Yes No
6-391
September 15, 2020 6.5 Fault Diagnosis of Electrical System
CLG920E/922E/923E 6.5.1 E1 Troubleshooting Solution for Battery Power Loss
6.5 Fault Diagnosis of Electrical System
6.5.1 E1 Troubleshooting Solution for Battery Power Loss
Fault SN Faults Consequence

E1 Battery power loss The battery is damaged.
System description
The battery functions: Store the electric energy; when the engine starts and powers the motor; for
gasoline engine, it can power the igniter; stabilize the system voltage; when the alternator does not
generate electricity or the voltage is low, the battery powers the electric equipment; when the alternator
is overloaded because of too many electric equipment, the battery assists the alternator to power; as the
battery is equivalent to a big capacitor, it will protect the components and parts in case of transient
overvoltage.
Hydrometer
OK
Change
Replace
Component location
6-392
6.5 Fault Diagnosis of Electrical System September 15, 2020
6.5.1 E1 Troubleshooting Solution for Battery Power Loss CLG920E/922E/923E
Step 1 The battery needs to be charged.
Check the battery hydrometer color when the ignition switch is in OFF position.
Inspection method
1. Check the color of the battery hydrometer through the opening on the cover of the battery, black
means that the battery needs to be charged.
2. Measure the voltage on both ends of the battery with a multimeter: use DC voltage gear (200V) of
multimeter, connect the red probe to the positive terminal and the black probe to the negative
terminal. Under the normal condition, the voltage is 24V. If the voltage is too low, the battery needs
to be charged.
Whether the battery needs to be charged or not?
Yes No
Charge the battery
Step 2 The battery is aging and lack of power.

Inspection method
The machine does not work for a long time and the battery has not been charged so it is lack of power
seriously. Check it by referring to E2.
Is the battery aging and lack of power?
Yes No
Replace it with a new one.
Inspection method
After replacing a new battery, connect the battery firmly.

Yes No
steps or contact the local LiuGong dealers and
Maintenance is over authorized service centers.
Return
6-393
CLG920E/922E/923E 6.5.2 E2 Troubleshooting Solution for Abnormal Battery
6.5.2 E2 Troubleshooting Solution for Abnormal Battery

E2 The battery is abnormal The battery is damaged.
System description
The battery functions: Store the electric energy; when the engine starts and powers the motor; for
gasoline engine, it can power the igniter; stabilize the system voltage; when the alternator does not
generate electricity or the voltage is low, the battery powers the electric equipment; when the alternator
is overloaded because of too many electric equipment, the battery assists the alternator to power; as the
battery is equivalent to a big capacitor, it will protect the components and parts in case of transient
overvoltage.
Common maintenance: the electric quantity of the battery can be learned by the change of the
hydrometer color. Green-Normal, Black-Charge, White-Scrapped.
Hydrometer
OK
Change
Replace
Component location
6-394
6.5.2 E2 Troubleshooting Solution for Abnormal Battery CLG920E/922E/923E
Step 1 Normal battery level
Inspection method
Check the color of battery hydrometer through the opening on the cover of the battery.
Is the color of battery hydrometer green?
Yes No
The battery level is normal.
Step 2 The battery needs to be charged
Inspection method
Is the color of battery hydrometer black?
Yes No
Charge the battery
Step 3 The battery is scrapped

Inspection method
Is the color of battery hydrometer white?
Yes No
Repair or replace battery
6-395
CLG920E/922E/923E 6.5.2 E2 Troubleshooting Solution for Abnormal Battery
Inspection method
Yes No
Return
6-396
6.5.3 E3 Automatic Slowdown Failed CLG920E/922E/923E
6.5.3 E3 Automatic Slowdown Failed

E3 Automatic slowdown fails Increased fuel consumption and noise
System description
When you are not operating the lever, pedal or attachment control lever, the engine speed will drop to the
preset idle speed so as to achieve the purpose of reducing fuel consumption or noise. No matter the
lever or pedal, either or the control lever of attachment is operated, the engine speed will restore to the
corresponding speed of the current accelerator knob.
Engine controller
Engine controller
(Black)
(Black)
Monitor
Monitor
CAN 1/2 shield
CAN 1/2 shield
CAN 1 low CAN 1 low
CAN 1 high CAN 1 high
Handle pilot Handle pilot

pressure switch
Engine
Engine speed
speed dial
dial
pressure switch
5V power supply
5V power supply
potentiometer
potentiometer
(White)
(White)
Pedal pressure switch
Pedal pressure switch
Sensor to ground
Sensor to ground
Pressure switch
Pressure switch
Pressure switch
Pressure switch
6-397
CLG920E/922E/923E 6.5.3 E3 Automatic Slowdown Failed
P29E00153
Component location
Handle pressure switch

Pedal
pressure
switch
Pressure switch
of appurtenances
Display Accelerator knob

6-398
6.5.3 E3 Automatic Slowdown Failed CLG920E/922E/923E
ECU
controller
Step 1 Operate the automatic idle speed control key to cancel the automatic idle speed function.
Whether the automatic idle speed function is canceled or not?

Yes No
Operate the control key of automatic idle speed
on the display to enable the automatic idle speed
function.
Step 2 Select mode L.
Inspection method
Check the display for automatic idle speed icon and no icon means the automatic idle speed function
is canceled.
Whether the automatic idle speed function is canceled or not?
Yes No
Operate the control key of automatic idle speed
on the display to enable the automatic idle speed
function.
6-399
CLG920E/922E/923E 6.5.3 E3 Automatic Slowdown Failed
Step 3 121305, 121405, 231012, 231014 alarm appears on the display.
Inspection method
Turn the ignition switch to ON state, and then check the alarm on the display.
Whether 121305, 121405, 231012, 231014 alarm appears on the display or not?
Yes No
Overhaul the machine in accordance with the
correspondingFault diagnosis and
troubleshooting steps of the DTC.
Inspection method
Operate the machine, and check whether each action is normal.

Yes No
Find out the engine system fault or contact the
local LiuGong dealers or authorized service
Maintenance is over centers.
Return
6-400
6.5.4 E4 Engine cannot be Started CLG920E/922E/923E
6.5.4 E4 Engine cannot be Started

Engine cannot be started (the engine does not
E4 Fail to work.
rotate)
System description
In the condition where there is no fault on the machine and the excavator is started in the correct steps,
and when the electric lock is switched to "Start" position, the start relay is jointly driven by the actuating
signal controlled by ECM, IPC and handle control signal of pilot actuating. Send the power supply signal
to the start power end of the starter motor, so as to start the engine.
Start relay K1
Battery
To ignition switch B2
Battery moter
Battery relay
Engine earthing
6-401
CLG920E/922E/923E 6.5.4 E4 Engine cannot be Started
Ignition witch
Pilot solenoid valve switch
IPC Controller
To battery relay B
Engine start
Start cut-off valve relay
Engine controller
Start protection
Preheating ground wire
Electric lock
power
supply 20A
Pilot cut-off 10A
Satety relay K11 Pilot control Controller control ECM control

start relay K7 start relay K8 start relay K9

6-402
P29E00129
6-403
Component location
Ignition switch
Ignition switch IPC
IPCcontroller
controller
Fuse box
Pilot cut-offFuse box
Pilot cut-off
valve switch
valve switch
Starting
Starting
motormotor
ECU
controller
6-404
Step 1 Immobilization alarm appears on the display
Inspection method
Turn the ignition switch to ON state, and then check the alarm on the display.
Do the alarm with DTCs of 261711, 261714 appear on the display?
Yes No
correspondingFault diagnosis and
troubleshooting steps of the DTC.
Step 2 Fuel level is too low
Inspection method
Check the fuel level.

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

Inspection method
1. Turn the start switch to ON state, and then check the display for the alarm with the DTC 101001
and 101017.
6-405
Black probe
Red probe
Voltage value is 24V in the normal condition.

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

Inspection method
1. Open the electrical control unit, remove the fuse, visibly check whether the fuse blows or check
whether both ends of the fuse are connected by the multimeter on the diode gear.
2. For the controller CM3620, open the fuse box, unplug the fuses 1 and 14 by a fuse clip; and for the
controller C101-D1, open the fuse box, unplug the fuses 1 and 12 by a fuse clip, then visually
check whether the fuse is blown or measure by the DIO position of multimeter whether both ends
of fuse are connected.
Note: There may be grounding fault, so please refer to step 14.
Is the fuse blown?
Yes No
Replace the fuse
6-406
Step 5 Ignition switch fault (internal open circuit)
Remove the battery negative cable.

Inspection method
Measure the resistance between the start switch B1 and S with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and S is infinite.
2. When the start switch is turned to START state, the resistance between B1 and S is less than 10Ω.
Whether the ignition switch is faulty?
Yes No
Replace the ignition switch
Go to Step 1 and 5 Go to Step 6
Step 6 Pilot solenoid valve cut-off switch fault

Inspection method
Measure the resistance between the pilot solenoid valve cut-off switch S13 (male 1) and S13 (male 3)
with multimeter
1. When the switch of pilot solenoid valve is turned to Locked state, the resistance between S13
(male 1) and S13 (male 3) is less than 10Ω.
2. When the switch of pilot solenoid valve is turned to Unlocked state, the resistance between S13
(male 1) and S13 (male 3) is infinite.
Whether the cut-off switch of pilot solenoid valve fails?
Yes No
Repair or replace the cut-off switch of pilot
For controller CM3620, go to Step 7;
solenoid valve
For the controller C101-D1, go to Step 8;
Go to Step 15
6-407
Step 7 Safety relay K11 fault (internal fault)

Inspection method
Measure the resistance between each two contacts of safety relay K11 with a multimeter.
1. Remove the safety relay K11, and then measure the resistance among all contacts.
The resistance between 85 and 86 (coil resistance) is approx. 353-358Ω.
The resistance between 30 and 87 is infinite.
The resistance between 30 and 87a is less than 10Ω.
2. Switch on 24V power to both ends of 85 and 86, and measure the resistance between each two
contacts.
The resistance between 30 and 87 is less than 10Ω.
The resistance between 30 and 87a is infinite.
Whether safety relay K11 fails?
Yes No
Replace the safety relay.
Step 8 Pilot control start relay K7 fails (internal fault).

Inspection method
Measure the resistance among all contacts of pilot control starter relay K7 with a multimeter.
1. Remove pilot control start relay K7, and then measure the resistance among all contacts.
contacts.
Whether the starter relay K7 controlled by the pilot fails or not?
Yes No
Replace the pilot control starter relay.
6-408
Step 9 start relay K8 controlled by controller fails (internal fault).

Inspection method
Measure the resistance among all contacts of starter relay K8 controlled by controller with a
multimeter.
1. Remove start relay K8 controlled by controller, and then measure the resistance among all
contacts.
contacts.
Whether starter relay K8 controlled by controller fails or not?
Yes No
Replace the starter relay controlled by a
controller.
Step 10 ECM controller start relay K9 fault (internal fault).

Inspection method
Measure the resistance among all contacts of ECM controller starter relay K9 with a multimeter.
1. Remove ECM controller starter relay K9, and then measure the resistance among all contacts.
contacts.
Whether ECM controller starter relay K9 fault?
Yes No
6-409
Replace the ECM controller starter relay.

Step 11 start relay K1 fault (internal fault).

Inspection method
Measure the resistance among all contacts of starter relay K1 with a multimeter.
1. Remove the start relay K1, and then measure the resistance among all contacts.
The resistance of coil is about 79-81Ω.
The resistance of the main contact is infinite.
2. Supply 24V power to both ends of the coil and measure the resistance between two main contacts.
The resistance of the main contacts is less than 10Ω.
Whether starter relay K1 fails or not?
Yes No
Replace the starter relay.
Step 12 Internal fault of starter motor
Remove the wiring on the input end 50 and end 30 on the starter motor.
When replacing the starter motor, please be sure to use the LiuGong parts.
Inspection method
1. Turn the start switch to ON position, and then measure the voltage to earth of wire 108 on the end
50, and make sure it is 24V.
2. Turn the start switch to START position, and then measure the voltage between the harness (#
182) at end 30 and the grounding?and the voltage is 24V.
If the input signals are normal, but the starter motor does not rotate, it can be judged that there is an
internal fault in the starter motor.
Whether the starter motor has internal fault or not?
Yes No
Replace the starter motor.
6-410
Step 1 3 Wire in harness is open circuited or the connector has poor contact.
wear.
Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, measure the resistance of the
following circuit, and the resistance shall be less than 10Ω in normal condition.
1. Wire 137 on the main contact of battery relay - wire 136 of the main contact of starter relay K1
2. Wire 182 on the main contact of start relay K1 - end 30 of starter motor
3. Wire 004 on the main contact of battery relay - X2(8) - X1(5) - end B1 of start switch
4. End S of start switch - X2(2) - end 30 of starter relay K7 controlled by the pilot
5. End 87 of the starter relay K7 controlled by the pilot - starter relay K8 (30-87A) controlled by
controller - ECM control starter relay K9 K8 (30-87A) - X1(19) - wire 181 on the starter relay K1
6. Wire 260 on the starter relay K1 - frame ground (GND)
7. Wire 102 on the main contact of battery relay -X2 (12) - end 30 of the safety relay K11
8. End 87 of safety relay K11- X1(21) -switch of pilot shut -off valve (3-1) - X2(3) -end 86 of starter
relay K7 controlled by pilot
9. Wire 85 on the start relay K7 controlled by pilot - frame ground (GND)
10. End B2 of start switch - X1(28) - end 86 of safety relay K11
11. Wire 85 on the safety relay K11 - frame ground (GND)
12. J2(female 23) - X2(15) - end 86 of the starter relay K8 controlled by controller
13. End 85 on the start relay K8 controlled by controller - frame ground (GND)
14. J2 (female 9) - X2(11) - end 86 of the start relay K7 controlled by ECM
15. End 86 of the start relay K7 controlled by ECM - X2(9) - J22 (female 57)
16. End S of ignition switch - J1 (female 10)
17. End B2 of start switch - End B of battery relay
18. End E of battery relay - frame ground (GND)
6-411
For the controller C101-D1:

Starter motor end:
1. Starter motor end 30 - position cable on main contact of battery relay
Main circuit at the end S of ignition switch:
1. Terminal S of ignition switch - terminal 30 of pilot control starter relay K7
2. End 87 of pilot control starter relay K7 - end 30 of controller control starter relay K8
3. End 87A of controller control starter relay K8 - End 30 of ECM control starter relay K9
4. End 87A of the ECM control starter relay K9 - starter relay coil of starter motor
Fuse box end:
1. Fuse box electric lock power supply 20A - end B1 of start switch
Control circuit at the end B2 of ignition switch:
1. End B2 of ignition switch - diode connector D6-2
2. Diode connector D6 -1- B+ of battery relay
3. End E (negative) of battery relay - frame ground (GND)
Pilot control starter control circuit:
1. Pilot shut-off valve switch (S13 -1) - end 86 of pilot control starter relay K7
2. Wire 85 on the start relay K7 controlled by pilot - frame ground (GND)
Controller control starter control circuit:
1. Controller connector J2-71 - end 86 of the controller control starter relay K8
2. End 30 on the start relay K8 controlled by controller - frame ground (GND)
ECM control starter control circuit:
1. ECM connector J22-9 - end 86 of the ECM control starter relay K9
2. End 85 of ECM control starter relay K9 - ECM connector J22-57
Yes No
Connect the harness again and wrap the harness
6-412
Step 14 Wire in harness shorted to the grounding wire

Inspection method
Remove the battery cable (-), and turn the start switch to OFF position, check whether the following
circuits are shorted to ground, and normally the resistance between any check point and the ground
shall be greater than 1MΩ.
1. Wire 137 on the main contact of battery relay - main contact of starter relay K1 - end 30 of the
starter motor
2. Wire 004 on the main contact of battery relay - X2(8) - X1(5)- start switch (B1-S) - X2(2) - relay K7,
K8, K9 (main contact) -X1(19)- wire 181 on the coil contact of starter relay K1
3. Start switch (B1-B2) - X2 (28) - end 86 of safety relay K11
4. Wire 102 on the main contact of battery relay -X2 (12) - safety relay K11 (main contact) - X1(21) -
switch of pilot shut-off valve (3-1) - X2(3) - end 86 of starter relay K7 controlled by pilot
5. Ignition switch (B1-S)- J1 (female 10)
Starter motor end:
1. Starter motor end 30 - position cable on main contact of battery relay
Main circuit at the end S of ignition switch:
1. Terminal S of ignition switch - terminal 30 of pilot control starter relay K7
2. End 87 of pilot control starter relay K7 - end 30 of controller control starter relay K8
3. End 87A of controller control starter relay K8 - End 30 of ECM control starter relay K9
4. End 87A of the ECM control starter relay K9 - end S of starter relay on starter motor
Fuse box end:
1. Fuse box electric lock power supply 20A - end B1 of start switch
Control circuit at the end B2 of ignition switch:
1. End B2 of ignition switch - diode connector D6-2
Diode connector D6 -1- end B of battery relay
Pilot control starter control circuit:

1. Pilot shut-off valve switch (S13 -1) - end 86 of pilot control starter relay K7
Controller control starter control circuit:
1. Controller connector J2-71 - end 86 of the controller control starter relay K8
6-413
ECM control starter control circuit:

1. ECM connector J22-9 - end 86 of the ECM control starter relay K9
2. End 85 of ECM control starter relay K9 - ECM connector J22-57.
Yes No
Inspection method

Yes No
6-414
6.5.5 E5-Engine Shuts Down during Operation CLG920E/922E/923E
6.5.5 E5-Engine Shuts Down during Operation

E5 Engine shuts down during operation System fault.
System description
During the operation, the engine shut down may be caused by the engine stuck because of overload, or
because of open circuit in the power circuit of the engine controller. The power circuit of engine controller
is shown in the following figure.
Ignition switch
Engine controller
Ignition
Engine Switch ON
controller 5A
Engine
Power -
controller 30A Power -
Electric lock
Power -
power 20A Power +
Power +
Power +
6-415
CLG920E/922E/923E 6.5.5 E5-Engine Shuts Down during Operation
P29E00154
Component location
Handle pressure switch
Pedal
pressure
switch
Ignition switch
Pressure switch
of appurtenances
Fuse box
6-416
Step 1 Ignition switch fault

Inspection method
Measure the resistance between the start switch B1 and B2 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and B2 is infinite.
2. When the start switch is turned to ON position, the resistance between B1 and B2 is less than
10Ω.
Is the start switch damaged?
Yes No
Step 2 Fuse blows
The start switch is in OFF state.

Inspection method
2. For the controller CM3620, open the fuse box, unplug the fuses 12, 13 and 14 by a fuse clip; and
for the controller C101-D1, unplug the fuses 10, 15 and 14 by a fuse clip, then visually check
whether the fuse is blown or measure by the DIO position of multimeter whether both ends of fuse
are connected.
Note: There may be grounding fault, so please refer to step 4
Is the fuse blown?
Yes No
Replace the fuse
6-417
CLG920E/922E/923E 6.5.5 E5-Engine Shuts Down during Operation
Step 3 Wire in harness is open circuited or the connector has poor contact.
Correctly tie up harness and wire.
wear.
Inspection method
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of start switch
2. X2(8) - X1(2) - J22 ( 1, 3, 5)
3. End B2 of start switch - X1(28) - X2(1) - J22 (female 15)
4. J22 (female 2,female 4,female 6) - frame ground (GND)
1. Fuse box fuse electric lock power supply 20A - terminal B1 of ignition switch
2. End B2 of ignition switch - Fuse box-Engine controller fuse 5A - Engine controller connector (J22-
78)
3. Engine controller connector (J22-2, J22-4, J22-6) - frame ground (GND)
4. Fuse box-Engine controller fuse 30A - Engine controller connector (J22-1, J22-3, J22-5)
Yes No
6-418

Inspection method
1. No. 50 Fuse terminal - X2(8) - X1(5) - end B1 of start switch
2. X2(male 8) - X1(2) - J22(female 1, female 3, female 5)
3. End B2 of ignition switch - X1(28) - X2(1) - J22 (female 15)
1. Fuse box fuse electric lock power supply 20A - terminal B1 of ignition switch
2. End B2 of ignition switch - Fuse box-Engine controller fuse 5A - Engine controller connector (J22-
78)
3. Fuse box-Engine controller fuse 30A - Engine controller connector (J22-1, J22-3, J22-5)
Yes No
Inspection method

Yes No
Maintenance is over local LiuGong dealers or authorized service
centers.
6-419
CLG920E/922E/923E 6.5.6 E6 Engine cannot be Shut Down
6.5.6 E6 Engine cannot be Shut Down

E6 The engine can not be shut down System fault.
System description
While the machine is operating, start switch is turned from ON to OFF to shut off the start signal of
engine controller, so that the engine shuts down. The power circuit of engine controller is shown in the
following figure.
Ignition switch
Engine controller
Ignition
Engine Switch ON
controller 5A
Engine
Power -
controller 30A Power -
Electric lock
Power -
power 20A Power +
Power +
Power +
6-420
6.5.6 E6 Engine cannot be Shut Down CLG920E/922E/923E
P29E00154
Component location
ECU
controller
Ignition switch
Fuse box
6-421
CLG920E/922E/923E 6.5.6 E6 Engine cannot be Shut Down
Step 1 Start switch fault (internal short circuit)

Inspection method
Measure the resistance between the start switch B1 and B2 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and B2 is infinite.
2. When the start switch is turned to ON position, the resistance between B1 and B2 is less than
10Ω.
Yes No
6-422
6.5.6 E6 Engine cannot be Shut Down CLG920E/922E/923E
Step 2 Thermal short circuit of wire in harness
wear.
Inspection method
circuits are shorted to the battery (+), and normally the resistance between any check point and the
battery (+) shall be greater than 1 MΩ.
1. End B2 of ignition switch - X1(28) - X2(1) - J22 (female 15)
1. Fuse box-Engine controller fuse 30A - Engine controller connector (J22-1, J22-3, J22-5).
Whether the harness fault?
Yes No
Inspection method

Yes No
local LiuGong dealers or authorized service
Maintenance is over centers.
Return
6-423
CLG920E/922E/923E 6.5.7 E7 Preheater does not work
6.5.7 E7 Preheater does not work

The machine is difficult to start or fails to
E7 Pre-heater fails to work
start.
System description
The preheating function is divided into manual preheating and automatic preheating. Manual preheating
means to turn the start switch from OFF position to HEAT position, preheating relay K3 is closed, and the
battery supplies power to the pre-heater of the engine. Automatic preheating means that the engine
controller can make judgment based on the external environment to determine whether it requires
preheating or not. When preheat is required in accordance with the judgment, the output of J22-31 on
engine controller is 24V, the driving automatic preheat relay K10 is close to make preheat relay K3
powered, so that the preheat relay K3 is close and the battery supplies power to the engine. The figure
below is the electrical circuit diagram of engine preheater.
Preheating relay K3
Grid heater
Battery relay Diode
Auto preheating 10A
Engine controller
Air intake
preheating (+)
Preheating
ground wire
Ignition switch
Auto preheating relay K10

6-424
6.5.7 E7 Preheater does not work CLG920E/922E/923E
P29E00155
6-425
Component location
Preheater
Ignition switch
Fuse box
Engine controller
Step 1 Ignition switch fault (internal open circuit)

Inspection method
Measure the resistance between the start switch B1 and G1 with multimeter.
1. When the start switch is turned to OFF state, the resistance between B1 and G1 is infinite.
2. When the start switch is turned to HEAT position, the resistance between B1 and G1 is less than
10Ω.
Yes No
6-426
Step 2 Preheating relay fault (internal fault)
When replacing the preheating relay, please be sure to use LiuGong parts.
Inspection method
Measure the resistance between each two contacts of preheating relay K3 with a multimeter.
1. Remove the preheat relay K3, and then measure the resistance among all contacts.
The resistance of coil is about 61-63Ω.
The resistance of the main contact is infinite.
2. Supply 24V power to both ends of the coil and measure the resistance between two main contacts.
The resistance of the main contacts is less than 10Ω.
Is there a fault in the preheating relay?
Yes No
Replace the preheating relay.
Step 3 Fuse blows
The ignition switch is in OFF state.

Inspection method
2. Open the fuse box, unplug the fuse 2 by a fuse clip, and observe by visual inspection whether the
fuse is blown or measure by the DIO position of multimeter whether both ends of fuse are
connected.
Is the fuse blown?
Yes No
Replace the fuse
6-427
Step 4 Open circuit or poor contact of wire in harness or connector
wear.
Keep away from high temperature parts (e.g. alternator block) as far as possible
Inspection method
1. Wire 105 on the main contact of battery relay - wire 104 of the main contact of preheating relay K3
2. Wire 185 on the main contact of preheat relay K3 - terminal of the pre-heater
3. End G1 of start switch - wire 190 on the coil of preheat relay K3
4. Wire 260 on the preheat relay K3 - frame ground (GND)
5. End 87 of automatic preheating relay K10 X1(20) - wire 190 on the coil of preheating relay K3
6. Wire 102 on the main contact of battery relay - X2(12) - end 30 of the automatic preheating relay
K10
7. End 86 of the automatic preheat relay K10 -X2(7)-J22 (female 31)
8. End 85 of the automatic preheat relay K10 -X2(9)-J22 (female 57)
Manual preheating main circuit:
1. Wire 103 on the main contact of battery relay - wire 104 of the main contact of preheating relay K3.
2. Wire 185 on the main contact of preheat relay K3 - terminal of the pre-heater.
Manual preheating control circuit:
1. End G1 of start switch - wire 190 on the coil of preheat relay K3
2. Wire 260 on the preheat relay K3 - frame ground (GND)
Automatic preheating main circuit:
1. #102 on the main contact of battery relay - end Y1-A8 of the automatic preheating fuse box
connector
2. End of Y1-C7 of auto preheating fuse box connector – end of 30 of auto preheating relay K10
6-428
3. End 87 of automatic preheating relay K10 - wire 190 on the coil of preheating relay K3
Automatic preheating control circuit:
1. Engine controller connector J22-31 – end 86 of auto preheating relay K10
2. End 85 of the automatic preheating relay K10 - engine controller connector J22-57.
Yes No

Inspection method

1. Wire 105 on the main contact of battery relay - main contact of preheating relay K3 - terminal of
pre-heater.
2. End G1 of start switch - wire 190 on the coil of preheat relay K3.
3. Wire 102 on the main contact of battery relay - X2(12) - automatic preheating relay K10 (main
contact) - X1(20)- wire190 on the coil of preheating relay K3
Manual preheating main circuit:
1. Wire 103 on the main contact of battery relay - wire 104 of the main contact of preheating relay K3.
Manual preheating control circuit:
1. End G1 of start switch - wire 190 on the coil of preheat relay K3.
Automatic preheating main circuit:
1. #102 on the main contact of battery relay - end Y1-A8 of the automatic preheating fuse box
connector
2. End of Y1-C7 of auto preheating fuse box connector – end of 30 of auto preheating relay K10
3. End 87 of automatic preheating relay K10 - wire 190 on the coil of preheating relay K3
6-429
Automatic preheating control circuit:

1. Engine controller connector J22-31 – end 86 of auto preheating relay K10
Yes No
Step 6 Preheater fault (internal fault)
When replacing the preheater, please be sure to use LiuGong parts.

Inspection method
Turn the start switch to HEAT position, when the voltage measured between the terminal of pre-heater
and the ground is 24V, if the pre-heater still does not work, it can be determined as the internal fault of
the pre-heater.
Is there a fault in the pre-heater?
Yes No
Replace the preheater.
Inspection method

Yes No
centers.
6-430
6.5.8 E8 All the Work Implements, Revolving and Traveling cannot Move CLG920E/922E/923E
6.5.8 E8 All the Work Implements, Revolving and Traveling cannot Move

All the work implements, revolving system and
E8 No action and fails to work.
travel system fail to move
System description
Power on, pull up the shut-off switch of pilot solenoid valve to connect wire 300 and 481, at this time, the
electrical circuit of the pilot shut-off solenoid valve is connected, and the oil path of the pilot shut-off
solenoid valve is open, so the hydraulic system starts running. The following is the electrical circuit
diagram of the pilot shut-off.
Pilot solenoid
Ignition switch valve switch
Pilot cut-off solenoid valve
Pilot cut-off 10A
Satety relay K11

Battery relay
6-431
CLG920E/922E/923E 6.5.8 E8 All the Work Implements, Revolving and Traveling cannot Move
P29E00156
Component location
Ignition switch
Fuse box
Pilot cut-off
valve switch
6-432
Step 1 Check whether the fuse 1 are blown

Inspection method
Unplug the fuse 1 by a fuse clip, visually check whether the fuse is blown or check whether both ends
of the fuse are connected by the multimeter on the diode gear.
Is fuse 1 blown?
Yes No
Replace the fuse
Step 2 Pilot solenoid valve cut-off switch fault

Inspection method
1. While pulling up the shutoff switch of pilot solenoid valve, the pin 2 and pin 3 on the shutoff switch
of pilot solenoid valve are connected, and at this time measure the shutoff switch with a multimeter
on the diode position.
Is the switch closed?
Yes No
Repair or replace the shut-off switch of the pilot
solenoid valve.
6-433
Step 3 Check whether the safety relay fails (for the controller C101-D1: skip this step and go to
step 4)

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

6-434
Inspection method
2. End 87 of safety relay K11 - X1(21) - S13 (female 3) of pilot shutoff valve switch
3. S13 (female 2) of pilot shutoff valve switch - pilot shutoff solenoid valve A1 (female 1)
4. Pilot shutoff solenoid valve A1 (female 1)- frame ground (GND)
6. Terminal 85 on the safety relay K11 -X2 (16) - frame ground (GND)
1. #102 on the main contact of battery relay - Y1(A8)/Y1(B8)/Y1(C8)
2. Y1(A8)/Y1(B8)/Y1(C8) - S13 (female 3) of pilot shutoff valve switch
3. S13 (female 2) of pilot shutoff valve switch - pilot shutoff solenoid valve A1 (female 1)
4. Pilot shutoff solenoid valve A1 (female 1)- frame ground (GND)
Yes No
6-435
Step 5 Wire in harness is fault -- shorted to ground wire.

Inspection method

2. End 87 of safety relay K11 - X1(21) - pilot shut off valve switch (3-2) - pilot shut off solenoid valve
A1 (female 1)
Remove the battery cable (-), and check whether the following circuits are shorted to ground, and
normally the resistance between any check point and the ground shall be greater than 1MΩ.
1. #102 on the main contact of battery relay - Y1(A8)/Y1(B8)/Y1(C8)
2. Y1(A8)/Y1(B8)/Y1(C8) - pilot shutoff valve switch (3-2)- pilot shutoff solenoid valve A1 (female 1)
Yes No
Inspection method

Yes No
Return
6-436
6.5.9 E9 Display Panel Showing Nothing CLG920E/922E/923E
6.5.9 E9 Display Panel Showing Nothing

E9 Display panel shows nothing It can not display the machine information.
System description
Protect the constant power end by fuse, control the energy power in the display by start switch, and if the
power circuit is normal, turn on the display.
Display
Ignition switch
power supply
power supply
lock ON
Ground
Ground
Electric
Battery
Battery
(Black) (Gray)
Controller,
display 30A
Battery relay
6-437
CLG920E/922E/923E 6.5.9 E9 Display Panel Showing Nothing
P29E00157
6-438
Component location
Ignition
Display switch
Fuse box
Step 1 Blowing of fuse

Inspection method
For the controller CM3620, unplug the fuse 15 by a fuse clip, and visually check if the fuse blows or
measure the both ends of the fuse are connected by the multimeter on the diode gear; and for the
controller C101-D1,unplug the fuse 11 by a fuse clip, and visually check if the fuse blows or measure
the both ends of the fuse are connected by the multimeter on the diode gear.
Is fuse blown?
Yes No
Replace the fuse.
6-439
wear.
Inspection method
1. Wire 004 on the main contact of battery relay -X2(8)-X1(1)-X3(6)- C4(female 6) of the display
2. X1 (female1)- X4 (7)- display C4 (femal7)
3. C4 (female 5) of the display-X4(5) - frame ground (GND)
4. C4 (female 10)-X3(10) of the display - frame ground (GND)
5. Terminal S of start switch - X3 (8) - C4 (female 26) of the display
1. # 004 on the main contact of battery relay - Y2(C7/C8) - X3(6) - C4 (female 6) of the display
2. Y2(C7/C8)- X3(6)- C4 (female 7) of the display
5. End M of ignition switch - X3 (8) - C4 (female 26) of the display
Yes No
6-440
Step 3 Wire in harness grounding fault --- shorted to ground wire

Inspection method
1. Wire 004 on the main contact of battery relay -X2(8)-X1(1)-X3(6)- C4(female 6) of the display
2. X1 (female1)- X4 (7)- display C4 (femal7)
3. End S of start switch - X3 (8) - C4 (female 26) of the display
1. # 004 on the main contact of battery relay - Y2(C7/C8) - X3(6) - C4 (female 6) of the display
2. Y2(C7/C8)- X3(6)- C4 (female 7) of the display
3. End M of ignition switch - X3 (8) - C4 (female 26) of the display
Yes No
Step 4 Display fault

Inspection method
Turn the start switch to ON position, check the power supply with the multimeter, when all the following
conditions are satisfied, if the display is still off, it can be determined as internal fault of the display.
1. The voltage to ground of the display C4 (6) is 24V
Whether the display fails?
Yes No
Replace the display.
6-441
Inspection method

Yes No
Return
6-442
6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature CLG920E/922E/923E
6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature

Reducing the pump current and engine
speed can affect the working performance
E10 Incorrect display of hydraulic oil temperature
of the complete machine, or cause damage
to the engine and hydraulic components
System description
The hydraulic oil temp sensor monitors the actual temperature, and outputs different resistances to the
engine controller; the engine controller sends the hydraulic oil temperature to the display through CAN
bus, so the hydraulic oil temperature can be displayed on the display.
Engine controller
Oil temperature
Oil
temperature
ground
Hyd temperature Sensor

6-443
CLG920E/922E/923E 6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature
Coolant temperature(°C)
Resistance (Ω)
Component location
Front
Hydraulic
oil tempera-
ture sensor
Step 1 The fault of hydraulic oil temp sensor (internal fault)

Inspection method
Turn the knob start switch to OFF position and disconnect sensor connector:
Whether the hydraulic oil temp sensor fails?
Yes No
Replace the hydraulic oil temp sensor.
6-444
6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature CLG920E/922E/923E
Correctly tie up harness and wire?
wear.
Inspection method
1. J22 (female 48) of engine controller - P7 (female 1) of hydraulic oil temp sensor.
2. J22 (female 45) of engine controller - P7 (female 2) of hydraulic oil temp sensor.
Yes No

Inspection method
J22 (female 48) of engine controller - P7 (female 1) of hydraulic oil temp sensor.
Yes No
6-445
CLG920E/922E/923E 6.5.10 E10 Incorrectly Displayed Hydraulic Oil Temperature
Inspection method

Yes No
Return
6-446
6.5.11 E11 Fuel Gauge cannot Display correctly CLG920E/922E/923E
6.5.11 E11 Fuel Gauge cannot Display correctly

The fuel level display is inaccurate, which
E11 Fuel gauge cannot display correctly
brings trouble to the work.
System description
IPC Controller
Fuel level
Fuel level sensor
P29E00140
6-447
CLG920E/922E/923E 6.5.11 E11 Fuel Gauge cannot Display correctly
Component location
Front
Fuel level sensor
Inspection method
Turn the start switch to the OFF position, and disconnect the connector from the fuel level sensor:
2. Turn the multimeter to its resistance function, and measure the resistance between the fuel level
sensor connector terminals 1 and 2 (normally, <2KΩ, for the specific resistance, see the figure.).
6-448

Yes No
wear.
6-449
CLG920E/922E/923E 6.5.11 E11 Fuel Gauge cannot Display correctly
Inspection method
controller (J2-30) and fuel level sensor for wear; and for the controller C101-D1, check the harness
(# 930) and the grounding wire (#255) between the controller (J1-8) and fuel level sensor for wear.
2. Disconnect the fuel level sensor connector and the controller connector. Check the harness for
open-circuit:
resistance between the grounding wire (#227) sensor end and the grounding (normally, <10Ω);
and for the controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance between the grounding wire (#255) sensor end and the grounding (normally, <10Ω).
Gray wire
b. For the controller CM3620,turn the multimeter to its resistance function, and measure the
resistance of harness between the connector port J2-30 and sensor (normally, <10Ω); and for
the controller C101-D1, turn the multimeter to its resistance function, and measure the
resistance of harness between the connector port J1-8 and sensor (normally, <10Ω).
White wire
To the
black probe
To the red probe

Yes No
harness.
6-450

Inspection method
Connect the fuel level sensor connector and disconnect the controller connector. For the controller
harness at the controller port J2-30 and the grounding (normally, <2 kΩ, for the specific resistance,
see the attached drawing); for the controller C101-D1, turn the multimeter to its resistance function,
and measure the resistance between the harness at the controller port J1-8 and the grounding
(normally, <2 kΩ)
Connect the black

probe to ground
Connect the red

probe to Pin 30
Yes No
Inspection method
Yes No

6-451
CLG920E/922E/923E 6.5.12 E12 Windshield wiper out of work
6.5.12 E12 Windshield wiper out of work

Foreign matters on glass cannot be
E12 Windshield wiper does not work
removed; the sight for operator is poor.
System description
The following diagram is the electrical circuit diagram of the wiper system: when the switch is in position
0, M4(1) and M4(3) are connected, wiper motor stops and resets to the original position; when the switch
is in position 1, M4(3) and the power are connected, and the wiper motor operates in the low speed
state; when the switch is turned to position 2, M4(2) and the power are connected, and the wiper motor
operates in the fast speed state.
Wiper Wiper motor

switch
Wiper switch
(Gray) (Black)
Wiper, washer 10A
Wiper relay K6
Battery relay
6-452
6.5.12 E12 Windshield wiper out of work CLG920E/922E/923E
P29E00158
6-453
Component location
Wiper switch
Wiper
motor
Fuse box
Step 1 Check whether the wiper & washer fuse is blown or not

Inspection method
For the controller CM3620, unplug the fuse 9 by a fuse clip, and visually check if the fuse blows or
measure the both ends of the fuse are connected by the multimeter on the diode gear; and for the
controller C101-D1,unplug the fuse 5 by a fuse clip, and visually check if the fuse blows or measure
the both ends of the fuse are connected by the multimeter on the diode gear.
Whether the wiper & washer fuse is blown or not
Yes No
Replace the fuse
6-454
Step 2 Wiper switch fault

Inspection method
Disconnect connector S1, check the connection condition of pins with the multimeter when the wiper
switch is turned to different positions, when there is no fault in the wiper switch, the connection
condition of pins are shown as follows:
1. When the wiper switch is in the 0 position, the resistance between pin 5 and pin 7 of S1 is less
than 10Ω, the resistance between pin 1 and pin 3 is infinite, and the resistance between pin 5 and
pin 3 is infinite.
pin 3 is infinite.
pin 3 is infinite.
Is the wiper switch damaged?
Yes No
Replace the wiper switch
wear.
6-455
Inspection method
1. Wiper switch S1 (female 1) - X3 (female3)- wiper motor M4 (female 2)
2. Wiper switch S1 (female 5) - X3 (2) -wiper motor M4 (female 3)
4. For the controller CM3620, # 102 on the main contact of battery relay - X2(14) - main contact and
end 86 of wiper relay K6 - X1(24) - wiper switch S1 (female 3) -X3(4)- wiper motor M4 (female 6);
for the controller C101-D1,# 102 on the main contact of battery relay - Y1(A8)/Y1(B8)/Y1(C8) -
main contact and end 86 of wiper relay K6 - Y1(C1) - wiper switch S1 (female 3) -X3(4)- wiper
motor M4 (female 6).
5. For the controller CM3620, End 85 on the wiper relay K6 - X2(4) - X5(1) - door control wiper
switch- X5(2) - frame ground (GND); for the controller C101-D1, end 85 on the wiper relay K6 -
Y1(B2) - X5(1) - door control wiper switch- X5(2) - frame ground (GND)
Yes No
Step 4 Wire in harness is fault -- shorted to ground wire

Inspection method
For the controller CM3620, # 102 on the main contact of battery relay - X2(14) - main contact and end
30 of wiper relay K6 - X1(24) - wiper switch S1 (female 3) -X3(4)- wiper motor M4 (female 6); for the
controller C101-D1,# 102 on the main contact of battery relay - Y1(A8)/Y1(B8)/Y1(C8) - main contact
and end 30 of wiper relay K6 - Y1(C1) - wiper switch S1 (female 3) -X3(4)- wiper motor M4 (female 6).
Yes No
6-456
Step 5 Wiper motor fault

Inspection method
Turn the start switch to ON position, check the power supply of the wiper motor with the multimeter;
when all the following conditions are satisfied, if the wiper motor is still off, it can be determined as
internal fault of the wiper motor.
1. When the wiper switch is in position 0, the voltage to ground of M4 (female 6) is 24V, and the
voltage to ground of M4 (female 4) is 0V.
2. When the wiper switch is in position 1, the voltage to ground of M4 (female 3) is 24V.
3. When the wiper switch is in position 2, the voltage to ground of M4 (female 2) is 24V.
Is the wiper motor damaged?
Yes No
Replace the wiper switch
Inspection method
Operate the wiper system and check whether each action is normal.
Yes No
6-457
CLG920E/922E/923E 6.5.13 E13-Travel alarm unable to sound
6.5.13 E13-Travel alarm unable to sound

Alarm system is faulty, causing potential
E13 Travel alarm does not sound
safety hazard.
System description
The figure below is the travel alarm electrical circuit diagram. Operators can cancel or enable the travel
alarm function by operating buttons on the display. The main controller (IPC controller) judges whether
the complete machine is on travel status in accordance with the foot controlled oil circuit pressure switch.
If it is in travel status, J1-1 foot of the main controller (IPC controller) outputs 24 V voltage to the travel
alarm. If not, J1-1 foot of the main controller (IPC controller) outputs 0 V voltage to the travel alarm.
IPC Controller (Black)

Display
CAN 1/2 shield
CAN 1 low
CAN 1 high
Travele alarm buzzer
(White)
Foot pedal pressure switch
Travel alarm (Option)
Pressure switch
6-458
6.5.13 E13-Travel alarm unable to sound CLG920E/922E/923E
Component location
Front
Traveling alarm
Step1 Open circuit or poor contact of lead in harness or connector.

It shall be kept away from moving components as far as possible to prevent tensile failure and wear.
Inspection method
1. Main controller J1 (female 1) – travel alarm N3 (female 1)
2. Travel alarm N3 (female 2) – frame ground
3. Main controller J2 (female 13) – foot controlled oil circuit pressure switch P10 (female 1)
4. Foot controlled oil circuit pressure switch P10 (female 2) - frame GND
Yes No
6-459
CLG920E/922E/923E 6.5.13 E13-Travel alarm unable to sound

Inspection method
1. Main controller J1 (female 1) – travel alarm N3 (female 1)
2. Main controller J2 (female 13) – foot controlled oil circuit pressure switch P10 (female 1)
Yes No
Step 3 Travel alarm fault (internal fault)

Inspection method
Start the complete machine but do not pull up the pilot shut-off valve switch, unplug connector P10 of
the foot controlled oil circuit pressure switch, and measure the voltage value of N3 (female 1) over the
ground with a multimeter. The voltage is 24 V under normal conditions.
Whether the travel alarm fails?
Yes No
Replace the travel alarm.
Inspection method

Yes No
centers.
6-460
6.5.14 E14 A/C panel unable to display CLG920E/922E/923E
6.5.14 E14 A/C panel unable to display

E14 A/C panel displays nothing A/C system cannot work
System Description
(1) For the electrical schematic diagram of the A/C system, see the attached drawing.
(2) The evaporator assembly arrangement schematic diagram
a. Front view
Back Vent servo motor Compressor relay Blower relay
Face
Fresh air
Defrost
Recirculated Air
Foot Water temperature Air-mixing servo motor Internal air sensor

sensor
CLG923E06001
6-461
CLG920E/922E/923E 6.5.14 E14 A/C panel unable to display
b. Bottom view
Hot water outlet Hot water inlet Expansion valve Inlet
Expansion valve outlet Internal-to-external air switching motor

CLG923E06002
c. Rear-side view
Blower Defrost sensor Defrost sensor
CLG923E06003
6-462
6.5.14 E14 A/C panel unable to display CLG920E/922E/923E
Step 1 Base machine power fault
Caution: When replacing the components, please be sure to use LiuGong parts.
Inspection Method
Check whether the voltage of the machine harness (No. 128) with mutually plugged A/C harness in the
cab is 24V with a multimeter.
Check the No. 128 wire having 24V voltage?
Yes No
Find out the reason according to Step 2. Check whether A/C 30A fuse is damaged.
Step 2 Wire grounding fault - failed to connect with the ground wire.
Inspection Method
Check whether the machine harness (No. 210) with mutually plugged A/C harness in the cab is
grounded with a multimeter.
Check the grounding wire is not open.
Yes No
Troubleshoot the grounding circuit of base
machine harness. Find out the reason according to Step 3
Step 3 The A/C 30A fuse is blown.
Caution: When replacing A/C fuse, please be sure to use LiuGong parts.
Inspection Method
Check A/C 30A fuse, visibly check whether the fuse is blown or check whether both ends of the fuse
are connected by the multimeter on the diode gear.
Is A/C 30A fuse blown?
Yes No
Replace the A/C 30A fuse. Find out the reason according to Step 4.
Step 4 A/C panel 5A fuse is damaged.
Caution: When replacing A/C fuse, please be sure to use LiuGong parts.
6-463
CLG920E/922E/923E 6.5.14 E14 A/C panel unable to display
Inspection Method
Check the 5A fuse on the evaporator assembly harness in the cab. Visibly check whether the fuse
blows or check whether both ends of the fuse are connected by the multimeter on the DIO position.
Is A/C panel fuse damaged?
Yes No
Replace 5A fuse of the A/C panel
Step 5: A/C panel fault (internal fault).
Caution: When replacing the A/C panel, please be sure to use LiuGong parts.
Inspection Method
Press the blowing rate switch, the air volume should be displayed in the A/C panel, and turn on the
LCD; after pressing other keys, indicators come on or corresponding icons are displayed on the LCD.
Check the A/C panel for any fault.
Yes No
Replace the A/C panel
Inspection Method
Operate the machine and check if each action is normal.

Yes No
Look for the electrical system fault or contact local
Maintenance is over LiuGong dealers and authorized service centers.
6-464
6.5.15 E15 A/C no air or abnormal air volume CLG920E/922E/923E
6.5.15 E15 A/C no air or abnormal air volume

E15 A/C blows no air or air volume is abnormal The service effect of A/C is poor
Step 1 Blower main relay fault (internal fault).
When replacing the A/C relay, please make sure to use LiuGong parts.
Inspection Method
Measure the resistance between each two contacts of blower main relay with a multimeter, and
determine whether the relay is damaged or not according to the resistance value provided in the
following table.
Code for both ends of wire
Relay Standard value
(contact)
Measure coil resistance 360±10%Ω
1-2 contact
Unplug the relay and measure the resistance between

each two contacts of the relay Infinite
Whether the blower main relay fails?

Yes No
Replace the blower main relay.
6-465
CLG920E/922E/923E 6.5.15 E15 A/C no air or abnormal air volume
Step 2 Power transistor fault.
Inspection Method
Press the air regulation switch on the A/C panel, and feel whether outlet airflow is changed with
adjustment of the blowing rate switch.
Whether outlet airflow is changed with adjustment of the blowing rate switch?
Yes No
Replace the power transistor
Step 3 Blower motor fault.
Inspection Method
Unplug the blower plug of the evaporator assembly, and check whether there is a short circuit or open
circuit of blower coil winding with a multimeter.
Whether the blower is faulty?
Yes No
Replace the blower. Find out the reason according to Step 4
Step 4 Fault of A/C lines.
Caution: When replacing the blower, please make sure to use LiuGong parts.
Inspection Method
Check whether connectors of A/C harness are connected stably and whether there is an open-circuit or
short-circuit caused by damage of wires.
Whether A/C wiring is abnormal?
Yes No
Check circuit fault points and repair them.
6-466
6.5.15 E15 A/C no air or abnormal air volume CLG920E/922E/923E
Step 5: Fault of A/C panel.
Inspection Method
If the A/C panel is checked to be normal through step 1 to step 4, it may have been damaged.
Check the A/C panel for any fault.
Yes No
Replace the A/C panel.
Inspection Method

Yes No
Look for faults of the A/C system or contact local
Maintenance is over LiuGong dealers and Authorized Service Centers.
6-467
CLG920E/922E/923E 6.5.16 E16 Poor A/C Refrigeration
6.5.16 E16 Poor A/C Refrigeration

E16 A/C cooling is poor A/C cooling effect is poor
Step 1 Compressor relay fault
Inspection Method
Measure the resistance between all contacts of compressor relay with a multimeter, and determine
whether the relay is damaged or not according to the resistance value provided in the following table.
Code for both ends of wire
Relay Standard value
(contact)
Measure coil resistance 400±10%Ω
1-2 contact
Unplug the relay and measure the resistance between
each two contacts of the relay Infinite
Whether the compressor clutch relay is faulty?

Yes No
Replace the compressor clutch relay Troubleshoot according to Step 2.
Step 2 Internal air sensor faulty.
Inspection Method
The internal sensor may fail and diagnose the fault of internal sensor
Whether the internal air sensor fails?
Yes No
Replace the internal air sensor. Find out the reason according to Step 3
6-468
6.5.16 E16 Poor A/C Refrigeration CLG920E/922E/923E
Step 3 High-low voltage protection switch fault.
Inspection Method
Unplug the pressure protection switch wiring harness on the high-pressure side connector of the
expansion valve, and use a multimeter to check whether both ends of the pressure switch is connected.
When the system pressure is greater than 0.196MPa (28.42psi) and less than 3.14MPa (455.3psi), the
pressure switch shall be connected.
Check the high-low pressure protective switch is not damaged.
Yes No
Replace the high and low voltage protection
switch. Find out the reason according to Step 4
Step 4 Compressor clutch fault.
Inspection Method
Unplug the compressor clutch plug, and use a multimeter to check whether the compressor clutch coil
is open. Whether the compressor grounding wire is in good condition?
Whether there is a fault in the compressor clutch?
Yes No
Replace the A/C compressor. Find out the reason according to Step 5
Step 5 Compressor fault.
Inspection Method
Remove the A/C belt, and rotate the A/C compressor pulley by hand to check whether clamping
stagnation and abnormal noise happens on the compressor A/C pulley.
Whether the compressor is faulty?
Yes No
Replace the A/C compressor. Find out the reason according to Step 6
6-469
CLG920E/922E/923E 6.5.16 E16 Poor A/C Refrigeration
Step 6 Fault of A/C lines.
Inspection Method
Check whether connectors of A/C harness are connected stably and whether there is an open-circuit or
short-circuit caused by damage of wires.
Is there a fault in the A/C wiring?
Yes No
Check circuit faults and repair them Find out the reason according to Step 7
Step 7 A/C panel fault.
Inspection Method
If the A/C panel is checked to be normal through step 1 to step 7, it may have been damaged.
Whether the A/C panel fails?
Yes No
Replace the A/C panel.
Inspection Method

Yes No
Look for the cooling system fault or contact local
Maintenance is over LiuGong dealers and authorized service centers.
6-470
6.5.17 E17 A/C Abnormal Alarm Display E13 -- Defrost Sensor Wire Broken CLG920E/922E/923E
6.5.17 E17 A/C Abnormal Alarm Display E13 -- Defrost Sensor Wire
Broken
This troubleshooting is only applicable to the Taybo A/C.

Abnormal A/C alarm E13 -- Defrost Sensor Wire
E17 A/C system is out of work
Broken
Step 1 Defrost sensor fault.

Inspection Method
1. Press OFF on the A/C panel, the LCD does not display, and the A/C stops running;
2. Press the increase and decrease keys of the temperature setting switch in the meantime for over 3
seconds, the LCD will display DTCs;
3. If DTC E13 appears, check whether the defrost sensor is not open-circuited by using a multimeter.
Whether the defrost sensor is not open-circuited?
Yes No
Replace the defrost sensor.
Step 2 Defrost sensor open-circuited.

Inspection Method
Check whether the wire from the defrost sensor to the A/C panel is not open circuited by using a multi-
meter?
Whether the defrost sensor line is not open-circuited?
Yes No
Check fault points and repair them
6-471
CLG920E/922E/923E 6.5.17 E17 A/C Abnormal Alarm Display E13 -- Defrost Sensor Wire Broken
Step 3 Fault of A/C panel.

Inspection Method
If no open circuit is found through checking by Step 1 and 2, it may be an internal fault of the A/C panel.
Check the A/C panel for any internal fault.
Yes No
Inspection Method

Yes No
Maintenance is over Look for faults of the A/C system or contact local
LiuGong dealers and Authorized Service Centers.
6-472
6.5.18 E18 A/C Abnormal Alarm Display E14 -- Defrost Sensor Short Circuited CLG920E/922E/923E
6.5.18 E18 A/C Abnormal Alarm Display E14 -- Defrost Sensor Short
Circuited

Abnormal A/C Alarm E14 -- Defrost Sensor Short
Circuited
Step 1 Defrost sensor fault.

Inspection Method
3. If DTC E14 appears, check whether the defrost sensor is not short circuited by using a multimeter.
Whether the defrost sensor is not short circuited?
Yes No
Replace the defrost sensor.
Step 2 Defrost sensor short-circuited.

Inspection Method
Check whether the circuit between the defrost sensor and the A/C panel is not shorted by using a mul-
timeter?.
Whether the defrost sensor circuit is not opened?
Yes No
6-473
CLG920E/922E/923E 6.5.18 E18 A/C Abnormal Alarm Display E14 -- Defrost Sensor Short Circuited

Inspection Method
If no short circuit is found through checking by Step 1 and 2, it may be an internal fault of the A/C panel.
Yes No
Inspection Method

Yes No
6-474
6.5.19 E19 A/C Abnormal Alarm Display E17 -- Solar Sensor Wire Broken CLG920E/922E/923E
6.5.19 E19 A/C Abnormal Alarm Display E17 -- Solar Sensor Wire Broken

Abnormal A/C Alarm E17 -- Solar Sensor Wire
Broken
Step 1 The solar sensor fault.

Inspection Method
3. If DTC E17 appears, check whether the solar sensor circuit is not opened by using a multimeter.
Whether the solar sensor is open-circuited?
Yes No
Replace the solar sensor?
Step 2 The solar sensor is open-circuited.

Inspection Method
Check whether the circuit between the solar sensor and the A/C panel is open-circuited by using a mul-
timeter.
Whether the solar sensor is open-circuited?
Yes No
6-475
CLG920E/922E/923E 6.5.19 E19 A/C Abnormal Alarm Display E17 -- Solar Sensor Wire Broken

Inspection Method
Yes No
Inspection Method

Yes No
6-476
6.5.20 E20 A/C Abnormal Alarm Display E19 -- External Air Sensor Wire Broken CLG920E/922E/923E
6.5.20 E20 A/C Abnormal Alarm Display E19 -- External Air Sensor Wire
Broken

Abnormal A/C Alarm E19 -- External Air Sensor
Wire Broken
Step 1 External air sensor faulty.

Inspection Method
3. If DTC E19 appears, check whether the circuit of the external air sensor at the condenser side is not
opened by using a multimeter.
Whether the external air sensor is not open-circuited?
Yes No
Replace the external air sensor.
Step 2 The external air sensor open-circuited.

Inspection Method
Check whether the circuit between the external sensor and the A/C panel is not opened by using a mul-
timeter.
Whether the external air sensor is open circuit?
Yes No
6-477
CLG920E/922E/923E 6.5.20 E20 A/C Abnormal Alarm Display E19 -- External Air Sensor Wire Broken

Inspection Method
Yes No
Inspection Method

Yes No
6-478
6.5.21 E21 A/C Abnormal Alarm Display E20 -- External Air Sensor Short-Circuited CLG920E/922E/923E
6.5.21 E21 A/C Abnormal Alarm Display E20 -- External Air Sensor Short-
Circuited

Abnormal A/C alarm E20 -- External Air Sensor
Short Circuited
Step 1 External air sensor faulty.

Inspection Method
3. If DTC E20 appears, check whether the circuit of the external air sensor at the condenser side is not
shorted by using a multimeter.
Whether the external air sensor is not short-circuited?
Yes No
Replace the water temperature sensor.
Step 2 The external air sensor short-circuited.

Inspection Method
Check whether the circuit between the external sensor and the A/C panel is not shorted by using a mul-
timeter.
Whether the external air sensor is short circuited?
Yes No
6-479
CLG920E/922E/923E 6.5.21 E21 A/C Abnormal Alarm Display E20 -- External Air Sensor Short-Circuited

Inspection Method
If no short circuit is found through checking by Step 1 and 2, it may be an internal fault of the A/C panel.
Yes No
Inspection Method

Yes No
6-480
6.5.22 E22 Air Conditioning Abnormal Alarm E43--Air Blowing Valve Abnormal CLG920E/922E/923E
6.5.22 E22 Air Conditioning Abnormal Alarm E43--Air Blowing Valve

Abnormal

Abnormal A/C alarm E43 -- Air blowing valve
abnormal
Step 1 Air-out servo motor fault (internal fault)
Inspection Method
3. If DTC E43 appears, check whether the circuit of the air-vent servo motor on the evaporator
assembly is shorted-circuited or open with a multimeter.
Check the air-vent servo motor is not faulty.
Yes No
Replace the air-out servo motor
Step 2 Circuit fault of the air-out servo motor.
Inspection Method
Check whether the circuit from the air-out servo motor harness to the A/C panel is short or open with a
multimeter.
Whether the air-out servo motor circuit is faulty?
Yes No
6-481
CLG920E/922E/923E 6.5.22 E22 Air Conditioning Abnormal Alarm E43--Air Blowing Valve Abnormal
Inspection Method
1. If no short circuit is found through checking by Step 1 and 2, it may be an internal fault of the A/C
panel.
Yes No
Inspection Method

Yes No
Look for faults of the A/C system or contact local
Maintenance is over LiuGong dealers and Authorized Service Centers.
6-482
6.5.23 E23 Abnormal A/C Alarm E44 - Air Mixing Valve Abnormal CLG920E/922E/923E
6.5.23 E23 Abnormal A/C Alarm E44 - Air Mixing Valve Abnormal

Abnormal A/C alarm E44 -- Air mixing valve
abnormal
Step 1 Air mixing door (A/M) servo motor fault (internal fault).
Inspection Method
3. If DTC E44 appears, check whether the circuit of the air-vent servo motor on the evaporator
assembly is shorted-circuited or open with a multimeter.
Check the air-vent servo motor is not faulty.
Yes No
Replace the servo motor of the air mixing
ventilation door (A/M)
Step 2 Circuit fault of the servo motor of the air mixing ventilation door (A/M).
Inspection Method
Check whether the circuit from the servo motor harness of the air mixing ventilation door to the A/C
panel is short or open with a multimeter.
Whether the servo motor circuit of the air mixing door (A/M) fails?
Yes No
6-483
CLG920E/922E/923E 6.5.23 E23 Abnormal A/C Alarm E44 - Air Mixing Valve Abnormal
Inspection Method
1. If no short circuit is found through checking by Step 1 and 2, it may be an internal fault of the A/C
panel.
Yes No
Inspection Method

Yes No
6-484
6.6 Fault Diagnosis of the Hydraulic System and Mechanical System September 15, 2020
6.6.1 System Table of the Hydraulic System and Mechanical System CLG920E/922E/923E
6.6 Fault Diagnosis of the Hydraulic System and Mechanical

System
6.6.1 System Table of the Hydraulic System and Mechanical System
1. When the machine applies the Kawasaki system, the systematic diagram is as follows.
Arm 1 Arm
Arm 2 cylinder
Bucket
cylinder Bucket Spare
Boom Boom
Boom 1 Boom 2 cylinder
cylinder
Travel Swing
motor-lh Travel-lh Swing motor
Straight Travel
Travel-rh motor-rh
travel
P2 (from the pilot

valve XB1)
6-485
September 15, 2020 6.6 Fault Diagnosis of the Hydraulic System and
Mechanical System
2. When the machine applies the Rexroth system, the systematic diagram is as follows.
CLG920E922E06001
6-486
6.6.2 H1 Excessive barking angle for slewing stop CLG920E/922E/923E
6.6.2 H1 Excessive barking angle for slewing stop
Excessive braking
angle for slewing stop
Yes
Check whether the No Slewing relief valve

slewing overflow
Yes
Check whether No Anti-reversing valve
Yes
Check the slewing Yes Clean and replace the
No
Check whether No Pilot valve fault
Yes
Check
No Spring fault
whether the
Yes
Swing motor fault

6-487
Mechanical System
6.6.3 H2 Abnormal Noise from Pump Mounting Position
Abnormal sound of
pump mounting
position
Yes
Check the flywheel inside Yes Coupling components:

for foreign matters Removal and repair
No
Check the coupling hub

spline for wear and the Yes Replace the hub or tighten
adjusting screw for fixing the adjusting screw.
the hub for looseness.
This abnormal sound may

be caused by the hydraulic
pump or the engine itself.
No Refer to the operating
instructions of the device
and the engine.
6-488
6.6.4 H3 Start the Engine, and All Operations have no Response CLG920E/922E/923E
6.6.4 H3 Start the Engine, and All Operations have no Response
When the engine is

started, all operations
are unresponsive.
Yes
Check whether the

Add oil to the specified
hydraulic oil level is No level as required.
normal.
No
The hydraulic pump Hydraulic pump fault:
sounds abnormally. Yes Remove and repair it.
Check whether the abnormal Yes
sound comes from the
hydraulic pump or pump
installation position. Yes
The pump installation position Troubleshoot by

No sounds abnormally. Yes referring to H2.
Check whether the pilot Check whether any oil flows Pilot relief valve fault:
pressure is normal. No out from the pilot pump. Yes
Repair or replace it
Pilot pump fault:

Remove and repair it.
No
Pilot valve or main

Check the pilot line for No control valve fault:
clogging or leakage.
Remove and repair it.
Clean the pilot line or

Yes
repair it.
6-489
Mechanical System
6.6.5 H4 Hydraulic Oil Emulsification
Hydraulic oil
emulsification
Yes
Sample the oil and drop Let the hydraulic oil sit
This may be due
the sample droplets onto Yes for a period of time,
to water in the
the hot iron plate, and and remove the water
hydraulic oil.
then check for bubbles. or replace the oil.
Check the suction

Yes This may be due line and the return
to air in the line, and cut off the
hydraulic oil. air-mixed source.
6-490
6.6.5 H5 Abnormal increase of hydraulic oil temperature CLG920E/922E/923E
6.6.5 H5 Abnormal increase of hydraulic oil temperature
Abnormal hydrau-
lic oil temperature
Yes
Check whether the Add oil to the

hydraulic oil level is No
specified level as
Yes
Check the oil Yes Clean the oil

cooler for cooler to keep the
No
Check whether the Adjust the belt

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

pressure of the main Yes Adjust the setting
relief valve, the port pressure again.
relief valve and the
No
Check whether the The check valve is

No
oil return check failed. Replace it.
valve is normal.
6-491
Mechanical System
6.6.7 H6 Slewing abnormally to Left and Right Directions
Slewing abnormally to
left and right directions
Yes
Whether other Troubleshoot it by referring to the

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

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

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

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

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

Clean or replace the
inside the pilot line pilot line.
6-492
6.6.8 H7 No Response for Slewing Single Direction Operation CLG920E/922E/923E
6.6.8 H7 No Response for Slewing Single Direction Operation
No reponse for
slewing single
direction opeation
Yes
Check whether the

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

The swing valve element
swing valve element Yes
gets stuck: Remove it,
gets stuck.
Swing relief valve fault:

No
Remove, repair or replace it.
7
6-493
Mechanical System
6.6.9 H8 Slewing cannot be Stopped
Rotation unable to
stop
Yes
Check whether the

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

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

Swing relief valve fault:
swing relief valve No
Remove or replace it.
pressure is normal.
LG922E930E06140
6-494
6.6.10 H9 Fail to Actuate Unilateral Travel Mechanism CLG920E/922E/923E
6.6.10 H9 Fail to Actuate Unilateral Travel Mechanism
Fail to actuate
unilateral travel
mechanism
Yes
Whether other Check whether the The travel valve

operation is No travel valve element Yes element gets stuck:
unresponsive or not? gets stuck. Remove and repair it.
No
Check whether the Clean or replace the pilot

travel pilot pressure is Travel pilot line and
No line. Travel pilot valve fault:
normal. pilot valve fault
Yes
Yes Check whether the The travel motor balance

travel motor balance Yes valve gets stuck: Remove,
valve gets stuck. repair or replace it.
No
Travel motor and

reducer fault: Remove
and repair it.
Troubleshoot
according to H3.
LG922E930E06141
6-495
Mechanical System
6.6.11 H10 Travel Deviation
Travel deviation
Yes
Let both left and right sides of

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

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

No Remove and repair it.
is functioning properly.
Yes
Main control valve fault:

Exchange the left pump output

hose and negative feedback
Hydraulic pump fault:
hose with the right ones, and Yes Remove and repair it.
check whether the fault
phenomenon transfers.
LG922E930E06142
6-496
6.6.12 H11 Slow Speed of the Boom, Arm or Bucket CLG920E/922E/923E
6.6.12 H11 Slow Speed of the Boom, Arm or Bucket
Slow speed of the

boom, arm or bucket
Yes
Whether the Adjust the engine

engine speed is No speed.
normal
Yes
Check whether the left Check whether both the Main pump fault:
and right traveling No left speed and the right Yes Remove and repair
speeds are normal. speed are slow. it.
No
Check whether the Check the pilot line Clean or repair the
boom, arm or bucket No inside for clogging or Yes pilot line.
pilot pressure is normal. leakage.
Yes No
Pilot valve fault:
Check whether the pilot valve is
No Remove and repair
functioning properly
it.
Check whether the

Check whether the pilot Just as above-
confluence is normal when
the boom rising or the arm No pressure of the boom (2) No mentioned, check the
expanding. or the arm (2) is normal. pilot line and pilot valve
Yes
Check whether the
Check whether the
above-mentioned valve Yes confluent valve element
element gets stuck. spring is functioning
No properly.
Yes
Confluent valve element Replace
gets stuck: Remove and No
repair it.
spring
Check the pilot line Pilot valve fault:

Check whether the boom,
arm or bucket pilot pressure No inside for clogging or No Remove and repair it.
is normal. leakage.
Clean or repair the pilot

Yes Yes line.
Check whether the Valve element gets

above-mentioned valve Yes stuck: Remove or
element gets stuck.
replace
No
Check whether the main Relief valve fault:
relief valve and the port relief
valve are functioning No Remove, repair or
properly. replace it.
Cylinder inside
Yes damage: Remove
and repair it.
LG922E930E06143
6-497
Mechanical System
6.6.13 H12 Weak Actions of the Boom, Arm or Bucket
Weak actions
of the boom,
arm or bucket
Yes
Check whether the Main relief valve fault:
main relief valve No Adjust the pressure, and
pressure is normal. repair or replace the valve.
Yes
Check whether the Port relief valve fault:
port relief valve No Adjust the pressure, and
pressure is normal. repair or replace the valve.
Yes
Check whether the Cylinder fault:
No
cylinder leakage rate Remove and repair it.
is normal.
Troubleshoot according
Yes
to the H11 fault.
LG922E930E06144
6-498
6.6.14 H13 Significantly Reduced Engine Speed or Engine Stalling CLG920E/922E/923E
6.6.14 H13 Significantly Reduced Engine Speed or Engine Stalling

Precautions:
(1) Shut down the engine and prepare to run the engine at high speed, and then conduct fault diagnosis.
(2) Check the harness connectors for looseness in advance.
Significantly reduced
engine speed or Check whether the system Main relief
Yes No
engine stalling, pressure is normal. valve fault
shutdown
Yes
Check whether the main Pump proportional

pump proportional valve is No valve fault: Repair
functioning properly. or replace it.
Yes
Engine or electronic
control system fault
LG922E930E06145
7-1
September 15, 2020 Removal and Installation
CLG920E/922E/923E
7 Removal and Installation

7.1 Overview ............................................................................................................................. 7-3
7.2 Power System ..................................................................................................................... 7-4
7.2.1 Removal and Installation of Diesel Engine Assembly ...................................................... 7-4
7.2.2 Removal and Installation of Hydraulic Oil Radiator........................................................ 7-12
7.2.3 Removal and Installation of Intercooler.......................................................................... 7-16
7.2.4 Removal and Installation of Water Radiator .................................................................. 7-20
7.2.5 Removal and Installation of Fuel Tank Assembly .......................................................... 7-24
7.2.6 Removal and Installation of Injector ............................................................................... 7-28
7.2.7 Removal and Installation of Engine Front Seal .............................................................. 7-33
7.2.8 Removal and Installation of Engine Rear Seal .............................................................. 7-39
7.2.9 Removal and Installation of Cylinder Head Assembly ................................................... 7-46
7.2.10 Removal and Installation of Fuel Cooler ...................................................................... 7-50
7.3 Track Travel System ......................................................................................................... 7-51
7.3.1 Removal and Installation of Track Roller ....................................................................... 7-51
7.3.2 Removal and Installation of Carrier Roller ..................................................................... 7-53
7.3.3 Removal and Installation of Track Assembly ................................................................. 7-55
7.3.4 Removal and Installation of Sprocket ............................................................................ 7-57
7.3.5 Removal and Installation of Idler Assembly and Tensioner Assembly .......................... 7-58
7.3.6 Removal and Installation of Revolving Frame ............................................................... 7-60
7.3.7 Removal and Installation of Slewing Bearing................................................................. 7-62
7.4 Covering Parts .................................................................................................................. 7-64
7.4.1 Removal and Installation of Engine Hood ...................................................................... 7-64
7.4.2 Removal and Installation of Counterweight ................................................................... 7-67
7.5 Hydraulic System .............................................................................................................. 7-69
7.5.1 Removal and Installation of Center Joint Assembly....................................................... 7-69
7.5.2 Disassembly and Assembly of Center Joint................................................................... 7-72
7.5.3 Removal and Installation of Hydraulic Oil Tank ............................................................. 7-76
7.5.4 Removal and Installation of Main Control Valve Assembly............................................ 7-80
7.5.5 Disassembly and Assembly of Main Control Valve........................................................ 7-85
7.5.6 Removal and Installation of Main Pump Assembly ...................................................... 7-109
7.5.7 Removal and Installation of Main Pump Assembly ...................................................... 7-113
7.5.8 Removal and Installation of Travel Pilot Valve Assembly ............................................ 7-138
7-2
Removal and Installation September 15, 2020
CLG920E/922E/923E
7.5.9 Disassembly and Assembly of Travel Pilot Valve ....................................................... 7-141

7.5.10 Removal and Installation of Hand Pilot Valve Assembly ........................................... 7-164
7.5.11 Disassembly and Assembly of Hand Pilot Valve Assembly ...................................... 7-167
7.5.12 Removal and Installation of Travel Motor & Speed Reducer .................................... 7-186
7.5.13 Disassembly and Assembly of Travel Motor & Speed Reducer Assembly ............... 7-191
7.5.14 Removal and Installation of Slewing Motor & Speed Reducer .................................. 7-245
7.5.15 Disassembly and Assembly of Slewing Motor & Speed Reducer ............................. 7-249
7.6 Work Implement ............................................................................................................. 7-278
7.6.1 Removal and Installation of Bucket ............................................................................. 7-278
7.6.2 Removal and Installation of Link and Lever ................................................................ 7-281
7.6.3 Removal and Installation of Arm ................................................................................. 7-284
7.6.4 Removal and Installation of Boom............................................................................... 7-287
7.6.5 Removal and Installation of Work Implement Assembly ............................................. 7-292
7.6.6 Removal and Installation of Bucket Cylinder Assembly .............................................. 7-296
7.6.7 Removal and Installation of Arm Cylinder Assembly................................................... 7-300
7.6.8 Removal and Installation of Boom Cylinder Assembly ................................................ 7-304
7.6.9 Disassembly and Assembly of Cylinder ...................................................................... 7-308
7.7 A/C System .................................................................................................................... 7-318
7.7.1 Removal and Installation of A/C Compressor Assembly ............................................. 7-318
7.7.2 Removal and Installation of A/C Evaporator Assembly ............................................... 7-321
7.8 Cab................................................................................................................................. 7-327
7.8.1 Removal and Installation of Cab ................................................................................. 7-327
7.8.2 Removal and Installation of Floor Frame Assembly .................................................... 7-333
7-3
CLG920E/922E/923E Removal and Installation
September 15, 2020 7.1 Overview
7.1 Overview
This chapter introduces the removal and installation methods for the main parts of this machine.
The removal and installation of components introduce the methods for removing and installing the component
for the entire machine. The disassembly and assembly of a component introduce the method for
disassembling the component into subcomponents and the method of assembly.
7-4
7.2 Power System CLG920E/922E/923E
7.2 Power System

7.2.1 Removal and Installation of Diesel Engine Assembly
Removal
Before removal, remove the battery negative (-) cable first in order to avoid electric arcs.
When the engine is operating, the anti-freeze is in the high–temperature state. Make sure the diesel
engine stops working and antifreeze is cooled before removing the water radiator or opening its cap in
order to prevent potential personal injuries.
Before removal, rotate the machine revolving frame to an angle suitable for removing. Park the
machine on plain and hard ground, then lower and shut down the work implement.
Figure Steps
1. Remove the engine hood (1). Refer to "Removal
and Installation of Engine hood" in this chapter for
details.
7-5
September 15, 2020 7.2 Power System
Figure Steps
2. Remove three bottom plates (2), (3) and (4).
3. Prepare a container for receiving antifreeze, open

water drain valve (5), and discharge antifreeze in
the water radiator.
Caution: Open the tank cap to accelerate the
water discharge time.
Caution: the capacity of anti-freeze in the

cooling system is about 25L (6.6US gal).It is
forbidden to directly discharge the anti-freeze to
ground so as to prevent from contaminating the
environment.
Caution: For safety operation, firstly make

sure the battery negative (-) cable is removed, and
then go to the next step.
4. Disconnect the negative (-) ground harness (6)

and the positive (+) connecting harness (7) from
the starter motor.
7-6
Figure Steps
5. Disconnect the connecting water hose at the
upper part of the engine:
5.1 Disconnect the engine water outlet pipe (8).
5.2 Disconnect the engine degassing pipe (9),
5.3 Disconnect the A/C heater water intake pipe (10)
and remove its fixing support;
6. Remove the intercooler tube (11) and the

intercooler hose (12);
7. Disconnect the intake hose (13) connecting the
turbocharger;
Caution: After disconnected, the intake line
and the inlets of the engine must be masked to
prevent engine wear due to dust and other foreign
matters entering the air intake system.
8. Disconnect the harness connecting the alternator

(14).
9. Remove the harness fixing support (15)
assembled on the engine cylinder block.
7-7
Figure Steps
10. Disconnect the frame harness from the engine:
1) Disconnect the A/C compressor harness
connector (16);
2) Disconnect the air intake heater harness (17);
3) Disconnect the connector (18) connected with
the engine ECM,
4) Remove the frame harness mounting support
(19);
11. Remove the fan guard (20);
12. Remove the A/C compressor (21) and place it on

the counterweight
7-8
Figure Steps
13. Remove the engine fan (22);
14. Disconnect the connecting water hose at the

lower part of the engine:
1) Disconnect the engine water supply hose (23),
2) Disconnect the A/C heater water return pipe (24);
15. Remove the right grill (25) of the covering part and
the main pump baffle (26).
7-9
Figure Steps
16. Close the fuel shutoff valve (27) of the oil line,
17. Disconnect the oil return pipe (28) and oil inlet
pipe (29) connecting the engine and two fuel
pipes (30), (31) connecting the remote secondary
filter;
Caution:
When removing the oil return pipe on the engine,

the oil port must be plugged or the oil return pipe
must be fixed at a height above the fuel liquid
level in the fuel tank in order to prevent from the
fuel flowing back.
After removing the fuel line, the oil ports on the

line and the engine must be masked to prevent
dust and other foreign bodies from entering the
fuel system to cause engine damages.
Meanwhile, pipeline must be identified to indicate

its mounting ports.
18. Remove the oil-filter mounting support (32) from

32 the main pump or cover, and bind the support
33 together with the engine oil filter (33) onto the
engine.
7-10
Figure Steps
19. Lift the main pump (34) with a lifting sling, remove
flange (35) mounting bolts, and move the main
pump and the flange outwards together so that
35 the coupler bushing is separated from the engine
34 flywheel.
(The total weight of the main pump and flange is
about: 180kg/397lb.)
20. Remove 4 shock absorber mounting bolts (36) on

the engine bracket.
36
21. Check the components around the engine, slowly

lift the diesel engine (37) after confirming that
there is no effect on lifting, and put it in a safe
place.
(Total weight of the engine, muffler, and other
components is about: 630kg/ 1389lb)
37
7-11
Installation
The installation sequence of the diesel engine is in the reverse order of removal.
• Properly clean the air intake line before assembly.
• For tightening torques in specific positions, follow the table below, and the others are subject to general
tightening torque;
• Refill antifreeze and restore the assembly of the negative battery cable. Operate the engine and check the
line for leakages and whether the water radiator is filled with antifreeze.
• Table for bolt tightening torques in specific positions:
Position Grade Tightening torque

Iron flywheel housing M10-10.9 65 N·m(48lbf·ft)
Iron flywheel housing M12-10.9 115 N·m(85lbf·ft)
Mounting bolts for couplers and flywheels M18 350 N·m(236lbf·ft)
Coupling bushing mounting bolts M16 120 N·m(88.5lbf·ft)
Shock absorber mounting bolt M22-10.9 800N·m(590lbf·ft)
Shock absorber mounting bolt M24-10.9 1020N·m(752lbf·ft)
If the coupling bushing(A) is removed from the main pump, the spline shaft of main pump must be
pushed to the snap ring (B) inside the coupling bushing and then locked up (the snap ring in the
coupling bushing is used for locating the assembly position of the main pump spline shaft).
7-12
7.2.2 Removal and Installation of Hydraulic Oil Radiator

Removal
Before removal, rotate the machine revolving frame to an angle suitable for removal, lower the work
implement to ground, shut down to park the machine, relieve accumulator pressure, open the
hydraulic oil tank cover to relieve pressure inside, and pump out the hydraulic oil from the tank.
Before removal, remove the battery negative (-) cable first to avoid electric arcs.
Seal the lines, fittings or hoses with plugs or caps when they are in disassembling state to prevent
pollution source from entering the hydraulic system.
Before removing pipelines, fittings, or hoses, it is necessary to clean the assembled oil port.
Figure Steps
1. Remove the engine hood (1). For details, refer to
“Removal and Installation of Engine Hood” in this
chapter.
7-13
Figure Steps
2. Remove the plate (2) under the platform;
3. Disconnect the oil inlet pipe connector (3) of the

hydraulic oil cooler and the oil inlet tube (4) at the
bottom;
Caution: After removing the oil inlet and
outlet pipe of the hydraulic oil cooler, check
whether the O-ring at the oil port is damaged.
3
Immediately make replacement in case of
damages, to prevent oil leakages after assembly
is restored.
4. Drain the hydraulic oil.

Caution: Collect the hydraulic oil with an
appropriate container with the capacity of about
6L (1.6US gal)
4
7-14
Figure Steps
5. Remove the 4 mounting bolts (5) at the side of the
hydraulic oil cooler;
6. Hook the hydraulic oil radiator (6) with a steel wire

rope, and slowly lift it out of the radiator frame.
Caution: Be careful not to scratch the
6 hydraulic oil radiator core during lifting.
Caution: be careful not to scratch the oil port

flange surface when lifting the hydraulic oil
radiator, which may cause oil leakage after
assembly is restored.
7-15
Installation
The installation sequence is in the reverse order of removal.
• Clean the components to be assembled properly before assembly.
• The tightening torque shall be matched up with the general specifications; Torque of pipe joint M10 screw:
28± 3N.m (20.65±2.21 lbf.ft)
• Refill hydraulic oil. Refill the hydraulic oil to the specified level via the filler. Restore the assembly of the
negative battery cable, operate the engine, make hydraulic oil circulate in the hydraulic system, check the
oil level once again and check the line for leakages.
7-16
7.2.3 Removal and Installation of Intercooler

Removal
Before removal, park the machine on flat and hard ground, and lower and shut down the work
implement.
After removing the air intake line, the air inlet of the intercooler, intercooler pipe and engine must be
masked immediately to prevent dust and other foreign matters from entering the air intake system to
cause engine wear.
Figure Steps
1. Rotate the machine revolving frame to an angle
suitable for removal, and remove the engine hood
(1). For details, refer to the “Removal and
Installation of Engine Hood” section in this
chapter.
7-17
Figure Steps
2. Remove the plate (2) under the platform;
3. Disconnect the connector (3) connecting the

intercooler.
4. Disconnect the hose (4) connecting the

intercooler.
7-18
Figure Steps
5. Remove the 4 mounting bolts (5) at the side of the
intercooler;
6. Hook the hydraulic oil radiator (6) with a steel wire

rope, and slowly lift it out of the radiator frame.
hydraulic oil radiator core during lifting.
7-19
Installation
• Properly clean the inner wall of the air intake pipe before assembly.
• The tightening torque shall be matched up with the general specifications;
• Restore the assembly of the negative battery cable, and operate the engine to check the line for leakages.
7-20
7.2.4 Removal and Installation of Water Radiator

Removal
Before removal, rotate the machine revolving frame to an angle suitable for removing. Park the
machine on plain and hard ground, then lower and shut down the work implement.
When the engine is operating, the anti-freeze is in the high–temperature state. Make sure the diesel
engine stops working and antifreeze is cooled before removing the water radiator or opening its cap in
order to prevent potential personal injuries.
Figure Steps
1. Remove the engine hood (1). For details, refer to
“Removal and Installation of Engine Hood” in this
chapter.
7-21
Figure Steps
2. Remove the bottom plate (2) under the radiator;
3. Prepare a container for receiving antifreeze; open

the water drain valve (3), and discharge antifreeze
in the water radiator (open the water tank cover to
accelerate water discharge time);
Caution: the capacity of anti-freeze in the
cooling system is about 25L (6.6US gal).It is
forbidden to directly discharge the anti-freeze to
ground so as to prevent from contaminating the
environment.
4. Disconnect the line connected to the water

radiator: water inlet pipe (4), degassing pipe (5)
and overflow pipe (6).
5. Remove the upper cover plate (7) of the shroud.
7-22
Figure Steps
6. Disconnect the water outlet pipe (8) at the lower
end of the water radiator.
7. Remove the lower cover plate (9) of the shroud
8. Remove 4 mounting bolts (10) at the side of the

water radiator.
7-23
Figure Steps
9. Hook the water radiator (11) with a steel wire rope,
and lift it out of the radiator frame.
radiator core during lifting.
Installation
• Clean the components to be assembled properly before assembly.
• The tightening torque shall be matched up with the general specifications;
• Refill antifreeze and restore the assembly of the negative battery cable. Operate the engine and check the
line for leakages and whether the water radiator is filled with antifreeze.
7-24
7.2.5 Removal and Installation of Fuel Tank Assembly

Removal
Before removal, park the machine on flat and hard ground, and lower and shut down the work
implement.
Prepare two appropriate fuel drums for receiving fuel during disassembly which can be reused.
Figure Steps
1. Operate the excavator and let the upper
equipment turn to the direction for convenience of
draining the diesel oil and removal. Open the oil
drain valve (1) to drain the diesel oil into the tank.
Caution: Collect the diesel oil with suitable
barrel, and the capacity of reusable fuel tank is
about 420L (111US gal)
7-25
Figure Steps
2. Remove two bottom plates (2) and (3) under the
fuel tank;
3. Disconnect three fuel pipes at the bottom of the

fuel tank: fuel drain pipe (4), suction pipe (5), and
return pipe (6).
Caution: After removal, the openings of the
fuel pipe opening and the port of the diesel fuel
tank must be masked immediately to prevent dust
and other foreign bodies from entering the fuel
system to cause engine damages.
4. Disconnect the harness (7) of the fuel level

sensor;
7-26
Figure Steps
5. Remove the handrail (8) and the trim cover (9);
Caution: If a machine model is equipped with
a fuel filling system, first remove the fuel refueling
pump filler pipe assembled on the fuel tank, and
go to the next step.
6. Remove the 6 mounting bolts (10) at the bottom of

fuel tank;
7. Check the connecting parts around the fuel tank

and make sure that they will impose no influence
on the lifting of the fuel tank. Afterwards, lift the
fuel tank via lifting rings welded at the top and the
sides of the fuel tank, and put it in a safe place.
7-27
Installation
• For the tightening torque of bolts, refer to the general tightening torque.
• Refuel, restore the assembly of the negative battery cable, operate the engine, check the line for leakages
and check whether the fuel level indication on the display is normal or not.
7-28
7.2.6 Removal and Installation of Injector

Removal
Figure Steps
1. Remove two injector packing screws, and remove
the injector packing clamp.
2. Remove the injector from the cylinder head.
Caution: The injector can also be pried out
using a small-size crowbar. Pry out the injector
packing flange (one part of injector body and right
above the cylinder head casting).
3. After removing the injector, make sure the injector

sealing washer is still connected at the bottom of
the injector. If the injector sealing washer is still in
the injector hole, it must be removed.
4. If the sealing washer is folded into two layers or
the sealing washer is incorrect, the injector
protrusion may be incorrect to cause high-
pressure fuel leakage and/or performance
problems.
7-29
Installation
Figure Steps
1. Check whether the thickness of the new injector
sealing washer is correct. The standard thickness
value of the injector sealing washer: d = 1.5mm
(0.059In)
Caution: If the sealing washer is incorrect,
the injector protrusion may be incorrect, causing
high-pressure fuel leaking and/or performance
problems.
Caution: There are two types of sealing

washers: flat washer (1) or disk washer (2). To
replace the injector sealing washer, only disk
washer rather than flat washer must be used.
Verify that a new appropriate sealing washer has
been installed at the injector end.
Caution: The used sealing washer may not be

"disk" due to the installation.
7-30
Figure Steps
2. Make sure the injector hole is clean and only one
sealing washer is installed at the injector nozzle.
3. The circular edge of the injector packing clamp
shall face to the rocker arm. The oil inlet hole on
the injector must face to the engine air intake side.
4. Use clean engine oil to lubricate injector O-ring.
5. Align the injector in the cylinder head in the
correct direction (fuel inlet port facing to the high-
pressure fuel connector).
6. Use a socket for injector transportation, and make
sure the injector is seated in the injector hole.
Caution: If injector solenoid valve
transportation cover is not used during the
installation of the injector, be careful not to apply
pressure to the conductor terminal. If the
conductor terminal is used to push the injector,
the terminal may be fractured.
7. Lubricate the fuel connector O-rings and the
threads of the fuel connector retaining nuts with
clean engine oil.
8. Be careful to insert the fuel connector.
9. Align the guide link with the anti-rotation slot in the
cylinder head and locate it in the 12 o'clock
position.
10. Install the high-pressure fuel connector retaining
nuts without tightening.
Caution: Apply uniform axial force during
installation to avoid damages. Make sure the O-
rings cannot be torn up during installation of the
connector.
7-31
Figure Steps
11. Install the injector packing parts and the injector
packing screws without tightening.
12. Apply initial torque to the fuel connector retaining
nuts, and start to seat the fuel connector in the
injector.
Torque value: 15 N·m (11lbf·ft)
Caution: This is not the final tightening
torque of the high-pressure fuel connector
retaining nut.
13. Tighten the injector packing screws.

Caution: Make sure to evenly tighten the
packing screws. Check to make sure the
clearance between the packing clamp and the
injector is equal to the interval around the injector
body. Alternately tighten the screws with one turn
by 90° until all of them reach the standard.
Torque value: 8 N·m (5.9lbf·ft)
14. Tighten the high-pressure fuel connector retaining

nuts.
Caution: Do not excessively tighten the
connector retaining nuts. Excessive tightening of
the retaining nuts may cause the connector to be
rotated out of the connector retaining groove. Do
not excessively tighten the fuel connector
retaining nuts. Excessive tightening of the
retaining nuts may cause the connector to be
rotated out of the connector retaining groove.
7-32
Figure Steps
15. For an engine equipped with a crankcase breather
installed on a rocker cover, the rocker cover
gasket must be installed before connecting the
injector solenoid valve conductor.
16. Connect the injector solenoid valve conductor to
each injector. Tighten the solenoid valve
conductor with Cummins ® service tool (part
number: 3823208) or torque wrench.
Caution: If the applied torque is too large, the
injector solenoid valve terminal will yield to cause
possible faults. Do not tighten it excessively.
Torque value: 1.5 N·m (11lbf·ft)
Make sure the solenoid valve conductor is not in

contact with the rocker arm during installation.
7-33
7.2.7 Removal and Installation of Engine Front Seal

Removal
Front crankshaft oil seal replacer toolkit (part number: 3164659)
Project No. Part number Description Quantity

1 3164667 Replace screw assembly 1
2 3164661 Crankshaft oil seal replacer 1
3 3164239 Hexagon socket screw, M12x1.25x60mm 2
4 3164217 Sheet metal screw, 10x25.4 mm 25 (6 shown)
Not shown 3164218 Drill bit 3.57mm (0.14In) 1
The crankshaft oil seal can be removed and installed without removing the front gear chamber cover.
7-34
Figure Steps
1. Remove the front crankshaft oil seal from the front
gear chamber cover with the tool (part number:
3164659)
2. Mount the replacer screw assembly (1) at the front
end of the crankshaft; mount 2 M12x12.5x60-mm
hex screw (3).
3. Lubricate the replacer screws with bond breaker

or appropriate grease.
4. Fix the replacer screws, and install the crankshaft
oil seal replacer (2) on the replacer screw as.
Rotate the crankshaft oil seal replacer clockwise,
and push it toward the oil seal until it touches the
front gear chamber cover.
7-35
Figure Steps
Caution: A small-size right-angle drilling

machine may be required due to space
limitations. The drill used for drilling screw holes
in the metal plate may also be shortened.
Caution: Drill the holes in the vertical

direction to reduce the possibility of damaging
the front cover or crankshaft.
Caution: Flange thickness of the crankshaft

oil seal replacer is 8 mm (0.315In).
5. Make a mark with tape at the drilling depth of 18

mm (0.709In) to control the drilling depth, and
apply grease to the drill to absorb metal drilling.
Stop drilling frequently to clear drilling.
6. Drill a hole with the depth of 10mm (0.39In) after
the crankshaft oil seal replacer touches the front
gear chamber cover. Make sure the marked tape
does not deviate from the original position.
7. Install one sheet metal screw (4) on the oil seal to
fix the crankshaft oil seal replacer in place.
8. Drill another 5 holes with a depth of 10 mm
(0.39In), and then install 5 sheet metal screws.
Caution: Make sure all the six sheet metal
screws pass through the inner and outer seal
housings. The sheet metal screws need to be
tightened alike to pull the entire inner and outer
seal housings.
7-36
Figure Steps
9. Slowly rotate the replacer screws clockwise until
the oil seal is replaced. Do not exceed the torque
value.
10. Remove the tool and discard the old seal upon the
completion of removal.
Caution: Do not use an impact wrench or
pneumatic tool. This will damage the tool.
Torque value: 33 N·m (24lbf·ft)
Caution: If the oil seal is pulled out by the

sheet metal screws or only the inner housing is
pulled out, then stop removing. Rotate the
replacer screws counterclockwise to force the
inner housing to exit. Remove the sheet metal
screws, lightly reorient the direction of the tool,
drill several new holes, and install sheet metal
screws in the new positions.
7-37
Installation
Figure Steps
1. Install the oil seal in the front gear chamber cover
with the tool (part number: 3164659)
2. Install the replacer screw assembly(1) at the front

end of the crankshaft. Install two M12x1.25x60-
mm hex screws (3).
7-38
Figure Steps
3. Place a new crankshaft oil seal at the front end of
the crankshaft, and slide it to the furthest position
toward the front gear chamber cover by hand as
much as possible.
Caution: Make sure the oil seal is in a right

angle with the crankshaft.
4. Install the crankshaft oil seal replacer (2) on the

replacer screw as while fixing the replacer screws.
5. Rotate the crankshaft oil seal replacer clockwise
oil seal.
6. Rotate the replacer screws counterclockwise until
the crankshaft oil seal replacer touches the front
gear chamber cover while fixing the crankshaft oil
seal replacer.
Caution: Do not tighten the replacer screw as
excessively after the crankshaft oil seal replacer
touches the front cover. This will damage the tool.
7-39
7.2.8 Removal and Installation of Engine Rear Seal

Tool(s)
Crankshaft rear oil seal replacer gp (part number: 3164660)
No. Part number Description Quantity

1 3164666 Replacer screw assembly 1
2 3164664 Crankshaft oil seal replacer 1
3 3164174 Hexagon socket head screw, M12x12.5x25mm 2
4 3164217 Sheet metal screw, 10×25.4 mm (0.39×1 In) in length 25 (7 shown)
Disposable plastic screwdriver (purchased together with
5 - 1
the crankshaft rear oil seal group)
Removal
Explosive gas may leak from the battery. To avoid personal injury, the engine compartment must be
with good ventilation before the maintenance of the battery. To avoid generating the electric arc, the
wire of the battery negative pole (-) must be removed at first and connected at last.
The weight of this component or assembly is more than 23 kg. Make sure to seek help or use
appropriate hoisting equipment to lift this component or assembly to prevent serious personal
injuries.
Use one container at least holding 26 L engine oil.

7-40
Figure Steps
Caution For the crankshaft rear lip oil seal

used in the engine involved in this step, the seal
rotating section is the contact surface between
the oil seal lip and the crankshaft.
1. Disconnect the battery.

2. Remove the main pump.
3. Remove the flywheel.
4. Remove the crankshaft rear lip oil seal using

screws and one sliding weight.
Caution: This step does not apply to the
engine with combined oil seals.
5. Drill two holes with 180°apart in the rigid section of

the oil seal.
6. Install two sheet metal screws with coarse-pitch

threads in the just drilled holes.
7. Remove the crankshaft rear oil seal with the
sliding weight.
7-41
Figure Steps
8. Clean the surface and hole of the crankshaft rear
oil seal with a solvent.
9. Blow the surface with compressed air.
Clean it and check whether it can be used continu-
ously.
Caution: When cleaning with solvent, acid, or
alkali materials, please follow the advice of the
manufacturer. Wear the goggle and the protective
suit to avoid personal injury.
Caution: You shall wear the proper goggle

personal injury.
Caution: Engine oil shall not remain on the

sealing lip or sealing surface of the crankshaft to
prevent oil seal leakages.
Installation
Figure Steps
1. Apply mild soap at the outer neck of the sealing
housing to facilitate installation.
Caution: Always replace the crankshaft rear
oil seal with the same type to the previously
installed ones. The installation of different types
of oil seals (lip seals, combined seals, etc.) may
cause engine oil leakages.
Caution: Engine oil shall not remain on the

sealing lip/hole or sealing surface of the
crankshaft to prevent oil seal leakages.
Caution: An oil seal guide tool (B) is provided

for a new oil seal on the engine with the rear
crankshaft lip oil seal. When installing the oil seal
on the front end of the crankshaft, this oil seal
must leave on the oil seal guide tool. This can
make sure not to damage the oil seal lip during
installation.
7-42
Figure Steps
2. Place the new crankshaft rear oil seal at the front
end of the crankshaft with the oil seal guide tool,
and slide it towards the flywheel housing by hand.
Caution: Make sure the oil seal is in a right
angle with the crankshaft.
Remove the oil seal guide.

Caution: Always replace the crankshaft rear
oil seal with the same type to the previously
installed ones.
3. Each new crankshaft lip oil seal is equipped with

one disposable oil seal screwdriver.
4. With the oil seal screwdriver (2) (usually plastic
ring) used for the rear gear train engine, install the
crankshaft oil seal at the correct depth in the
flywheel housing hole.
5. For the rear gear train engine, the disposable

plastic screwdriver attached to the new crankshaft
rear oil seal can be designed to be used for two
types of oil seals.
6. Double outer dust-proof crankshaft rear lip oil seal
- for this type of oil seal, one side of the
disposable screwdriver (1) with a big angle of
chamfer on the inner diameter must be in contact
with the crankshaft rear oil seal.
7. Single outer dust-proof crankshaft rear lip oil seal -
for this type of oil seal, one side of the disposable
screwdriver (2) with a small angle of chamfer on
the inner diameter must be in contact with the
crankshaft rear oil seal.
7-43
Figure Steps
Caution: Tap the crankshaft rear oil seal with

one plastic hammer to assist installing the oil seal
if no disposable oil seal screwdriver is available.
Install the oil seal at the correct depth of the

housing using the disposable oil seal screwdriver
attached to each new crankshaft rear oil seal.
Press the oil seal into the housing with a plastic

hammer until the aligning tool touches the
housing.
Tap the position point 12, 3, 6, and 9 on the tool,

and evenly press in the oil seal to avoid bending
the oil seal carrier.
8. Alternative method:
For a rear gear train engine, 2 holes are designed at
the outer ring of the disposable plastic screwdriver
attached to the new crankshaft rear oil seal. These
holes are designed to use the screwdriver together
with the crankshaft oil seal replacer group (part num-
ber: 3164660).
9. For the oil seal type to be installed, make the
correct side of the disposable screwdriver towards
the outer side, and push the disposable
screwdriver to the center of the crankshaft oil seal
replacer.
10. Fix the disposable screwdriver on the crankshaft
oil seal replacer. Use two sheet metal screws (No.
10, 19 mm long).
Caution: Do not use sheet metal screws
attached to the crankshaft rear oil seal replacer
group (service tool part number: 3164660). These
sheet metal screws are too long. To select correct
sheet metal screws, make sure the top ends of the
sheet metal screws will not protrude out of the
end face of the screwdriver. Or the crankshaft oil
seal may be damaged.
7-44
Figure Steps
11. After the crankshaft rear oil seal is installed on the
crankshaft flange as previously described in this
step, install the replacer screw as (1) at the rear
end of the crankshaft.
12. Install two M12x1.25x60-mm hex screws (3).
13. Lubricate the replacer screws with bond breaker

or appropriate grease.
14. Fix the replacer screws, and install the crankshaft
oil seal replacer (2) on the replacer screw as.
15. Rotate the crankshaft oil seal replacer clockwise,
crankshaft rear oil seal.
16. When fixing the crankshaft oil seal replacer, rotate

the replacer screws counterclockwise until the
disposable screwdriver attached to the crankshaft
oil seal replacer touches the flywheel housing.
Caution: Do not tighten the replacer screw as
excessively after the crankshaft oil seal replacer
touches the flywheel housing. This will damage
the tool.
17. Install the flywheel in case of removal.

18. Installed the main pump.
19. Connect the battery.
20. Operate the engine, and check for leakages.
7-45
Last step
The weight of this component or assembly is more than 23 kg (51 lb). Make sure to seek help or use
appropriate hoisting equipment to lift this component or assembly to prevent serious personal injuries.
Explosive gas may leak from the battery. To avoid personal injury, the engine compartment must be with good
ventilation before the maintenance of the battery. To avoid generating the electric arc, the wire of the battery
negative pole (-) must be removed at first and connected at last.
7-46
7.2.9 Removal and Installation of Cylinder Head Assembly

Removal
The weight of this component or assembly is more than 23 kg (51 lb). Make sure to seek help or use
appropriate hoisting equipment to lift this component or assembly to prevent serious personal
injuries.
If the cylinder head equipped with an injector is removed, make sure not to damage the injector end.
Do not put the cylinder head equipped with an injector on combustion front with the mouth facing
downwards. Or the injector end may be damaged.
Figure Steps
1. Remove the cylinder head screws and the
cylinder head.
2. Remove the cylinder head gasket from the

cylinder block.
7-47
Installation
Plug torque value

Dimension Torque Torque
Actual thread external Install it into aluminum Install it into the cast iron
Thread
diameters components. or steel components.
in. mm [in] N.m [ft-lbs] N.m [ft-lbs]
1/16 8.1 [0.32] 5 [45 in-lb] 15 [10]
1/8 10.4 [0.41] 15 [10] 20 [15]
1/4 13.7 [0.54] 20 [15] 25 [20]
3/8 17.3 [0.68] 25 [20] 35 [25]
1/2 21.6 [0.85] 35 [25] 55 [40]
3/4 26.7 [1.05] 45 [35] 75 [55]
1 33.5 [1.32] 60 [45] 95 [70]
1¼ 42.2 [1.66] 75 [55] 115 [85]
1½ 48.3 [1.90] 85 [65] 135 [100]
Figure Steps
1. Install the cylinder head gasket.
Caution: Make sure the gasket is correctly
aligned with the hole in the cylinder block. If the
gasket is not correctly aligned, the cylinder block
may be damaged.
7-48
Figure Steps
2. Be careful to put the cylinder head on the cylinder
boy, and seat it on the locating pin.
Caution: The weight of this component or
assembly is more than 23kg (51lb). Make sure to
seek help or use appropriate hoisting equipment
to lift this component or assembly to prevent
serious personal injuries.
3. Lubricate the threads of the cylinder head

mounting screws and the lower faces of the screw
ends with clean engine oil.
4. Install and tighten the screws by hand.
5. For six-cylinder engine: tighten the cylinder head

screws in the sequence shown in the figure.
6. Tighten the cylinder head screws.
7. Torque value:
Step 1 90N.m (66lbf.ft)
Step 2 Loosen and tighten again.
Step 3 90N.m (66lbf.ft)
Step 4 Rotate by 90° clockwise.
7-49
Figure Steps
8. Operate the engine until the working temperature
is reached.
9. Check whether there is no leakage.
10. Record the oil pressure reading when the engine
idling.
11. The minimum oil pressure at low engine idling is
69Kpa (10psi).
12. Increase the engine revolution to rated revolution

and continuously revolve the diesel engine for 30
seconds.
13. Record the oil pressure reading when the engine
running at the rated speed.
14. The minimum oil pressure at rated engine speed
is 207Kpa (30psi).
15. Remove the engine oil pressure gauge /

Compuchek™ pipe connectors, and then install
the plugs removed previously.
16. Apply a layer of plug sealed glue (the part number
is 3375066) or similar object on the thread.
17. Tighten pipe plugs to the appropriate torque
value.
7-50
7.2.10 Removal and Installation of Fuel Cooler

Removal
Figure Steps
1. Rotate the machine to an appropriate angle, open
the right door, open the fuel drain valve (1) and
receive the fuel with a container.
Caution: Prepare a fuel holding container to
receive the fuel from the fuel tank. (The diesel fuel
capacity is about 420L (111US gal))
2. Remove the assembly hollow bolts of the fuel

pipes (2) and (4);
3. Remove the assembly bolts of the fuel cooler (3).
Caution: After removal, the diesel pipe ports
and fuel cooler port must be masked immediately
to prevent dust and other foreign bodies from
entering the fuel system to cause damage.
Installation
• Restore the assembly of the fuel radiator first, and then reassemble the fuel pipes;
• Refuel the fuel tank;
• Operate the engine to check the fuel pipeline for leakages.
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September 15, 2020 7.3 Track Travel System
7.3 Track Travel System

7.3.1 Removal and Installation of Track Roller
Removal
Figure Steps
1. Support the complete machine so that the
platform forms a 90° angle with the travel frame,
and then support the track beam of one side.
2. Loosen the filling valve (1), discharge grease in

the tensioner, reducing the track tensioning level.
Danger: due to the high-pressure of the
internal grease, the valve may fly off. Therefore,
do not loosen the filling valve 2 for more than two
cycles.
7-52
Figure Steps
3. Remove the mounting bolts of track roller.
Installation
The installation steps are in the reverse order of removal.
• Referring to the "Measurement and Adjustment of Track Tension" in the chapter of "5. Test and Adjust-
ment", adjust the track tension to a proper level.
• Apply the anaerobic thread locker (TONSAN 1277) to the track roller mounting bolts, with the tightening
torque of 415±35N·m (306.1±25.8 lbf·ft).
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7.3.2 Removal and Installation of Carrier Roller

Removal
Figure Steps
1. Loosen the filling valve (1), discharge grease in
the tensioner, reducing the track tensioning level.
cycles.
2. Support the track beside the carrier roller (2) with

a hydraulic jack (or wooden block) to the height
suitable for the removal of carrier roller.
7-54
Figure Steps
3. Unscrew the carrier roller mounting bolts with a
wrench, and then remove the carrier roller. Take
out the carrier roller from the mounting hole
Installation
• Apply the anaerobic thread locker (TONSAN 1277) to the carrier roller mounting bolts, with tightening
torque 415±35N·m (306.1±25.8 lbf·ft).
7-55
7.3.3 Removal and Installation of Track Assembly

Removal
Figure Steps
1. Move the complete machine forwards with the
kingpin (1) in front of the idler.
2. Loosen the filling valve (2) with a wrench to

discharge grease, and reduce track tensioning
level.
cycles.
7-56
Figure Steps
3. Squeeze out the main pin with a pin squeezing
machine (3).
4. Move the complete machine forward to unfold the

track.
Installation
7-57
7.3.4 Removal and Installation of Sprocket

Removal
Figure Steps
1. For removing the track assembly, please refer to
the Section “Removal of Track Assembly”. Rotate
the work implement by 90° and jack up the
complete machine with the work implement.
1) Rotate the track to the sprocket (1) side. Unfold
the track.
2. Remove the 30 of sprocket mounting bolts, and

thenremove the sprocket.
Installation
• Apply the anaerobic thread locker (TONSAN 1277) to the sprocket mounting bolts, with tightening torque
305±25 N.m (224.9±18.44 lbf·ft).
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7.3.5 Removal and Installation of Idler Assembly and Tensioner Assembly

Removal
Figure Steps
1. For removing the track assembly, please refer to
the Section “Removal of Track Assembly”.
2. Push out the idler and tensioner (1) out of the idler
bracket with a crowbar;
7-59
Figure Steps
3. Lift the idler and tensioner assembly (1) and then
move forward for removal.
4. Remove the tensioner from the idler assembly.
Installation
• Apply the anaerobic thread locker (TONSAN 1277) to the tensioner and idler assembly connecting bolt,
with tightening torque 305 ± 25N·m (224.9 ± 18.44 lbf·ft).
7-60
7.3.6 Removal and Installation of Revolving Frame

Removal
Figure Steps
1. Remove the work implement assembly. For
details, see the “Removal and Installation of Work
Implement Assembly” section
2. Remove the counterweight assembly. For details,
see the “Removal and Installation of
Counterweight Assembly” section
3. Disconnect the hose (1) - (4).
Label on the disconnected hoses and tubes to
prevent mistakes during reinstallation.
4. Lift the boom cylinder assembly (5) temporarily.
5. Remove the plate (6) and the pin shaft (7), and
then remove the boom cylinder assembly (5).
6. Remove the opposite boom cylinder assembly in
the same steps.
7-61
Figure Steps
7. Remove bolts (8) from the center connector.
8. Disconnect hoses (9) (10) and tubes (11) - (14).
9. Label the disconnected hoses and tubes to
prevent mistakes during reinstallation.
10. Lift the platform assembly temporarily.
11. Remove the 40 mounting bolts and remove the
revolving frame assembly.
Installation
• Before installing the mounting bolts of the slewing bearing, please clean the threaded hole and then apply
the anaerobic thread locker (TONSAN 1277), with the tightening torque of 800±70N·m {590±51.6 lbf·ft}.
• Tightening torque of pin shaft fixing bolt M12: 120±10N·m {88.5±7.375 lbf·ft}.
7-62
7.3.7 Removal and Installation of Slewing Bearing

Removal
Figure Steps
1. Remove the revolving frame assembly. For
details, see the “Removal of Revolving Frame”
section
2. Remove 40 mounting bolts (1) to remove the
slewing bearing.
3. Lift the slewing bearing (2).

Weight of slewing bearing: 330Kg {727.65 lb}
7-63
Installation
• Before installing the mounting bolts of the slewing bearing, please clean the threaded hole and then apply
the anaerobic thread locker (TONSAN 1277), with the tightening torque of 800±70N·m {590±51.6 lbf·ft}
• When installing the slewing bearing, the tape mark S on the slewing bearing inner ring needs to face the
right side
Soft part of inner race
Soft part of outer race

The front of the machine
7-64
7.4 Covering Parts CLG920E/922E/923E
7.4 Covering Parts

7.4.1 Removal and Installation of Engine Hood
Removal
If the engine is in the high-temperature state when the machine works, remove the engine hoods after
the engine cools down.
Be careful not to damage the rubber sealing strip and sponge during the removal of engine hood.
Figure Steps
1. Lower down the work implement, and shut it
down.
2. Open engine hood (1).
7-65
September 15, 2020 7.4 Covering Parts
Figure Steps
3. Remove the pin (2) connecting the engine hood
and the mast with pliers.
4. After laying the engine hood flat, remove 4 bolts

(3) mounting the engine hood.
5. Lift down the engine hood, and put it on flat

ground covered by foam cardboard.
Caution: The engine hood weighs 65Kg
(143lb).
6. If there is a combined hood, lift the left hood first

and then the left hood
Caution: The engine hood weighs 62Kg
(137lb).
7-66
Installation
• The tightening torque of engine hood mounting bolts M10: 72 ± 6N·m (53.1 ± 4.4lbf·ft).
For the M12 mounting bolt, the tightening torque is 120 ±10N·m (88.5±7.4lbf·ft)
• Install and adjust the counterweight:
Tighten the four mounting bolts of the engine hood hinge. Adjust the engine hood lock if it cannot be buck-
led due to displacement.
7-67
September 15, 2020 7.4 Covering Parts
7.4.2 Removal and Installation of Counterweight

Removal
Before the removal of the counterweight, move the machine to the plain level to make sure there is no
heavy sway when lifting the counterweight in order to prevent personal injuries.
Figure Steps
1. After removing the engine hood, stably lift the
counterweight with a steel wire rope and a
hoisting equipment to prevent it from falling down
during removal.
2. Remove the 4 counterweight mounting boles

M30(1) and washers with a torque wrench.
7-68
Figure Steps
3. Lift and remove the counterweight and put it on a
plain and safe location.
Caution: Do not knock the counterweight
against the engine or radiator.
The counterweight weighs 4300kg (9482lb).
Installation
• The tightening torque of the counterweight mounting bolts M30: 4 pcs, 1850±150N·m (1364.4±110.6lbf·ft).
The bolt thread shall be coated with adhesives (TONSAN 1277, JB/T7311-2008).
• Install and adjust the counterweight:
1. Adjust the level difference or clearance difference among the counterweight, revolving frame, and covering
part by the shims.
2. Fix the counterweight to make the longitudinal clearance among the counterweight, slewing platform and
the door consistent, and the clearance should be in the range of 15 ± 3mm (0.59 ± 0.12 In).
3. The clearance between the outer profile's straight-line contoured surface of the door and the outer profile's
straight-line contoured surface of the counterweight in the transverse direction of the complete machine is
located within the range of 5±3 mm (0.20±0.12In).
4. The outer profile of the revolving frame is aligned with the outer profile of the counterweight;
7-69
September 15, 2020 7.5 Hydraulic System

7.5.1 Removal and Installation of Center Joint Assembly
Removal
Before removing the hydraulic pipe, lower the work implement completely down to the ground, shut
down the engine. Turn the key to KEY ON and operate all the hydraulic control levers several times to
release the residual pressure in the hydraulic system. Screw off the dust cap located at the breather
valve, press the exhaust valve stem located at the breather valve, and release the internal pressure of
the hydraulic tank.
Before removing the lines, fittings or hoses, marks them to prevent the wrong installation while
restoring. Clean the periphery of the assembled oil port as required, and put a drip pan to collect oil.
Figure Steps
1. Remove the 2 pilot pipes (1);
2. Remove 4 travel pipes (2);
3. Remove the 2 oil return pipes (3).
7-70
Figure Steps
4. Remove 4 travel pipes (4);
5. Remove the oil return pipe (5);
6. Remove the pilot pipe (6).
7. Remove T-clamps (7);

8. Remove the stop plates (8).
9. Pre-tension the center joint with a sling and

hoisting equipment.
7-71
Figure Steps
10. Remove 4 fixing bolts (9), and lift down the
center joint body.
Lifting weight: about 33kg (72.8lb)
Installation
• Tightening torque of center joint mounting bolt M16-10.9: 305±25N·m (224.9±18lbf·ft)
• Tightening torque of angle-sealed connector with O -ring: G3/8: 75±5N·m (55.3±3.7lbf·ft)? G3/4:
165±15N·m (121.7±11lbf·ft)
7-72
7.5.2 Disassembly and Assembly of Center Joint

Disassembly
Choose a clean location. Lay rubber plates or cloth, etc. for removal, and be careful not to damage
parts.
Figure Steps
1. Remove the four bolts (1) and washers (2).
Notice: be careful to fix the center joint to
prevent hard objects from scratching the sealing
surface of each oil port.
2. Remove the end cover (3)

Caution: be careful not to damage the inner
O-ring while taking out the end cover.
7-73
Figure Steps
3. Remove the sealing cover O-ring (4)
Notice: be careful not to damage the O-ring.
4. Remove the snap ring (5) from the spindle (6).

Caution: be careful in operation and not to
damage the mounting face.
5. Remove the stop ring (7).

7-74
Figure Steps
6. Extract the spindle (6) out of the center joint body
(8) with a puller.
7. Remove the bushing (9).
Caution: hook the claw end of the puller to
the flange surface, and push the spindle out of the
cover.
Caution: while taking out the bushing, be

careful not to damage the sealing surface of the
spindle.
8. Remove the seal rings (12) (14) dust ring (10)

and the upper center joint body.
Caution: be careful not to damage the sealing
surface of the joint body.
Caution: when the seal rings cannot be taken

out, the seal rings can be taken out by destroying,
and replace them with new seal rings during re-
installation.
9. Remove the four plugs (11) at the end of the

spindle (6).
Caution: be careful not to damage the O-ring
(13).
7-75
Assembly
The assembly sequence is just opposite to the removal sequence. Pay attention to the assembly of the
following items.
(1) Repair the damaged section during removal, and prepare replaceable parts in advance.
(2) Thoroughly clean each part with cleaning oil, and dry with compressed air.
(3) The clean working oil must be applied to the spindle section and the center joint body before assembly.
(4) O-ring, oil seal and other seals shall be replaced in principle.
(5) Prepare torque wrenches used for mounting bolts and oil plugs at each section.
• Tighten according to the torques specified in the following table.
Name Specifications Tightening torque

Bolt M10×25-8.8-Zn.D 52±6N·m(38.4±4.4 lbf·ft)
Plug G1/2 110±10 N·m(81.1±7.3 lbf·ft)
7-76
7.5.3 Removal and Installation of Hydraulic Oil Tank

Removal
the hydraulic tank.
Figure Steps
1. Rotate the revolving frame, and evacuate a
removal and installation space for fuel tank bottom
plate.
7-77
Figure Steps
2. Remove 2 fuel tank bottom plates (1);
3. Place a barrel below the oil drain port of the tank,

remove the drain plug (2) and drain the oil
completely, and then reinstall the drain plug back.
4. Remove the dipstick (3);

5. Remove the pilot valve bank (4).
7-78
Figure Steps
7. Remove the pump oil return pipe (6).
8. Remove the front cover plate (7).

10. Remove the solenoid valve group (9).
11. Remove 7 oil return hoses (10);
7-79
Figure Steps
12. Remove 5 oil suction tube flange mounting bolts
(12), and remove 6 fuel tank mounting fixing bolts
(13).
13. Penetrate through the lifting eyes, and lift and

move the fuel tank to a clean and safe place with
a sling and hoisting equipment.
Lifting weight: 173kg (381.5lb)
Installation
The installation sequence is just opposite to the removal sequence.
• Tightening torque of mounting bolt is: M16-10.9: (305±25) N·m (224.9±18lbf·ft).
• Clean the threaded hole before installation, and the threads of mounting bolts shall be applied with the
anaerobic thread locker (Tonsan 1277).
• Refill hydraulic oil.
7-80
7.5.4 Removal and Installation of Main Control Valve Assembly

Removal
the hydraulic tank.
Figure Steps
plate.
7-81
Figure Steps
2. Remove the fuel tank bottom plates (1).

4. Remove the front cover plate (3).

7-82
Figure Steps
5. Remove the bottom plate (4) under the main
control valve.
(I) When the machine applies the Kawasaki system,

please remove according to the following steps
7. Remove the pilot hose (7).
8. Remove the working port hose (8).
9. Remove 3 fixing bolts (9) of the main control

valve.
9
7-83
Figure Steps
10. Shift the main control valve out with lift equipment
such as a sling.
Lifting weight: about 220kg (485.1lb)
(II) When the machine applies the Rexroth system,

11 please remove according to the following steps
10
11. Remove the return oil hose (10);
13. Remove the working port hose (12).
12 CLG920E922E07003
7-84
Figure Steps
14. Remove 3 fixing bolts (13) of the main control
valve.
13
CLG920E922E07004
15. Shift the main control valve out with lift equipment
such as a sling.
Lifting weight: about 222kg
CLG920E922E07005
Installation
The installation sequence is just opposite to the removal sequence.
• Tightening torque of the mounting bolts of the main control valve assembly: M16-10.9?305±25 N·m;
• Tightening torque of pilot hose: M16x1.5: (26±2)N.m
7-85
7.5.5 Disassembly and Assembly of Main Control Valve

Related drawings
(1) Main Control Valve, Kawasaki System
Please refer to the structure drawing relating to the introduction of the main control valve in the section
"Structural function and service". The numbers involved below are subject to the part numbers in the structure
drawing.
As hydraulic elements are precisely machined parts, select an especially clean place to carry out the
removal and installation.
In addition to handling the control valve, special attention shall be paid not to allow dust, sand, etc. to
invade the interior.
When removing the control valve from the machine, seal every interface with a cover. Before removal,
confirm again such covers are completely installed, and thoroughly clean the outside of the whole
component assembly. Operation shall be performed on an appropriate workbench, which shall be
paved with clean paper sheets or rubber plates, and then the operation shall be started.
Supporting force in handling and moving the control valve shall be acted on the solid positions of the
body and shall never be acted on the protruding positions such as the spool and spring cover, so it is
necessary to work carefully.
Although various tests (such as the overflow properties test, internal leakage test and passage loss
test) will be carried out after the removal and assembly of elements, these must be carried out on a
hydraulic test device. Do not perform removal in a place where test adjustments cannot be done due to
restrictions, even though the removal is available based on the structure. Prepare clean cleaning oil,
working oil and lubricant, etc, in advance.
Disassembly
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The numbers in the bracket behind the part name represent the part number in the structure drawing.
Figure Steps
1. Place the control valve on an operation platform.
Caution: Perform removal in a clean place.
Do not damage the flange face.
2. Removal of main spool:

(the travel (301), bucket (304), rotation (305),
optional (309), arm 2 (306), boom 2 (307) and
rotation priority (311)).
1) Loosen the hexagon socket bolt (273), and
remove the spring cover (201 or 202) and O-ring
(261).
2) Remove the spool, spring, its seat (332), stopper
(335 or 339) and bolt with liners (336) from inside
the valve body as a spool group.
Caution: When removing the spool group
from the valve body, be careful not to damage the
valve body.
7-87
Figure Steps
3) Use a bench vice containing a shield over the jaw
to sandwich a protection plate (such as an
aluminum plate) between the bench vice and the
spool so that the spool is fixed. Remove the bolt
with liners (336) from the spool group, and
disassemble the spring, stop (335 or 339) and
spring seat (332).
3. Removal of the boom 1 spool (303):

remove the spring cover (201) and O-ring (261).
2) Remove the boom 1 spool (303), springs (320,
328), spring seat (332), stopper (335) and bolt
with liners (336) from inside the valve body A
(101) in the spool group state.
from the valve body A (101), be careful not to
damage the valve body.

spool so that the boom 1 spool (303) is fixed.
Remove the bolt with liners (336) from the spool
group, and disassemble the spring (320, 328),
stopper (335) and spring seat (332).
4) After removing the above (3) items, do not further
remove the boom 1 spool (303).
7-88
Figure Steps
4. Removal of arm 1 spool (302):
2) Remove the arm 1 spool (302), springs (320,
328), spring seat (332), stopper (335) and bolt
with liners (336) from inside the valve body B
from the valve body B (102), be careful not to

spool so that the arm 1 spool (302) is fixed.
4) After removing the above (3) items, do not further
remove the arm 1 spool (302).
5. Removal of straight travel spool (308):
2) Remove the straight travel spool (308), springs
(322, 323), spring seat (332), stopper (335) and
bolt with liners (336) from inside the valve body A
from the valve body A (101), be careful not to

spool so that the straight travel spool (308) is
fixed. Remove the bolt with liners (336) from the
spool group, and disassemble the spring (322,
323), stopper (335) and spring seat (332).
4) After the removal of ? items above, do not
perform further removal of the straight travel
spool (308).
7-89
Figure Steps
6. Removal of bypass stop valve (310):
2) Remove the bypass stop spool (310), springs
(372, 373), spring seat (331), stopper (337) and
bolt with liners (333) from inside the valve body B
from the valve body B (102), be careful not to

spool so that the bypass stop spool (310) is fixed.
7. Removal of spring covers (204, 205, 206)
Loosen the hexagon socket bolt (273), and
remove the spring covers (204, 205, 206) and O-
ring (264).
When removing the bucket spool cover (206), first
loosen the plug (258) before removing the spool
cover from the valve body B (102). Remove the
plunger (211) after removing the spool cover.
7-90
Figure Steps
8. Removal of main relief valve (601) and interface
relief valves (602, 604):
Remove the main relief valve (601) and interface
relief valves (602, 604) from the valve body.
Main relief valve (601)
Interface relief valve (602)
Interface relief valve (604)
1) After the relief valves are removed from the valve

bodies, do not perform further removal of the
relief valves.
7-91
Figure Steps
9. Removal of lock valve selector pair (252):
Loosen the hexagon socket bolt (252-171), and
remove the lock valve selector pair (252) and O-
ring (252-161).
After the lock valve selector pair (252) is removed
from the valve body, do not perform further
removal of the lock valve selector pair.
10. Removal of negative control relief valve (610)

Remove the negative control valve (610) from the
valve body.
After the negative control valve (610) is removed
from the valve body, do not perform further
removal.
7-92
Figure Steps
11. Removal of arm regeneration stop valve (257):
Remove the bushing (257-253), spring (257-231),
spring seat (257-232), spool (257-211) and valve
bushing(257-212) from the valve body B (102).
7-93
Figure Steps
12. Removal of logic control valve (251), rotary logic
valve group (254) and arm 2 logic valve group
(256):
1) Unscrew the hex bolt (251-120), and remove the
logic control valve (251) and O-rings (251-112.-
113).
2) Remove the rotary logic valve group (254) and
arm 2 logic valve group (256) from the valve
body.
3) After the logic control valve is removed from the
valve body and the logic valve groups are
removed, do not perform further removal.
7-94
Figure Steps
13. Removal of check valve:
1) CP1?C2?CCb?LCb?LCo?LCk?LCa?LCAT2
Remove the plug(551), and then remove the cone
valve (511) and spring (521).
2) CMR1, CMR2
3) CRa?CRb
Remove the plug (552), and then remove the
cone valve (513) and spring (523).
4) CCk?CCo
5) Remove the plug (550), and then remove the
steel ball (541), spring (543) and spring seat
(542).
7-95
Figure Steps
14. Removal of flange (209)
remove the flange (209) and O-ring (165).
15. Removal of the plate (210):
remove the plate (210) and O-ring (165).
16. Removal of the orifice plug for signal oil circuit:
Except special circumstances, do not generally
remove the plug (151) and orifice plug (156).
17. Removal of the valve body:
1) Except special circumstances, do not generally
remove the anchor bolt of the valve body B (102).
2) As the plugs unrecorded in the above procedures
are used for technological holes and valve body
sanitary holes, do not remove them except
special circumstances.
Post-removal inspection
Thoroughly clean all the removed parts with clean mineral oil, and inspect them after they are dried by com-
pressed air. Place all parts on clean paper or cloth.
Inspection of control valve
1) Inspect the entire surface of each part. No burrs, rough edges, drag marks, galling, scratches, or other
defects are allowed.
2) Confirm that the seal groove faces of the valve body and valve block are smooth. Defects such as
impurities, deformations, pits and corrosion are not allowed.
3) If any deformations and pits on the valve seat surface of the check valve and its block, eliminate them by
grinding.
Be careful not to keep abrasive paste remain in the valve body and valve block.
4) Confirm that sliding and mating parts are able to flexibly rotate by hand and no impurities are left in all
grooves and passages.
5) Replace the spring with a new one in case of a break or deformation.
6) When the relief valve acts ineffectively, repair it according to the removal and assembly of the relief valve.
7) Replace all seals and O-rings with new ones.
Inspection of relief valve
1) Make sure the spool and valve seat head seal surface of each valve has no defects and the mating
surfaces are in uniform contact.
2) Make sure the spool and valve seat of the main valve are easily and freely slid by hand.
7-96
3) Make sure the main valve spool outer circumferential surface and valve seat inner circumferential surface
have no drag marks and galling.
4) Make sure the springs have no breaks, deformations, or abrasion.
5) Make sure the damping holes of the spool and valve seat of the main valve are not blocked by impurities.
6) Replace all O-rings with new ones.
7) When minor damage is found in the above inspection, it can be eliminated in the abrading method.
8) When a defective part exists, replace the relief valve by group.
Assembly
The number in the () after a part name represents a symbol in the structure drawing.
Precautions in assembling O-ring seals
1) Note that the seals must have neither forming defects nor the scars generated in use.
2) Apply grease or working oil in the positions of the seals and similarly shaped seals to ensure sufficient
lubrication.
3) Do not stretch the seals to a permanent deformation that they cannot recover.
4) When installing an O-ring, do not install it in a distorted way. A distorted O-ring is difficult to naturally
recover after being installed, which is the cause of oil leakage.
5) For the mounting bolts of all parts, fix them with a tool such as a torque wrench according to the mounting
torque as shown in Maintenance Criteria.
1. Install the check valve:
1) Install the cone valves (511, 512, 513, 514) and springs (521, 522, 523).
Install O-ring (561) in the plug (551, 552), and fasten it in specified torque.
Caution: The following is the assembly of combination of cone valve, spring and plug used.
Cone valve Spring Plug Installation site

511 521 551 8 pc (s)
512 522 553 2 pc (s)
513 523 552 2 pc (s)
514 521 551 2 pc (s)
Plug Hexagon socket

Mounting torque
No. wrench
(551) 12mm(0.47In) 230 ~ 260N·m(169.6~191.8lbf·ft)
(552) 12mm(0.47In) 230 ~ 260N·m(169.6~191.8lbf·ft)
(553) 10mm(0.39In) 130 ~ 150 N·m(95.9~110.6lbf·ft)
2) Install the steel ball (541), spring seat (542), and spring (543):
Install an O-ring (166) on the plug (550) and fasten it in the specified torque, with the mounting torque of
25~29 N·m (18.4~21.4lbf·ft).
7-97
2. Mounting plate (210):

Install the O-ring (165) on valve body B (102) and fasten the hex socket bolt (274) in the specified torque,
with the mounting torque of 98~120 N·m (72.3~88.5lbf·ft).
When the orientation of the board is downward, exchange the orientation of the control valve.
3. Install the flange (209):
Install an O-ring (165) on the flange (209), fasten the hex bolt (971) in the specified torque, and the
mounting torque is 49-65N·m (36.1 ~ 47.9lbf·ft).
4. Installation of logical control valve (251) and rotary logical valve assembly (254):
1) Install the rotary logical valve group (254) on the valve body B (102).
2) Install the O-ring (251-112, -113) on the valve body (251-101) of the logical control valve, and fasten it in
specified torque with hex socket bolt (251-120) with the mounting torque of 49~65 N·m (36.1~47.9lbf·ft).
5. Install the logical control valve (251) and arm 2 logical valve group (256):
1) Install the arm 2 logical valve group (256) to the valve body A (101).
2) Install the O-ring (251-112, -113) on the valve body (251-101) of the logical control valve, and fasten it in
specified torque with hex socket bolt (251-120) with the mounting torque of 49~65 N·m (36.1~47.9lbf·ft)].
6. Installation of negative control relief valve (610):
Install the negative control relief valve (610) into the valve body, and fasten it to the specified torque as
shown below, with the mounting torque of 69~78 N·m (50.9~57.5lbf·ft).
7. Installation of arm regeneration stop valve (257):
Install the valve bushing (257-212), spool (257-211), spring seat (257-232), and spring (257-231) on the
valve body (102). Install the O-ring (257-265) on the bushing (257-253), and fasten it in specified torque,
with the mounting torque of 69-78N·m (50.9~ 57.5lbf·ft).
8. Installation of lock valve selector valve (252):
Install the O-ring (252-161) on the lock valve selector pair (252), and fasten it to the specified torque with
a hex socket bolt (252-171), with the mounting torque of 10-14N·m (7.4~ 10.3lbf·ft).
9. Installation of main relief valve (601) and port relief valve (602, 604);
Install the main relief valve (601) and interface relief valve (602, 604) on the valve body, and fasten it in
the following specified torque.
Tool(s) Mounting torque

Main relief valve (601) Wrench 32mm (1.3 In) 69 ~ 79 N·m (50.1~58.3 lbf·ft)
Interface relief valve Wrench 32mm (1.3 In) or
69 ~ 79 N·m (50.1~58.3 lbf·ft)
(602) Socket wrench 32mm (1.3 In)
Interface relief valve Wrench 36mm (1.4 In) or
120 ~ 140 N·m (88.5~103.3 lbf·ft)
(604) Socket wrench 36mm (1.4 In)
7-98
10. Installation of the straight travel spool (308):

1) Use the bench vice provided with shield on the vice jaw, sandwich guard plate (aluminum plate, etc.)
between the bench vice and spool, and fasten the intermediate part of the straight travel spool (308).
Install the spring seat (332), spring (322 and 323) and stopper (335), and tighten the bolt with liner (336)
according to the specified torque. The mounting torque is 16 ~ 18 N.m(11.8 ~ 13.3 lbf.ft)
Caution: Before installing the bolt with liner (336), apply #262 thread locker on it.
The straight travel spool (308) will deform if it is sandwiched improperly, so do not clip the bench
vice too tightly.
2) Upon the installation of item (1), install the spool group into the valve body A (101).
Caution: Install the spool group on valve body A (101) slowly and prudently.
Never push the spool into the valve body forcibly.

11. Installation of the boom 1 spool (303):
between the bench vice and, and fasten the intermediate part of the boom 1 spool (303). Install the spring
seat (332), spring (320 and 328) and stopper (335), and tighten the bolt with liner (336) according to the
specified torque. The mounting torque is 16 ~ 18N·m (11.8~13.3 lbf·ft)
The boom 1 spool (303) will deform if it is sandwiched improperly, so do not clamp bench vice tightly.
11.2 Upon installation of item 1, install the spool group to the valve A (101).
Caution: Install the spool group on valve body A (101) slowly and prudently.

12. Installation of the arm 1 spool (302):
between the bench vice and spool, and fasten the intermediate part of the arm 1 spool (302). Install the
spring seat (332), spring (320 and 328) and stopper (335), and tighten the bolt with liner (336) according
to the specified torque. The mounting torque is 16 ~ 18 N.m(11.8 ~ 13.3 lbf.ft)
The arm 1 spool (302) will deform if it is sandwiched improperly, so do not clamp bench vice tightly.
3) Upon the installation of item (1), install the spool group into the valve body B (102).
Caution: Install the spool group on valve body B (101) slowly and prudently.

7-99
13. Installation of main valve spool

(Travel (301), bucket (304), rotation (305), standby (309), bucket rod 2 (306), bucket rod 2 (307), rotation
priority (311)):
1) 13.1Use the bench vice provided with shield on the vice jaw, sandwich guard plate (aluminum plate, etc.)
between the bench vice and spool, and fasten the intermediate part of each spool. Install the spring seat
(332), spring and stopper (335 or 339), and tighten the bolt with liner (336) in specified torque, and the
mounting torque is 16~18N·m (11.8~13.3 lbf·ft)
The boom spool will deform if it is sandwiched improperly, so do not clamp bench vice tightly.
2) Upon the installation of item (1), install the spool group into the valve body A (101) and valve body B
(102).
Caution: When installing the spool group to the valve A (101) and valve B (102), do it slowly and
prudently.

14. Installation of the bypass stop spool (310):
between the bench vice and valve spool, and fasten the intermediate part of bypass stop spool (310).
Install the spring seat (331), spring (372 and 373) and stopper (337), tighten the bolt with liner (333) in
specified torque, and the mounting torque is 16~18N·m (11.8~13.3 lbf·ft)
The bypass stop spool (310) will deform if it is sandwiched improperly, so that protect the valve body
from being clamped too tightly with bench vice.
2) Upon the installation of item (1), install the spool group into the valve body B (102).
Caution: Install the spool group on valve body B (102) slowly and prudently.
Never push the spool into the valve forcibly.

15. Installation of cover:
1) Install the spool cover (204, 205, 206) on the side opposite to spring group of the, fasten the hex bolt
(273) in specified torque, and the mounting torque is 25~34N·m (18.4~25 lbf·ft)
Caution: Verify that the O-ring (264) has been installed on the spool cover (204, 205, 206).
2) Installation of the bucket spool cover (206):

Install the plunger (211) in the bucket spool cover (206). Install O-ring (561) to the plug (258), and tighten
it to the specified torque. After fastening it, install the bucket spool cover (206) in the same way as that of
item (1), and the mounting torque is 150-180N·m.
3) Install spring cover (201, 202 and 203) to the spool spring group side, and tighten the spool hexagon
socket bolt (273) to the specified torque, and the mounting torque is 25~34 N·m (18.4~25 lbf·ft)
Caution: Confirm that the O-ring (261) has been installed on the spring cover (201, 202, 203).
(2) Main Control Valve, Rexroth System
7-100
Figure Steps
1. Replace the check valve spool
1) Unscrew and take out the screw plug with a
hexagon socket wrench (British system).
2) Take out the pressure spring and gasket with a
magnet clamp.
3) Set the removed parts aside.
4) Ensure that there is no dust particle
contaminating the mounting hole.
CLG920E922E07006
5) Check the seal ring on the screw plug. The

surface must be clean without damage.
6) Check the mounting hole on the valve block. If
the hole is damaged, replace the valve body.
7) Manually put the check valve into the mounting
hole slightly. Pay attention to the correct position
of the pressure spring, gasket, and the screw
plug in the hole. Tighten the screw plug clockwise
with a torque wrench under a certain torque.
CLG920E922E07007
2. Replace the one-way throttle valve

1) Unscrew and take out the screw plug with a
hexagon socket wrench (British system).
2) Take out the pressure spring and gasket with a
magnet clamp.
3) Set the removed parts aside.
CLG920E922E07008
7-101
Figure Steps
5) Check the seal ring on the screw plug. The
surface must be clean without damage.
7) Manually put the throttle valve into the mounting
hole slightly. Pay attention to the correct position
of the pressure spring, gasket, and the screw
plug in the hole. Tighten the screw plug clockwise
with a torque wrench under a certain torque.
CLG920E922E07009
3. Replace the one-way throttle valve

1) Unscrew and take out the pilot control valve.
2) Set the removed pilot control valve aside.
CLG920E922E07010
4) Check the sealing condition of the pilot control

valve. Ensure it is clean without damage.
6) Install the pilot control valve into the mounting
hole manually.
7) Tighten the pilot control valve with a torque
wrench.
CLG920E922E07011
7-102
Figure Steps
4. Replace the secondary relief valve/screw plug
1) Unscrew and take out the secondary relief valve
counter-clockwise.
2) Set the removed the secondary relief valve aside.
CLG920E922E07012
Caution: Note that the settings of the

secondary relief valves are different. Please
confirm the sequence of each secondary relief
valve.
4) Check the sealing condition of the valve and

ensure it is clean without damage.
5) Check the mounting hole on the valve body. If it is
damaged, please replace the valve block.
6) Install the secondary relief valve into the
mounting hole and tighten it clockwise with a
torque wrench.
CLG920E922E07013
CLG920E922E07014
7-103
Figure Steps
5. Replace the valve spool assembly
1) Loosen the screw and end cover in the figure
anti-clockwise on the B side of the multiway
valve.
2) Set the end cover in a clean area.
3) Protect the end cover and mounting hole from
particle contamination and moisture.
4) Take out the pressure spring, spring seat, and
valve spool without tilting.
CLG920E922E07015
5) Install the pressure spring, spring seat, and valve

spool into the hole manually.
6) Lock the end cover with a torque wrench.
CLG920E922E07016
6. Replace the main valve spool

1) Unscrew the end cover of the main valve element
on both sides of the multiway valve anticlockwise
with a hexagon socket tool as shown in the figure.
CLG920E922E07017
7-104
Figure Steps
4) Remove the spring and its seat, and take out the
spool horizontally without tilting. Ensure that there
is no particle contamination in the mounting hole.
CLG920E922E07018
Caution: Mark the mounting position of the

main valve spool. Mark a line at the B side bottom
of the main valve spool.
CLG920E922E07019
5) Install the main valve spool into the mounting

hole horizontally (without tilting).
6) Install the spring and its seat.
CLG920E922E07020
7) Lock the end cover of the main valve spool with a

certain pretightening force by using a torque
wrench.
CLG920E922E07021
7-105
Figure Steps
7. Replace the pilot shuttle valve.
1) Tighten the pilot shuttle valve with a 3-4 mm self-
tapping screw and pull out the shuttle valve.
2) If the shuttle valve is damaged when removing, it
must be replaced.
CLG920E922E07022
3) Install the shuttle valve to the hole and then press

it into the valve block.
4) Lock the end cover.
CLG920E922E07023
8. Replace the shut-off valve spool

1) Unscrew the long screw in the figure
anticlockwise with a hexagon socket tool, and
pay attention not to drop the end cover.
CLG920E922E07024
4) Carefully take out the shut-off spool.

5) Set the valve spool in a clean area.
6) Ensure that there is no particle contaminating the
mounting hole.
CLG920E922E07025
7-106
Figure Steps
7) Manually install into the hole horizontally without
tilting.
8) Tighten the end cover with a torque wrench
under a certain pretightening force.
CLG920E922E07026
9. Replace the end cover and direction valve on the

multiway valve block
1) Unscrew the long screw by using the hex socket
tool anticlockwise, and pay attention not to drop
the end cover and direction valve.
2) Remove the end cover and direction valve from
the valve body.
3) Remove the O-ring (111).
4) Clean the junction surface of valve block and
direction valve to ensure that no particles enter
into the mounting hole.
5) The seal ring and its contact surface shall also be
cleaned up to ensure there is no damage. The
direction valve must be replaced if it is broken.
CLG920E922E07027 6) Install the O-rings with all sealing and mating

surfaces clean, dry and undamaged.
7) Tighten and fix the direction valve and the end
face of the valve body with a long screw and a
torque wrench.
7-107
Figure Steps
10. Replace the oil inlet block
1) Unscrew the longer screw with a hexagon socket
wrench anticlockwise.
2) Lift and remove the end cover. Ensure that there
is no moisture and particle contaminating the
mounting hole on the end cover.
CLG920E922E07028
3) Remove the O-ring as shown in the figure.

4) Clean the junction surface between the end face
of the oil inlet block and the O-ring, without any
particle. The oil inlet block must be replaced if it is
broken.
CLG920E922E07029
7-108
Figure Steps
11. Replace main relief valve
1) Unscrew and take out the MHDBN 22 K2-3X/
main relief valve anticlockwise by using a socket
head wrench.
2) Set the main relief valve in a clean area.
3) Ensure that there is no particle contaminating the
mounting hole.
4) Check the sealing elements. Ensure the surface
is clean without damage.
5) Check the mounting hole is not damaged. If it is
damaged, replace the oil inlet block.
6) When installing the main relief valve, please first
CLG920E922E07030 to lubricate, and then tighten it to the mounting
hole clockwise with a torque wrench as shown in
the figure.
12. Replace the check valve of the main relief valve.
1) Unscrew the screw with a hexagon socket
wrench anticlockwise as shown in the figure.
2) Remove the spring and its seat with a magnetic
clamp.
3) Set the removed check valve in a clean area.
4) Ensure that there is no particle contamination in
the mounting hole.
5) Check the sealing elements and screws for their
surfaces are clean and undamaged.
6) Check the mounting hole on the valve block. If it
is damaged, please replace it.
7) Install the check valve into the hole manually and
CLG920E922E07031
ensure that the positions of spring and its seat in
the hole are correct. Tighten the screw clockwise
by using the torque wrench.
7-109
7.5.6 Removal and Installation of Main Pump Assembly

Removal
the hydraulic tank.
Figure Steps
plate.
7-110
Figure Steps
2. Remove the fuel tank bottom plates (1).

4. Remove the engine hood (3);

5. Remove the angle block(4)?
7-111
Figure Steps
6. Remove the oil filter (5);
7. Remove the angle block (6), (7)
8. Remove the engine oil filter support (8);
9. Unplug the harness connected to the pump
10. Remove the main pump drain pipe (9);

12. Remove the pilot pump suction pipe by wrench
(11).
13. Remove 2 high-pressure pipe (12).
14. Remove suction tube (13).

7-112
Figure Steps
15. Lift the main pump with sling and hoisting
equipment, and remove 12 bolts of the mounting
flange (14).
16. Lift out the main pump and flange.

Lifting weight: 127kg (280lb)
Installation
The installation of the main pump is in the reverse order of removal.
Pay attention to the following technical requirements during installation:
• Tightening torque of main pump mounting screw M20-10.9: (600±55) N.m(442.5 ± 40lbf·f); it is necessary
to apply thread locker on the screw thread (TONSAN 1277) before installation.
• Tightening torque for angle seal threaded joint with O-ring: G1/4: (37.5±2.5) N·m (27.6±1.8 lbf·ft); G3/8:
(75±5) N·m (55.3±3.7 lbf·ft); G3/4: (165±15) N·m (121.7±11lbf·ft).
• Tightening torque for the 24° cone seal threaded hose joint with O-ring: M16×1.5: (26±2) N·m (19.2±1.5
lbf·ft);
7-113
7.5.7 Removal and Installation of Main Pump Assembly

Disassembly of pump body
(I) When the machine applies the Kawasaki system, please remove the pump body according to the following
steps.
1. Part drawing for pump body
Part number involved in the chapter is based on the following drawing.
7-114
2. Disassembly of pump body
Figure Steps
1. Select the disassembly site.
Caution: Select a clean site.
Cover the workbench with rubber plate or cloth,

etc., never collide the parts and protect them from
damage.
2. Remove the rubbish, rusting, etc. on the pump
surface with cleaning oil, etc.
3. Remove the oil plug (468) of the oil leak joint to
release all oil in the pump housing (271).
Caution: Remove the oil plugs on the front
pump and the rear pump.
4. Remove the hexagon socket bolt to remove the
adjuster and remove the hexagon socket bolt with
washer to remove PTO unit (05).
For the pump without PTO unit, dismantle hex bolt
(414) to remove the lower cover (326).
5. Unscrew the hex bolt with washer to remove the

gear pump (04).
7-115
Figure Steps
6. Unscrew the hexagon socket bolt (401) connected
to swashplate supporting platform (251), pump
housing (271) and oil distributor (312).
7. Put the regulator on the operation platform

horizontally with the mounting face downward,
and separate the pump housing (271) and oil
distributor (312).
Caution: While the fitting surface of the
regulator is downwards, rubber plate, etc. must
be laid on the workbench so as to protect the
fitting surface from collision.
Caution: When separating pump body and oil

distributor, remove the first gear (116) at the same
time.
8. Pull out the cylinder block (141) from pump

housing (271) straightforwards based on the drive
shaft (111, 113), and meanwhile remove the
plunger valve (151, 152), return plate (153),
sphere bushing (156), and return spring (157).
Caution: Protect the sliding surface of
cylinder block, sphere bushing, skid shoes and
swashplate from being damaged.
7-116
Figure Steps
9. Remove hex bolt (406) to remove the cap (F)
(261).
Caution: A hole (M6 bolt) used for pulling out
is provided on the cap (F), so the cap can be
pulled out easily after a bolt is installed.
Caution: Because oil seal is installed on the

cap (F), protect the oil seal from being damaged
during removal.
10. Knock the rear end of the drive shaft (111, 113)
gently so as to separate the drive shaft from
swashplate supporting platform (251).
11. Remove the shoe plate (211) and swashplate

(212) from the pump housing (271).
7-117
Figure Steps
12. Knock the fitting flange part of the swashplate
supporting platform (251) on the pump housing
side gently to separate the swashplate supporting
platform from the pump housing.
13. Remove the plate (313, 314) from the oil
distributor (312).
14. Remove link stopper (L) (534), link stopper (s)
(535), servo plunger (532) and tilt pin (531) from
the pump housing (271) in accordance with the
necessity. What’s more, remove the needle
bearing (124) from the oil distributor (312).
Caution: While removing the tilt pin, protect
the head of the tilt pin from being damaged and
remove it with clamp.
Caution: Because thread lock is applied on

the mating part of tilt pin and servo plunger,
protect the servo plunger from being damaged.
Caution: Except for considering the needle

bearing life, try not to remove it.
Caution: Never unscrew the hexagon socket

nuts on oil distributor and swashplate supporting
platform randomly. Otherwise the flow set already
will change.
Caution: While carrying out the 7th operation,

there is falling off, so pay attention to it.
3. Assembly of pump body
Repair the damaged section during removal, and prepare replaceable parts in advance.
Thoroughly clean each part with cleaning oil, and dry with compressed air.
Assembly must be carried out after the slide part and bearing are applied with clean working oil.
O-ring, oil seal and other seals shall be replaced in principle.
On the occasion where pumps are in series, components of front pump and rear pump shall not mix
together.
7-118
The assembly sequence is just opposite to the removal sequence. Pay attention to the assembly of the
following items.
Mounting torque table
Specification
Part Name Mounting torque Tool name and size B
s
M5 6.9N·m(5.1lbf·ft) 4mm(0.16 In)
M6 12 N·m(8.9lbf·ft) 5mm(0.2 In)
M8 29N·m(21.4lbf·ft) 6mm(0.24 In)
M10 57N·m(42lbf·ft) 8mm(0.31 In)
Hexagon socket bolt
M12 98N·m(72.3lbf·ft) 10mm(0.39 In) Hexagon wrench
(Material SCM435)
M14 160N·m(118lbf·ft) 12mm(0.47 In)
M16 240N·m(177lbf·ft) 14mm(0.55 In)
M18 330N·m(243.3lbf·ft) 14mm(0.55 In)
M20 430N·m(317.1lbf·ft) 17mm(0.67 In)
RC1/16 6.9N·m(5.1lbf·ft) 4mm(0.16 In)
RC1/8 10N·m(7.4lbf·ft) 5mm(0.2 In)
PT heavy bolt (S45C
material) Note) Wrap 1.5~2 RC1/4 17N·m(12.5lbf·ft) 6mm(0.24 In) Hexagon wrench
turns with the sealing tape.
RC3/8 34N·m(25.1lbf·ft) 8mm(0.31 In)
RC1/2 49N·m(36.1lbf·ft) 10mm(0.39 In)
G1/4 36N·m(26.6lbf·ft) 6mm(0.24 In)
G3/8 74N·m(54.6lbf·ft) 8mm(0.31 In)
ROH oil plug G1/2 110N·m(81.1lbf·ft) 10mm(0.39 In)
Hexagon wrench
(Material S45C) G3/4 170N·m(125.4lbf·ft) 14mm(0.55 In)
G1 190N·m(140.1lbf·ft) 17mm(0.67 In)
G 1 1/4 270N·m(199.1lbf·ft) 17mm(0.67 In)
7-119
Disassembly and assembly of regulator

1. Regulator part drawing
The part numbers involved in the paragraph below please refer to the figure below.
Adjuster section diagram VIEW D
VIEW C SECTION B-B

7-120
2. Disassembly of regulator
Figure Steps
1. Select one disassembly site.
Caution: Select one cleaning site.
Caution: To protect the parts from being

damaged, rubber plate or cloth, etc. shall be laid
on the workbench.
2. Wash out the dust, rust, etc. on the surface of

regulator with cleaning oil.
3. Remove the hex screw (438) and take down the
cap (C) (629).
Caution: The cap (C) (629) has been installed
with the adjusting wheel (C) (627), adjusting
screw (C) (628), locknut (630), hex nut (801, 802),
and adjusting screw (924).
Caution: Never loosen these screws or nuts.

If they are loosened, the setting pressure—flow
will be changed.
4. After removing the cap (C) (629), remove the
outer ring spring (625), inner ring spring (626) and
spring seat (C) (624) from the compensator part,
and pull out the regulating ring (Q) (645), guide
spring (646) and spring seat (644) from the pilot
part.
Caution: It is easy to remove the adjusting
ring (Q) (645) by using a M4 screw.
7-121
Figure Steps
5. Take down the hex screws (436, 438) and remove
the pilot cover plate (641).
After removing the pilot cover (641), please take
out the pin (898) and Pf bushing (631) from the
compensator, and then remove the set spring
(655) from the pressure regulator part.
6. Remove the backup ring (814), spring seat (653),

reset spring (654), and bushing (651).
Caution: The snap ring (836) fixes bushing
(651), and while removing snap ring (814),
restoring spring (654) can pop. Protect the
restoring spring from losing.
7. After removing lock ring (858), remove center plug

(614) and adjusting plug (615).
Caution: It is easy to remove center plug
(614) and adjusting plug (615) with M6 bolt.
7-122
Figure Steps
8. Remove lever (2) (613), but do not pull out pin
(875)
Caution: It can make the operation easier to
use a pair of tweezers.
9. Push out the pin (874), and remove the feedback

rod (611).
Push out the pin (874) (pin diameter φ4) with
slimy steel bar, and meanwhile, avoid hitting rod
(1) (612)
10. Take out the lever (1)(612). But do not pull the pin
(875) out
11. Remove the pilot plunger (643) and spool (652)
12. Remove the plunger bushing (622), compensator
plunger (621), and compensator rod (623).
These are the complete operating steps
Caution: During removal of plunger bushing
(622), it can be extruded from the compensator
rod (623) end on the opposite side to plunger
bushing (622).
7-123
3. Assembly of regulator
Apply clean hydraulic oil on component surface to get lubrication effect before assembly.
7-124
Figure Steps
1. Select the assembly site.
Caution: Select one cleaning site.
Caution: To protect the parts from being

damaged, rubber plate or cloth, etc. shall be laid
on the workbench.
2. Install compensating rod (623) into compensating

hole of housing (601).
3. Snap the pin (875) installed on lever (1) (612) into
the slot of compensating rod (623), and then snap
lever (1) (612) into pin (876) embedded on
housing (601).
Caution:
Please make sure that spool (652) and valve

bushing (651) can not get stuck in housing (601),
and they can slide neatly.
Pay attention to the installation direction of spool

(652).
4. Install the feedback rod (611) and insert the pin

(874) into the feedback rod (611) after aligned.
Caution:
It is easy to operate to insert a part of pin (874)

into feedback rod (611) in advance.
Do not make installation wrong direction of

feedback rod (611).
5. Install pilot plunger (643) into the hole for pilot

plunger (643) of housing (601).
Caution: Make sure that pilot plunger (643)
can not be stuck in housing (601), and it can slide
neatly.
7-125
Figure Steps
6. Snap pin (875) pressed in lever (2) (613) into the
slot of pilot plunger (643), and then install lever (2)
(613).
7. Align pin (876) pressed into center plug (614) to

the pinhole of lever (2) (613), install it into center
plug (614), and then install the lock ring (858).
8. Install the adjusting bushing (615), and then install

the lock ring (858).
Caution: Do not install adjusting plug (615)
into the hole of center plug(614), so as to replace
adjusting plug (615).
Caution: At this time, shake feedback rod

(611) to make sure there is no serious waggle and
no failure such as getting stuck.
7-126
Figure Steps
9. Install reset spring (654) and spring seat (653) into
the hole of spool (652), and then install Snap ring
(814) on spool (652).
10. Install setting spring (655) in the hole of spool

(652), and install compensating plunger (621),
plunger bushing (622), Pf bushing (631) and pin
(898) in the compensating hole respectively.
Caution: Make sure the compensating
plunger (621) and pin(898)are not stuck and they
can slide flexibly.
11. Upon installation of pilot valve (641), install and

fasten it with hex bolt (436), (438).
12. Install spring seat (Q) (644), pilot spring (646) and
regulating wheel (Q) (645) in the pilot hole, and
install spring seat (C) (624), internal spring (626)
and external spring (625) in the compensating
hole.
Caution: Pay attention to the orientation of
spring seat (Q) (644).
7-127
Figure Steps
13. Install adjusting screw (C) (628), regulating wheel
(C) (627), locknut (630), hex nut (801), and hex
positioning screw (924) installed on cover (C)
(629) together on housing (601), and fasten them
with hex bolts (438).
7-128
Disassembly and Assembly of Pilot Pump

1. Removal of pilot pump
Choose a clean location. Lay rubber plates or cloth, etc. for removal, and be careful not to damage
parts.
Figure Steps
1. After removing pilot pump (1) from main pump,
find a clean site to disassemble it.
2. Place the pilot pump shaft end (2) downwards.

Caution: Because input shaft of pump is
more protuberant than mounting face, it is best to
provide supporting objects on the two ends of the
mounting face.
7-129
Figure Steps
3. Remove four mounting screws (3) on the pump
cover from the upper end.
4. Pull out the upper cover (4) of pilot pump upwards

slowly and gently.
Caution: be careful in operation and not to
damage the mounting face.
5. Put the upper cover aside. Remove O-ring

carefully.
Caution: The damaged O-ring cannot be
O-ring
reused.
7-130
Figure Steps
6. 6. Grasp one end of driven gear, and pull out the
driven gear (5) straight up slowly.
Caution: Make the mark and note the fitting
direction of driven gear.
Caution: Protect supporting shaft on two

ends of gear and the mounting face matched with
it from damage.
7. Grasp one end of drive gear, and pull out the

driven gear (6) straight up slowly.
Caution: Make the mark and note the fitting
direction of driven gear.
Caution: Protect supporting shaft on two

ends of gear and the mounting face matched with
it from damage.
2. Assembly of pilot pump

The assembly sequence is opposite to that of disassembly.
Mounting torque
No. Name Specifications Tightening torque

1 Bolt M8X60 17 N·m(12.5 lbf·ft)
2 Bolt M8X50 17 N·m(12.5 lbf·ft)
7-131
(II) When the machine applies the Rexroth system, please remove the valve body according to the fol-
lowing steps
Parts List of Rexroth Main Pump
9 33
15
15
13
15 8
11
6 5
12 2
17 3 17
12 7
6 1
10 4
14 16 CLG920E922E07032
1 - Slewing body 7. Housing 13. Shaft seal

2 - Slewing body 8. Oil supplement pump 14 Circlip
3. The main shaft with bearings 9. Control valve 15. Cylindrical pin
4. Swashplate 10. Flange 16. Hex socket screw
5. Swashplate 11. Flange 17. Angle Sensor
6. Variable unit 12. Gasket 33. O-ring
Figure Steps
1. Remove the control valve parts
1
1) Unscrew the bolt (1)
2) Remove the control valve (2) and gasket (3) from
2 the housing.
3 4
CLG920E922E07033
7-132
Figure Steps
2. Install the control valve parts
1
1) Check the feedback rod (5) can be adjusted. If
the feedback rod cannot be adjusted, then the
2 control valve is problematic.
3 4
2) Install the gasket (3) to the control valve (2)
5 bottom.
6 3) Install the control valve (2) on to the housing, and
adjust to the appropriate position.
7
4) Tighten the bolt (1) by using a torque wrench
under a certain pretightening force.
CLG920E922E07034
3. Replace the shaft seal

1) Remove the snap spring (1).
5 2) Remove the mounting shim (4) if necessary.

2
3) 3-3 Clamp the shaft seal (3) according to the
4 arrow with a circlip plier.
3
4) Remove the shaft seal (3) from the flange base
with a circlip plier.
5) Check the keyway of the main shaft (6) and
1 6 install the shaft seal according to scheme B.
6) Apply a little grease between the shaft seal and
dust cover to prevent dry wear.
CLG920E922E07035
7) Install the gasket (4) onto the main shaft.
8) Install the shaft seal onto the main shaft (6) with
the tooling.
7-133
Figure Steps
4. Replace the shuttle valve
1 2 3
1) Unscrew and take out the screw plug (3).
2) Replace the O-ring (2).
3) Release the shuttle valve (1).
4) Installation is in the reverse order of the above-
4 mentioned way.
CLG920E922E07036
5. Replace the angle sensor.

1) Unscrew and take out the fastening bolt (5).
2) Remove the lower protective cover (4) and
locating pin (3).
3) Take out the angle sensor (2) from the housing
1 (6).
2 3
4 4) Replace the O-ring (1).
Installation is in the reverse order of the above-
mentioned steps.
6
5
CLG920E922E07037
7-134
Figure Steps
6. Remove the flange cover
1 1) Unscrew and take out the fastening bolt (1) from
the pump body (6).
2) Remove the flange support (3) and the sling for
2 main shaft (2) from the housing (6).
3 3) Remove the gasket (4).

4) Remove the cylindrical locating pin (5).
CLG920E922E07038
7. Remove the oil supplement pump
6 1) Remove the O-ring (2).

2) Unscrew and take out the fastening bolt (1).
3) Remove the oil supplement pump (3) from the
2 rear cover base (5) and main shaft (4).
1 4) Remove the locating pin (6) from the base.
5
3 4
CLG920E922E07039
7-135
Figure Steps
8. Remove the rear end cover.
1 1) Unscrew and take out the bolt (1) from the pump
body (6).
2 2) Remove the rear end cover (3) and the shaft (2)
from the valve body (6) by using the sling.
3 3) Remove the gasket (4).
4) Remove the locating pin (5).
4
5
6
CLG920E922E07040
9. Remove the main shaft with bearings

1) Remove the snap spring (1).
2) Press the main shaft (2) and the bearing (3) out
of the flange.
4 10. Install the main shaft with bearings
1) Heat the flange (4).
3 2) Press the main shaft (2) and the bearing (3) into
2 the heated flange (4) completely.
1
3) Install the snap ring (1).
CLG920E922E07041
7-136
Figure Steps
11. Install the flange support
1
1) Install the cylindrical locating pin (5) onto the
housing (6).
2 2) Install the gasket (4) onto the housing (6).
3 3) Insert the flange (3) with main shaft (2) into the
coupling sleeve and lift the flange with the sling.
4) Tighten the bolt (1) to the housing (6) with a
4
5 certain pretightening force.
6 5) Remove the special tooling mounting pin (7).
6) Locking screw plug (9).
7
9
CLG920E922E07042
12. Install the rear end cover.

1 1) Install the cylindrical locating pin (5) onto the
housing (6).
2) Install the gasket (4) onto the housing (6).
2
3) Insert the flange (2) with main shaft (3) into the
coupling sleeve with the sling.
4) Tighten the bolt (1) with a certain pretightening
3
4 force.
5) Remove the special tooling mounting pin (7).
5 6) Locking screw plug (9).
6
9
CLG920E922E07043
7-137
Figure Steps
13. Install the oil supplement pump
5 1) Install the oil-supplement pump housing (3) onto

4 the rear end cover (6). Rotate the main shaft (4)
3 to drive the inner ring of the oil supplement pump
to interlock the inner and outer rings of the gear
2
pump.
1
2) Install the O-ring (2) onto the oil-supplement
pump housing (3).
3) Tighten the bolt (1) to the rear end cover (6) with
a certain pretightening force.
6
CLG920E922E07044
14. Inspection after installation

1) Install and tighten the slings onto the main shaft.
2) Place a long rod through the sling.
3) Drive the main shaft for turning a circle. For the
details, refer to the rotary direction stamped on
the nameplate.
CLG920E922E07045
7-138
7.5.8 Removal and Installation of Travel Pilot Valve Assembly

Removal
the hydraulic tank.
Figure Steps
1. Remove the bottom plate (1) under the foot pilot.
7-139
Figure Steps
2. Remove the 6 pilot pipes (2).
3. Remove the two connectors (3)
4. Remove the anti-slip step (4) with a cross

screwdriver;
5. Remove floor mat (5) and rubber pedal (6).
7-140
Figure Steps
6. Remove four bolts with a wrench to remove pedal
(7).
7. Remove 4 fixing bolts (8) and then remove foot

pilot valve upwards.
Installation
The installation of travel pilot valve is in the reverse order of removal.
• Tightening torque of joint: (36±2) N.m (26.6±1.5lbf·ft);
• Tightening torque of hose joint: (26±2)N.m(19.2±1.5lbf·ft);
7-141
7.5.9 Disassembly and Assembly of Travel Pilot Valve

Part drawing of the travel pilot valve
For the part numbers involved in the section, this part drawing below shall prevails.
101. Housing 215. Washer 337. Spring

102. Housing 217. Washer 412. Bushing
153. Oil plug 218. Spring seat 413. Camshaft
191. Valve seat 220. Hexagon socket bolt 420 Cam
194. Steel ball 224. Piston 423. Positioning screw
201. Valve cover 225. Steel ball 431. Seat
202. Screw plug 271. Hex socket screw 471. Positioning screw
203. Oil Cup 301 Slide valve 472. Locknut
210. Oil Cup 311. Spring seat 473. Hexagon socket bolt
211. O-ring 313. Washer 501. Rubber sleeve
212. O-ring 324. Spring 520. Pedal
213. O-ring 335. Spring 521. Pedal sleeve
214. Push rod 336. Spring 522. Hexagon socket bolt
7-142
Disassembly
Special tool
For removing bushing
&HQWHUKROHDOORZDEOH EHORZɎ
(1) There shall be a capacious site to place the removed components and parts. Prepare a stable workbench
where components and parts will not fall off and roll during operation.
(2) Prepare tools and related materials.
(3) All components and parts have been processed precisely. During operation, it is requiring to handle with
care, and do not fall or collide between parts.
(4) Do not consider that all components and parts are solid and firm. During removal, the excessive knocking,
prising and cutting will lead to trimming, deformation and damage, which cause unable to assemble, oil
leak as well as performance degradation. Therefore, operate with care and patience.
(5) No corresponding disposal or random placement in removing midway after removing will cause rusted
components and parts due to humidity and impurity. If the operation must be interrupted, pay attention to
taking protective measures against rust and dust.
Figure Steps
1. Clean the pilot valve with white kerosene.
Caution: All connectors are blocked with
plugs.
2. Fix the pilot valve on the bench vice with buffer

plate (the copper plates or other soft plates).
Remove the pedal cover (521) from the pedal
(520), by removing it from the upper side.
7-143
Figure Steps
3. Unscrew the hex bolt (522) with a hexagon socket
wrench, and then remove the pedal (520).
4. Unscrew the hex bolt (473) with a hexagon socket

wrench, and then remove the seat (431).
5. Remove the rubber bushing (501) from the upper

side of valve cover (201).
7-144
Figure Steps
6. Unscrew the positioning screw (423) with a
hexagon socket wrench.
Caution: Note the required releasing torque
is large due to the application of threaded locker
#241.
7. Align the round rods (below φ8) with the one end
of the camshaft (413), and then knock it with a
hammer to remove.
8. Unscrew the positioning screw (471) and locknut

(472) on the cam (420), and then remove them in
pairs.
Caution: Record the positional relationship
between the cam and valve cap (201).
Caution: During removal, please note the

push rod (214) may be ejected.
7-145
Figure Steps
9. Unscrew the hex screw (271) with a hexagon
socket wrench.
10. Remove the valve cap (201).

Caution: Record the positional relations
between the valve cap and the buffer housing
(102).

push rod (214) and its bushing (202) may be
ejected because of the elastic forces of the buffer
springs (336), (337).
(The push rod bushing may not be ejected from

buffer housing because of the sliding resistance of
the O-ring (212) )
11. Remove the push rod (214) from plug (202).

Caution: Record the positional relationship
between plug and push rod.
Note: take care not to damage the surface of

the push rod.
Caution: During removal, please note that the

plug may be ejected.
7-146
Figure Steps
12. Remove the plug (202) together with lubricating oil
cup (203) and NHU oil cup (210).
between the thread plug and the buffer housing.

plunger may be ejected due to the elasticity of
buffer spring.
13. Remove the plunger (224) from the bumper

housing.
between the plunger and the buffer housing hole.
14. Remove the buffer springs (336) and (337) from

the buffer housing.
between the buffer spring and the buffer housing
hole.
7-147
Figure Steps
15. Remove the spring seat (218) from the buffer
housing.
between the plunger and the buffer housing hole.
16. Take out the steel ball (225) with a magnet, etc.
Caution: Keep the steel balls to prevent loss.
17. Loosen the hexagon socket bolt (220) with a

7-148
Figure Steps
18. Remove the buffer housing (102).
between the buffer housing and the housing
(101).

pressure-reducing valve group can be ejected
due to the elastic force of reset spring (335).
19. Remove the O-ring (211) and the O-ring (213)

from the valve body.
7-149
Figure Steps
20. Remove the pressure-reducing valve group and
reset spring (335) from the housing.
between the buffer housing holes.
21. Place the valve cap (201) on the platform

horizontally, then align with the bushing (412) by
special tool 1. Knock at it gently with the hammer,
and remove the bushing.
7-150
Figure Steps
22. After fixed the cam group on the bench vices,
unscrew the locknut (472) with a wrench, and
remove the locknut and positioning screw (471).
Caution: Because the positioning screw must
be adjusted as per the central position when
assembling, it will be kept in form of cam group in
the subsequent process if the screw is not
required to be replaced.
23. For the removal of pressure-reducing valve group,

please upright place the slide valve (301) on a flat
workbench, and then remove the 2 circular
washers (215) with the head of a small straight
screwdriver by pressing the spring seat (311).
Notice: Be careful not to damage the surface
of the slide valve.
Caution: There is no further compression of

more than 4 mm (0.16 In) for spring seat.
24. Separate the spring (324), washer (215) and

washer (313) for the secondary pressure setting
of the spring seat (311) of the slide valve (301).
Caution: Keep in a group form until
assembling.
Caution: Washer (215) is used for presetting

and adjustment of spring for secondary pressure
setting. Because the thickness of each slide valve
is different, it may also not be used.
7-151
Figure Steps
25. Remove the lubricating oil cup (203) from plug
(202).
26. Remove the NHU oil cup (210) from plug (202).
Please use a small plastic plate to remove.
Caution: Never touch the inner face of plug.
27. Remove the O-ring (212) from the plug (202).

7-152
Cleaning of Components and Parts

1. Clean all components and parts by putting into a coarse cleaning container with white kerosene. (Coarse
cleaning)
• If all parts are cleaned initially in the unclean oil, those parts can be damaged easily, therefore, clean them
after fully immersed and the impurities and grease are floating.
• The unclean white kerosene will damage the components and parts and causing performance degradation
after reassembled; therefore keep the white kerosene clean completely.
2. Put all components and parts into a cleaning container with white kerosene, and clean while rotating them
until the inside is clean (after cleaning operation). Clean the white kerosene adhering on components and
parts with a clean cone screw.
If drying with compressed air, the components and parts can be damaged and rusted because of impurity and
moisture in compressed air, so do not use it.
Rust protection of components and parts.
Apply antirusting additive on components and parts.
If it is placed without antirust treatment after cleaning, it will be rusted and cannot fully play its function after
reassembly.
Assembly
The same as the removal, get the operation platform, tools and related data ready.
Please pay attention to the general precautions for removal.
Metal scraps and foreign matters of all parts during assembling shall be eliminated. Moreover, ensure
there is no trimming, damage, bruise, etc. on the components and parts. In the case of the above-
mentioned situation, please remove it with abrasive stone.
In principle, replace with new products for the O-ring and NHU seal ring.
When installing the O-ring and NHU seal ring, pay attention not to damage them. (For easy assembly,
please apply little grease)
When assembling components and parts, please use grease to prevent dropping.
Fasten the bolts, etc. according to mounting torque as shown in the assembly sectional diagram.
All connectors shall be sealed with plugs after installing to avoid intrusion of impurities.
7-153
Figure Steps
1. Install to the slide valve (301) according to the
sequence of washer (313), washer (217),
secondary pressure set spring (324) and spring
seat (311).
Caution: Washer 2 is used for presetting and
adjustment of spring for secondary pressure
setting. Because the thickness of each slide valve
is different, it may also not be used.
2. Place the lower end of slide valve (301) vertically

and uprightly on a flat workbench, press the
spring seat (311), and then install half-round
washer (215) on the spring seat upside. Do not
make the washer overlap in two-slices.
Caution: Make the acute angle (no arc) side
of washer 1 facing upward. Be careful not to
install the slide valve head forcedly.

more than 4 mm (0.16 In) for spring seat.
Caution: Make the acute angle side (no arc

side) of washer 1 face upward. Be careful not to
install the slide valve head forcedly.

more than 4MM (0.16In) for spring seat.
Acute
angle side
7-154
Figure Steps
3. Install the reset spring (335) into valve body.
Caution: Install it according to the position
before removing.
4. Install the pressure reducing valve group as a

pack into the valve body according to above-
mentioned No.4
before removing.
Caution: When installing the pressure

reducing valve group, be careful not to make the
lower end of slide valve excessive impact the
valve angle.
Note the valve body angle
7-155
Figure Steps
5. Install the O-ring (211) and O-ring (213) on to the
valve body.
6. Install the buffer housing (102) and housing (101)

together with hex bolt (220), and fasten them
according to the specified torque.
before removing.
Caution: the two hexagon socket bolts (220)

shall be evenly screwed so that the buffer
housing (102) is mounted in parallel and secured.
7. Attract the steel ball (225) to the weak magnet, or

install it into the buffer housing (102) with a pair of
tweezers, etc.
7-156
Figure Steps
8. Install the spring seat (218) into buffer housing.
before removing.
9. Install the buffer spring (336) into buffer housing.

before removing.
10. Install the buffer spring (337) into buffer housing.

before removing.
Caution: Note not to make it engage with the

buffer housing (336).
7-157
Figure Steps
11. Install piston (224).
before removing.
12. Install O-ring (212) onto the plug (202).
13. Install NHU oil cup (210) into push rod bushing.
Caution: pay attention to the direction when
NHU seal ring is installed.
Caution: apply a thin layer of grease to the

NHU sealing ring before installing to make it
easier.
7-158
Figure Steps
14. Install lubricating oil cup (203) into push rod
bushing.
15. Install the push rod (214) into the push rod
bushing.
Caution: The push rod surface shall be
applied with hydraulic oil before installing.
Caution: do not force it into as it may damage

the lip of the NHU seal ring.
16. According to (15) (16) (17) (18) items, the push

rod group shall be installed into the buffer housing
in the group form.
7-159
Figure Steps
17. Compress the bushing (412) on the valve cap
(201) with special tool 1, and then knock it with
hammer to press it into the cover.
Note: when pressing, pay attention not to
knock the sleeve end out of the inner side of the
cover plate.
18. Install the cover to the buffer housing.

before removing.
Caution: The cover may be ejected because

of the elastic force of the buffer springs (336),
(337).
7-160
Figure Steps
19. Install and fasten the hex bolt (271) according to
the specific torque.
Caution: The cover should be installed
horizontally without deflection.
Caution: Install the locating screw (471) to

the cam (420), and install the locknut (472)
temporarily.
20. Install the cam (420) on the cover.

before removing.
7-161
Figure Steps
21. Press the cam (420); meanwhile, insert the
camshaft (413) into the cam from outside.
22. The surface of the hex locating screw (423) shall

be applied with the thread rubber #241 or other
appropriate objects.
23. Install and fasten the hex locating screw (423)

7-162
Figure Steps
24. Adjust the height of the locating screw (471),
parallel the cam (420) upside with the cover
underside, and turn the cam right and left. After
confirm that the cam will not be loose in the
neutral position, install and fasten the locknut 472
Caution: Attach the 4 push rods (214) to
appropriate positions with the set screws. When
over-tightening the set screws, the control lever
shall be loose in the neutral position and acute
movement will happen when starting the engine
and attention shall be paid to this.
25. After tilting the cam, the push rod top side shall be
applied with the grease; meanwhile the grease
cup (203) of the plug (202) shall be filled with
grease.
Caution: When applying and filling the
grease, please do not damage the push rod and
the surface of the plug, and conduct with soft flat
material.
26. After inserting the upper end of rubber cover (501)

into cam, insert the lower end into the slot of
cover.
Caution: Before the rubber bushing lower
end is inserted into the cover groove, spray the
injection-type anti-rust oil onto the components
and parts in the rubber bushing.
Caution: If the rubber bushing is not inserted

into the groove properly or installed in a
distorting state, the dust tightness and
waterproofness shall be reduced.
7-163
Figure Steps
27. Install the seat (431). Install and fasten the hex
bolt (473) according to the specified torque.
28. Install the pedal (520), and install and fasten the
hex bolt (522) according to the specified torque.
29. At last, install the pedal cover (521) on to the

pedal (520).
7-164
7.5.10 Removal and Installation of Hand Pilot Valve Assembly

Removal of Left Hand Pilot Valve Assembly
the hydraulic tank.
Figure Steps
1. Pull out rubber jacket (1) of pilot valve, unplug
wire (2), remove locknut (3) of control lever, and
then remove the control lever.
7-165
Figure Steps
2. Remove the 4 mounting bolts (4) from the handrail
box, and move the handrail box cover out.
3. Remove 4 fixing bolts (5) from hand pilot.
4. Pull out hand pilot slightly, and remove 6 pilot

pipes (6).
5. Remove the hand pilot valve.
7-166
Installation of Left Hand Pilot Valve

• The installation of the left-hand pilot valve assembly is in the reverse order of removal. Tightening torque of
the joint: (36±2 ) Nm (26.6±1.5 lbf·ft);
• Tightening torque of hose joint: M18×1.5:(37±2)N.m(27.3±1.5lbf·ft).
Removal and Installation of Right Hand Pilot valve
By referring to removal and installation of left-hand pilot valve, remove and install the right-hand pilot valve.
7-167
7.5.11 Disassembly and Assembly of Hand Pilot Valve Assembly

Part drawing of hand pilot valve
This section introduces disassembly and assembly of two types of hand pilot valves, and the two types can be
installed on the machine. Please identify the type firstly, and then disassemble and assemble it in accordance
with the corresponding type.
For the part numbers involved in the section, this part drawing below shall prevails.
PV48K1 type
7-168
PV48KC1 type
(1) All components and parts have been processed precisely. Pay attention to handling with care and not
crashing or dropping components and parts.
(2) Remove without knocking, prising and cutting; otherwise; the components will produce trimming,
deformation and damage, which will result in failing to be assembled, oil leak and performance
degradation. Therefore, please operate with care and patience.
(3) It is recommended to continuously operating. If the operation is interrupted, please adopt the protective
measures against rust and dust.
7-169
Disassembly
Figure Steps
1. Clean the pilot valve with white kerosene.
Note: the port should be plugged.
2. Fix the pilot valve on the bench vive.

3. Remove the ripple protection cover (501).
Caution: Do not break and pinch the
protection cover (501).
4. Clamp distance between the adjusting nut (312)

and the disk (302) with a wrench. Remove the
adjusting nut and disk.
7-170
Figure Steps
5. Rotate the connector (301) to the left with a clamp
and then loosen it.
Caution: When the elastic force of the reset
spring (221) is large, the cover (151), the push rod
bushing (211) and the push rod (212) may be
ejected at the time of unscrewing the connector
(301). When pulling out the connector, they may
also be ejected out.
6. Remove the cover plate (151).

7-171
Figure Steps
7. The push rod bushing (211) may be blocked in the
valve body (101) because of the weak restoring
spring (221) and the O-ring slide resistance, and
please remove it with a straight screwdriver.
Caution: Utilize the bushing peripheral
groove under the condition of the bushing (211)
not being damaged result from deflection.
Notice: The push rod bushing (211) may be

ejected because of the elastic force of the
restoring spring (221).
8. Pull out the push rod (212), its bushing (211), the
pressure reducing valve group and restoring
spring (221) from the valve body (101).
Note: record the relationship between
positions of valve body hole.
9. Keep the interface plate (111) upward, and fix the

pilot valve on the bench vice by using the copper
plate.
10. Loosen the oil plug (293) with a hexagon socket
wrench. (For PV48KC1 only)
7-172
Figure Steps
11. Pull out the valve seat (291) from the interface
plate (111). (For PV48KC1 only)
12. Remove the steel ball (292) with the magnet, etc.
from the interface plate (111). (Only for PV48KC1)
As shown in the figure, hold the valve

seat and pull it out.
Pay attention not to damaging the joint
surface of steel ball.
Steel ball
Valve seat
LG922E930E07291
7-173
Figure Steps
13. Loosen the hexagon socket bolt (125) with a
14. Remove the interface plate (111) O-ring (122)

from the valve body (101).
15. Remove the bushing (131) from the valve body
(101).
7-174
Figure Steps
16. For removal of the pressure reducing valve,
pressing the spring seat (216) to compress the
secondary pressure spring (241) and meanwhile
make the spring seat (216) crosswise a bit and
pass via the bigger hole side, and then remove
the slide valve (201).
Then separate the slide valve (201), the spring
seat (216), the secondary pressure spring (241)
and the washer (217).
Be careful not to damage the surface of the slide
valve (206).
The room for further compressing of the spring
seat (216) is no more than 6 mm (0.24 In).
Keep it well as a pack until reassembly.
17. When installing the two segmented-breaking

spring (246) and its holder (218), remove them
from the push rod (212).
7-175
Figure Steps
18. Pull out the push rod (212) from push rod bushing
(211).
19. Remove the O-ring seal ring (214) and seal ring
(213) from the push rod bushing (211) with small
straight screwdriver or other tools.
7-176
Cleaning of Components and Parts
Put components and parts into a cleaning container filled with white kerosene and clean them roughly.
Put components and parts into a cleaning container filled with white kerosene, rotate slowly and clean
them until insides of them are completely clean. Wipe up white kerosene adhering to components and
parts with clean rag after cleaning.
Components and parts need soaking sufficiently, and clean them after impurities and grease float.
Unclean white kerosene can damage components and parts, and it can cause degradation of their
performance after assembling them, so it shall guarantee the cleanness of white kerosene.
Impurities and moisture in compressed air can cause rust, therefore do not dry them with compressed
air.
Rust prevention of components and parts

Apply anti-rust onto components and parts If they are placed without rust prevention after rinse, this may cause
rust and then affect their performances.
Assembly
Metal scraps and foreign matters of all parts during assembling shall be eliminated. Moreover, ensure
there is no trimming, damage, bruise, etc. on the components and parts. In the case of the above-
mentioned situation, please remove it with abrasive stone.
O-rings and protective washers shall be replaced with new ones in principle.
While installing the O-ring and the protective washer, take care not to damage them. (Please apply a
little lubricating grease for easy installation and smoothness)
When assembling components and parts, please use grease to prevent dropping.
All connectors shall be sealed with plugs after installing to avoid impurities.
The figure below shows tightening torque value of mounting torque of bolts, etc. Measure mounting torque
value with torque wrench.
Functional Thread
Tool(s) Dimension Mounting torque
parts Specification
Hexagon socket
Hexagon socket wrench 6mm(0.24In) M8 20.6±1.5Nm(15.2±1.1 lbf·ft)
bolt
Hexagon socket wrench
Only for (PV48KC1 5mm(0.2In) ROH oil plug G1/8 11.8±1.0Nm(8.7±0.7 lbf·ft)
specification)
7-177
22mm(0.87In) Adjusting nut M14

Wrench 68.6±4.9Nm(50.6±3.6 lbf·ft)
32mm(1.26In) Disk M14
Special clamp 24mm(0.94In) Joint M14 47.1±2.9Nm(34.7±2.1 lbf·ft)
Figure Steps
1. Fix the pilot valve with the copper board by
placing the mounting surface of interface plate
(111) upwards.
2. Install bushing (131) and O-ring (122) on valve
body (101).
7-178
Figure Steps
3. Put the gasket (121) between interface board
(111) and valve body (101), and fix it with hex bolt
(125).
Caution: Pay attention to the assembling
position when assembling the spring pin (126) in
the hole of the valve body(101).
Caution: The gasket(121) shall be replaced

with a new one.
4. Fix hex bolts (125) with a hexagon socket wrench

according to specified torque.
Caution: While installing, screw them in pairs
alternately and slowly.
7-179
Figure Steps
5. Install the steel ball (292) into the interface plate
(111) with magnet, etc. (PV48KC1)
6. And then install the valve seat (291) into the
interface plate (111). (For PV48KC1 only)
7. Fix the oil plug (293) to the specified torque with a

hexagon socket wrench. (For PV48KC1 only)
7-180
Figure Steps
8. Install washer 2(217), secondary pressure spring
(241), and spring seat (216) in sequence into slide
valve.
Then press in the spring seat (216) to compress
the secondary pressure spring (241) as stagger-
ing the spring seat (216) horizontally a bit, and
make it through the larger side of the hole and
then install it onto the slide valve (201).
Caution: The room for further compressing of
the spring seat (216) is no more than 6mm (0.24
In).
9. Install the reset spring (221) into the valve body

(101). Install pressure reducing valve group into
the valve body (101).
before removing.
7-181
Figure Steps
10. Install the O-ring (214) to the push rod bushing
(211).
11. Install the seal ring (213) onto the push rod
bushing (211).
Note: the lip side of the seal ring (213) should
be installed according to the figure below.
7-182
Figure Steps
12. Install the push rod (212) into the push rod
bushing (211).
Push rod
bushing If there is a spring (246) and a spring seat (218)
Sealing used for two segmented breaking, install them
onto the push rod (212).
Caution: Apply working oil onto the surface
of the push rod (212).
Push Apply
rod
working oil Caution: Be careful not to leave the slide
valve tilted (201); otherwise, it will cause damage
to the hole of the valve body (101).
LG922E930E07315
7-183
Figure Steps
13. Install the push rod group into the valve (101).
When elasticity of the reset spring (221) is weak,
the spring may not pop up because of sliding
resistance of the O-ring (214).
When the reset spring (221) is strong, the cover
(151) can be used to install 4 push rods with con-
nectors (301) temporarily at the same time.
Caution: Pay attention to the pop out of the
push rod bushing group and the cover (6).
7-184
Figure Steps
14. Install it on (151).
15. Install the connectors (301) to the valve body
(101) according to the specified torque with a
clamp.
16. Install disk (302) on the connector (301).

Caution: Adjust the 4 push rods (212) to the
even contacting position, and then install the
screws. If the screws are over screwed, it may
cause the base machine malfunction because the
control lever placed in the neutral position may
produce secondary pressure. So pay special
attention to the adjustment of to screwing
position of disc (302) screws.
7-185
Figure Steps
17. Here is the way to adjust nuts (312). Clamp
opposite sides of the disc (302) with a wrench and
install it on, then fix the adjusting nut (312) as per
specified torque.
Caution: While installing, do not move the
disc (302).
18. Apply grease onto slewing parts of connectors

(301) and the top of the push rod (212).
19. Install the ripple protection cover (501).

Caution: be careful not to break and pinch
the protection cover (501).
20. Add anti-rust to each port, and then install the

plug.
7-186
7.5.12 Removal and Installation of Travel Motor & Speed Reducer

Removal
the hydraulic tank.
Attach the identification label to each pipe to prevent wrong installation in the subsequence
procedures.
Figure Steps
1. Refer to the method for the removal of the track
assembly to remove it
2. Remove 4 M16 bolts (1), and then remove plate of
travel motor.
7-187
Figure Steps
1) Remove the 2 high-pressure pipes (3);
2) Remove the pilot pipe (4).
4. Unscrew 30 bolts (5), and remove sprocket.
5. Binding the travel motor with sling, adjust the rope

to the center-of-gravity position, and straining it
with hoisting equipment slowly.
7-188
Figure Steps
6. Remove 30 mounting bolts (6).
7. Remove travel motor.
Lifting weight: about 275kg (606.4 lb)
Installation
Figure Steps
1. Install the travel motor onto the track beam, and
the motor oil port shall face to the underframe
side.
7-189
Figure Steps
2. Clean bolt hole, apply thread locker Tonsan 1277
to mounting bolt, tighten the bolt timely, and apply
corresponding pretightening force to the bolt in
symmetrical cross strengthening method.
Tightening torque: 305±25Nm (225±18.4lbf·ft).
3. Tighten pilot pipe, oil return pipe and two high-

pressure pipes.
Tightening torque of M16 pilot pipe: 26±2Nm
(19.2±1.5lbf·ft)
Tightening torque of M22 oil return pipe: 47±2Nm
(34.7±1.5 lbf·ft)
Tightening torque of M36 high-pressure pipe:
126±6Nm(93±4.4lbf·ft)
7-190
Figure Steps
4. Tighten the plate mounting bolts of the travel
motor.
Tightening torque: 305±25 Nm (225±18.4lbf·ft).
7-191
7.5.13 Disassembly and Assembly of Travel Motor & Speed Reducer Assem-
bly
Relevant part drawing
Numbers involved in the section are subject to numbers in the following drawing.
Part drawing for reduction gear

7-192
Assembly diagram for treval motor and reduction gear
行走马达及减速机装配图

Removal and Installation
Section A-A
Section B-B Section C-C

CLG920E/922E/923E
September 15, 2020
7-193
Part diagram for hydraulic motor

液压马达部分零件图
7-194
Part list of slewing motor & speed reducer

1. Hub 106. Skid shoe 219. O-ring
2. Shaft 107. Thrust plate 220. Plunger seal
3. Fixed flange 108. Thrust steel ball 301. Rear cover flange
4. RV gear A 109. Thrust plate 323. valve rod
5. RV gear B 110. Washer 324. Screw plug
6. Axle gear 111. Bushing 325. Spring seat
7. Supporting gear 112. Plunger 326. Screw plug
8. End cover 113. Spring 327. Valve
9. Crankshaft 114. Spring 328. Spring
12. Gasket 115. Friction plate 330. Spring
13. Washer 116. Matching plate 336. O-ring
15. Sleeve 132. Oil seal 337. O-ring
17. Pin 135. O-ring 341. Plain pin
19. Hex socket screw 139. O-ring 343. Bolt
20. Elastic snap ring for holes 145. Elastic snap ring for holes 346. Hex socket screw plug
21. Angle bearing 149. Deep groove ball bearing 352. Hex socket screw plug
22. Cone bearing 150. Deep groove ball bearing 354. Hex socket screw
23. Needle bearing 151. Needle 355. O-ring
25. Elastic snap ring for rods 161. Plunger 357. Hex socket screw plug
27. O-ring 162. Skid shoe 358. O-ring
29. O-ring 167. Hinge 359. O-ring
30. O-ring 171. Positioning pin 3 363. valve rod
31. Floating seal ring 193. Spring 366. Spring
33. Screw plug 201. Valve 368. Steel ball
34. Mounting pin 202. Valve bushing 379. Filter
35. Hex socket screw 203. Spring stopper 380. Screw plug
36. Steel ball 204. Screw plug 381. Plunger
37. Washer 205. Snap Ring 382. Screw plug
42. Positioning pin 206. Spring 383. O-ring
43. O-ring 208. O-ring 384. O-ring
102. Drive shaft 209. O-ring 385. Steel ball
103. Swashplate 210. O-ring 397. Strainer
104. Cylinder block 211. Support ring 398. Hex socket screw plug
105. Plunger 217. Support ring 399. Nameplate
7-195
Special tool
No. Name Figure Quantity
1 Pre-tightening clamp of bearing 1
2 Fixing clamp 2
3 Press-in tool 1
7-196
4 Press-in tool (I) 1
5 Press-in tool (II) 1
6 Press-in tool (III) 1

7-197
7 Press-in tool (IV) 1
8 Cusp chisel 1
9 Bar 1
7-198
10 Aluminum bar 1
11 Sling 1
12 Inserting clamp (I) 1

7-199
13 Inserting clamp (II) 1
14 Press-in tool (III) 1
15 Lifting clamp 1
7-200
16 Pull-up clamp 1
17 Plugging tool 1
Disassembly
Before disassembly, make a judgment about spot check item and anomalous nature of abnormal spot,
and then disassemble it in the disassembly sequence.
During disassembly, operate in accordance with aftermentioned disassembly steps in clean site.
Lay the rubber and plastic gasket on the workbench.
Be sure to mark the junction surface of each component during disassembly.
Do not bump and lose components during disassembly, and settle the removed components.
Once the seal component is removed, Even if you think there is no injury or abrasion, it must be
replaced in principle, and it is not allowed to deform the component.
7-201
Figure Steps
1. Remove the valve group from the rear flange
[301].
2. Remove O-ring [208], [209], [210] and support
ring [211], [217] from the valve group.
Caution: The removed O-ring cannot be re-
used
Impact wrench and ratchet wrench

Screw socket (32mm) (1.3In)
3. Remove 12 hex screws [343].

Ratchet wrench
Additional pipe
Hexagon socket wrench (14mm) (0.55In)
4. Remove relief valve group from spindle [2].

Caution: Drive shaft [102] may be removed
together with the relief valve.
7-202
Figure Steps
5. Remove thrust plate of valve group [109], dowel
pin [341] and ball bearing [150] from relief valve
group.
6. Remove 2 O-ring [29] and O-ring [2] from spindle.
used
7. Turn over the travel motor assembly with the

cover facing upward
8. Remove 3 plugs [33].
9. Remove 12 hex screws [33].
Ratchet wrench
7-203
Figure Steps
10. Install 2 lifting rings (PF1/2) in threaded hole of
plug [33] on the cover.
11. Tighten the lifting ring, and then lift cover [8].
Caution: If it is difficult to take off the cover
because of the O-rings or other reasons, knock it
on gently with plastic hammer.
12. Remove O-ring from the cover.

used
13. Release gear oil

Lifting tool
Lifting ring (PF1/2)
Plastic hammer
Waste oil container (about 8L)
1. Disassembly of brake valve
Figure Steps
1. Remove spool [323]
1) Remove the 2 plugs [301] from cover flange.
Remove O-ring [336] from each plug.
Caution:
Remove 2 plugs [324] already unscrewed when

the relief valve is installed on spindle.
The removed O-ring cannot be re-used.
Ratchet wrench
7-204
Figure Steps
2) Remove 2 springs [328], check valve [325] and
spool [323] from cover flange [301].
Caution:
Protect outside surface of spool [301] and

actuating surface of cover flange [323].
Spool and cover flange are matched, so cover

flange gp must be replaced when any part is
replaced.
Ratchet wrench
2. Removal of check valve

1) Remove the plug [326] from cover flange [301].
Caution: Remove the 2 plugs [326] already
unscrewed when the relief valve is installed on
spindle.
Hexagonal rod wrench

Ratchet wrench
2) Remove the 2 springs [330] and valve[327].

Caution: Be careful not to damage the relief
valve [301] and valve [327].
3) Remove the O-ring [337] from plug [326].

used.
7-205
Figure Steps
3. Remove spool [363]
1) Remove the plug [357] from the relief valve [301].
Caution: Remove plug [357] already
unscrewed when relief valve [301] is installed on
spindle [2].
3.2. Remove spool [363] from relief valve [301].

3.3 Remove the O-ring [355] from plug [357].
The removed O-ring cannot be re-used.
4. Remove inner components from relief valve [301].

1) Remove the 2 plugs [380] from the relief valve
[301].
used.
Hexagon wrench joint (8mm) (0.3In)

7-206
Figure Steps
3) Remove the piston [381] from the relief valve
[301].
Caution: Actuating surface of the piston
cannot be damaged.
Piston and relief valve are matched, so the relief

valve group must be replaced when any part is
replaced.
4) Remove the 2 bolts [382] from cover flange [301]

5) Remove the O-rings [383], [384] from the plug
[382].
used.
6) Remove the 2 steel balls [385] from the relief

valve [301].
7-207
Figure Steps
5. Remove safety valve group.
1) Remove the plug [204] from valve bushing [202].
3) Remove the shim [205] from plug [204]

7-208
Figure Steps
4) Remove spring stop dog [203], spring [206] and
valve [201] sequentially.
7-209
Figure Steps
5) Remove piston seal [220] from valve [201].
6) Disassemble another safety valve in the same
Piston seal steps.
Valve
2. Disassembly of hydraulic motor assembly
Figure Steps
1. Disassemble parking brake
1) Rem ove the piston [112] from cavity of shaft [2]
with the compressed air.
Caution: If compressed air is pumped too
rapidly, piston [112] may fly out from spindle [2],
which may lead to injury, therefore put a
protective cap, etc. on the plunger [112] to protect
operator.
Compressed air 3~5kg/cm² (43.5~72.5 psi)

Air gun
7-210
Figure Steps
2) Remove the O-rings [135] and [139] from the
piston [112].
used.
2. Remove components in the assembly

1) Turn over the travel motor assembly to the
assembly side
2) Empty the hydraulic oil from the assembly cavity.
3) Remove cylinder block [104] out of the cavity of
the spindle [2] by holding it with hands.
Caution:
While overturning assembly side, place an oil

container below it to make hydraulic oil flow into
the container.
Before removing cylinder block, turn it clockwise

and anticlockwise for 2 or 3 times, and remove it
from swashplate; otherwise, some piston may fall
into the cavity of spindle.
Oil collecting container

7-211
Figure Steps
4) Remove the friction plate [115] and oil distribution
plate [116]
5) Remove the piston group [105, 106], thrust plate
[107], thrust steel ball [108], washer [111], and 5
ejector rods [151] from the cylinder block [104].
Caution: Cylinder body, piston group, thrust
plate, etc. cannot be supplied separately, and they
can be purchased together as a whole.
6) Remove swashplate [103] from the cavity of

spindle [2].
7) Pull out the drive shaft [102] from the spindle[2]

(bearing [149] shall be pulled out together with
the drive shaft [102]).
Caution: Do not take out the oil seal
simultaneously.
8) Remove the 2 fulcrum shafts [167] and 2 pins

[171] from the spindle [2].
Caution: It is easy to pull out the drive shaft
[102] by knocking the top of drive shaft on the
speed reducer gently with plastic hammer firstly
before pulling it out. If it is knocked heavily, the
drive shaft [102] may fly out suddenly.
7-212
Figure Steps
9) Infiltrate 2-speed oil circuit by compressed air,
and remove piston gp and spring [193] from the
cavity of spindle [2].
Caution: Piston [161] and skid shoe [162], as
a whole, cannot be supplied separately, and only
the piston group can be supplied.
Caution: If compressed air is pumped too

rapidly, the piston [112] may fly out of the spindle
[2], which may lead to injury, therefore put a
protective cap, etc. on the thrust plate [112] to
protect the operator.
Compressed air (3~5kg/cm²) (43.5~72.5psi)

Air gun
3. Disassemble the cylinder block
1) The cylinder block is placed on a workbench and
the press-in clamp is placed on the washer [110].
Caution: Pressure load is beyond 200kg
(19.60Mpa).
2) Press the press-in clamp by compressing it

slowly, and remove spring backup ring [145] from
backup ring slot with backup ring pliers.
Caution:
Before pressing in, make sure to line up the axes

of press-in metal clamp (1), washer [110] and
cylinder block. Protect the cylinder block from
being bumped.
Apply a layer film on the cylinder block to protect

the surface of cylinder block [104] from scratch.
7-213
Figure Steps
3) Remove elastic snap ring [145], spring [114] and
washer [110].
Caution: Never remove spring [114] from the
cylinder until making sure to replace the spring
[114].
Loosening the compressed spring [114] rapidly

may make it fly out and lead to personal injury. So
relax the compression slowly.
3. Disassembly of speed reducer
Figure Steps
1. Remove sun gear
Remove steel ball [36] and input gear [6] from
sleeve [15].
7-214
Figure Steps
2. Remove gear bracket
1) Remove elastic snap ring [25] from each drive
shaft [9] of planetary gear.
2) Remove gear bracket [7] from each drive shaft [9]
of planetary gear drive shaft.
Caution: Use the cusp of pliers to remove
backup ring, and the backup ring may fly out, so
pay attention to it.
Retainer pliers
3. Remove the sleeve

1) Remove the sleeve [15] from drive shaft [102].
4. Remove support flange

1) Turn the turntable to the top and bottom position,
and make spindle[2] upwards.
2) Fix the housing [1] and spindle [2] with fixed tool.
Caution: Before removing support flange [3],
the housing [1] and spindle [2] must be fixed by
fixing tool; otherwise; the spindle [2] may fall on
the operation platform.
Fixing clamp
Hexagon wrench
7-215
Figure Steps
3) Turn the turntable to the top and bottom position,
and make support flange [3] upwards.
4) Remove the 3 spring backup rings [20] and 3
washers [13] from support flange [3].
Caution: Make position mark on washer [20]
and support flange [3] with oil pen, so that the
reassembly can be operated in accordance with
the marked position.
Retainer pliers
5) Grind off the fullering bulge on the holes of 6
parallel pins [34] on support flange [3] with air-
actuated grinding head.
Caution: Please wear protective glasses and
face mask while grinding off fullering bulge in the
hole.
Air-actuated grinding head

6) Place clamps for pulling out the pin, screw stud
into dowel pin [34], screw the nut and pull up
dowel pin [34] until the upper end of dowel pin
[34] sprays to the lower end surface.
Large-torque hexagon wrench (22mm) (0.87In)
7-216
Figure Steps
7) Unscrew 3 hex screws [6] slowly and remove
them.
Caution: Binder is applied in a threaded hole
of hex screw [19]. It is difficult to loosen it, so
unscrew the hex screw [19] slowly.
Large-torque hexagon wrench (19mm) (0.75In)
8) Remove support flange [3] from the spindle [2].

Caution: Make marks as the alignment
identification of support flange [3] and spindle [2]
on support flange [3] with oil pen and the
identification line must be aligned during
reassembly.
5. Remove the fixing clamp
Turn the workbench to upper and lower direction,
and make the spindle upwards.
9) Remove 2 fixed clamps.
6. Remove the spindle
Screw 2 lifting rings and then lift spindle [2] from
housing [1].
Caution: Protect the main bearing from being
bumped while lifting the spindle.
Lifting ring (M16)

7-217
Figure Steps
7. Remove speed reducer assembly, ball bearing
[21] and pin [17]
1) Knock cusp chisel with hammer so as to knock
bearing [21] out from housing [1], and remove
speed reducer gp and pin [17].
Caution:
Hammer Protect ball hearing [21] from being damaged
Sharpen punch while removing it, and knock the end face of pin
with hammer and cusp chisel at the position of
trisection or quartering position, so as to knock
Pin out ball bearing [21].
Ball bearing While ball bearing [21] coming out the housing,
ball bearing [21], speed reducer gp and pin may
drop, so place rubber pad under workbench to
avoid bumping.
Speed reducer group consists of speed reducer

group, planetary gear drive shaft, gasket, and
components in ball bearing can not be supplied
separately, so please purchase them as a set
when they are needed.
8. Remove the ball bearing [21]
Hammer 1) Remove the floating seal [31] from the housing.
2) Overturn the turntable to upper and lower
direction.
3) Knock ball bearing [21] in the housing with
Sharpen punch
hammer and cusp chisel, and then remove it.
Hammer
Cusp chisel
Ball bearing
7-218
Figure Steps
9. Remove components in spindle [2].
1) Remove the floating seal [31] from the housing.
2) Remove the outer ring of cone bearing [22] from
the spindle [2].
10. Remove the outer ring of cone bearing [22] from

support flange [3].
Remove 3 outer rings of cone bearing [22] from
the support flange [3].
11. Remove oil seal [132]

Remove the oil seal [132] from spindle as shown
in the figure.
Caution: The removed oil seal [132] can not
Oil seal
be used again.
Screwdriver (small size)

Hammer
7-219
Figure Steps
12. Remove ball bearing [149].
1) Place the keeper [II] on a workbench, and insert
the drive shaft [102] in keeper [II].
2) Press the ball bearing [149] from the end of drive
shaft [102] with compressor.
Caution: Do not remove the ball bearing [149]
unless a replacement is required.
Caution: The removed ball bearing [149]

cannot be reused.
Press
Keeper [II]
7-220
Assembly
Operation shall be carried out in a clean site.
It is prohibited to wear fabric gloves during assembly.
Sealing elements such as O-ring and floating SEA, etc. must be replaced while parts damaged during
assembly are repaired.
The removed hex screw [19] must be replaced, and then conduct the assembly.
Each part must be cleaned thoroughly and be blown to dry with an air gun.
Moving parts, sliding contact surface and other parts of hydraulic system assembly must be applied
with grease [class NAS9] with good cleanliness before assembly.
During the installation of bolt and plug in refixation position, the torque of torque wrench shall be
subject to the specified value shown in the following table.
Part number Name Thread dimension Quantity Tightening torque

19 Hex socket screw M24(P3.1) 3 708.5±107.8Nm(522.5±79.5 lbf·ft)
33 Plug PF1/2 3 98.1±19.6Nm(72.3±1 lbf·ft)
35 Hex socket screw M12(P1.75) 12 102±15.7Nm(75.2±11.5 lbf·ft)
202 Valve bushing PF1 2 245±49.0Nm(180.7±36.1 lbf·ft)
204 Plug PF1/2 2 98.1±19.6Nm(72.3±14.5 lbf·ft)
324 Plug M36(P1.5) 2 441±88.2Nm(325.2±65 lbf·ft)
326 Plug M36(P1.5) 2 255±39.2Nm(188.1±28.9 lbf·ft)
343 Hex socket screw M16(P2.0) 12 252±39.2Nm(184.3±28.9 lbf·ft)
346 Plug PF1/4 2 29.4±4.9Nm(21.7±3.6 lbf·ft)
352 Plug PF1/4 2 29.4±4.9Nm(21.7±3.6 lbf·ft)
354 Hex socket screw NTPF 1/16 8 9.8±2.45Nm(7.2±1.8 lbf·ft)
7-195
357 Plug PF1/2 2 98.1±19.6Nm(72.3±14.5 lbf·ft)
380 Plug PF3/8 2 58.8±9.81Nm(43.3±7.2 lbf·ft)
382 Plug PF1/8 2 14.8±2.45Nm(10.9±1.8 lbf·ft)
398 Hex socket screw PF1/8 4 12.3±2.45Nm(9.1±1.8 lbf·ft)
7-221
1. Assembly of control valve
Figure Steps
1. Assemble the check valve
1) Install the O-ring [337] to plug [326].
2) Install spring [330] and valve [327] to plug [326],
apply lubricant on the spring [330] and valve
[327], and then fix the spring.
3) Install a plug [326] on the relief valve [301], and
then tighten it to specified torque.
Caution:
Apply lubricant on O-ring [337].
Apply seal on the plug [326].
Screw the plug [326] with torque wrench.
Tightening torque (255±39.2) Nm (188.1±28.9)

lbf·ft
Torque wrench
2. Assemble the spool
1) Insert the spool [323] into the relief valve [301].
2) Install the O-ring [336] into the plug [324].
Caution:
Apply hydraulic oil on spool [323], and then insert

it in the relief valve [301].
Axes of the relief valve shall be aligned to the

spool axes when installing spools. Protect the
hole of relief valve and spool periphery from
being damaged by contact.
The hole of relief valve and spool periphery may

be damaged because of contact, after the
assembly, interior of travel motor assembly may
leak oil, and then the performance may be poor.

7-222
Figure Steps
3) Install check valve [325] and spring [328] to the
plug [324], screwing the plugs [324] (two) in the
relief valve [301], and tighten them to specified
torque.
Tightening torque (441±88.2) Nm (325.2±65) lbf·ft
Caution: The relief valve [301] is in the relief
valve group, so the whole of relief valve group
must be replaced if one of the above-mentioned
component is needed to be replaced.
Torque wrench
Socket wrench 41mm (1.6In)
3. Assemble the 2-speed control valve [363]

1) Install O-ring [355] into plug [357].
2) Put the spring [366] on spool [363] and then
insert the spool [363] in the hole of rear flange
[301].
Caution:
Apply hydraulic oil on spool [363].


assembly, interior of travel motor assembly may
leak oil, and then the performance may be poor.
7-223
Figure Steps
4. Install plug [324] to rear flange [301] and tighten it
to specified torque.
Tightening torque (98.1±19.6 ) Nm (72.3±14.4 )
lbf·ft
5. Assemble the internal parts of rear flange

1) Mount the steel ball (385) in the rear flange (301).
2) Install the O-ring [383], [384] into the plug [382]
Caution: Apply lubricant on O-ring [383] and
[384].
3) Install plug [382] to relief valve [301] and tighten it

to specified torque.
Tightening torque (14.8±2.45) Nm (10.9±1.8) lbf·ft
7-224
Figure Steps
4) Insert the plunger into the rear flange [301];
5) Install O-ring [359] into plug [380];
Caution:
Apply hydraulic oil on spool [323], and then insert

it in the relief valve [301].


assembly, interior of GM as may leak oil, and then
the performance may be poor, so pay attention to
this point.
The relief valve [301] and piston [381] compose

the relief valve group, so the whole of relief valve
group must be replaced if one of the above-
mentioned components is needed to be replaced.
6) Install plug [380] to rear flange [301], and tighten
the plug [380] in specified torque.
Tightening torque (58.8±9.81) Nm (43.4±7.2) lbf·ft
7-225
Figure Steps
6. Assemble safety valve.
1) Install the O-rings [208], [209] and [219] and
backup ring [211], [217] to the valve bushing
[202].
2) Install O-ring [210] into plug [204].
Caution: Apply lubricant on O-ring [383] and
[384].
3) Place the shim [205] into the screw plug (204).
Caution: Shim removed during disassembly
is used because the pressure is adjusted by the
shim, and if any inner part is needed to be
replaced, the whole valve body must be replaced.
4) Mount the piston seal (220) into the valve (201).

Caution: The piston seal [220] is composed
of O-ring and seal ring, apply lubricant on the O-
ring and seal ring, and then install O-ring and seal
ring on the valve [201].
7-226
Figure Steps
5) Install valve [201], spring [206] and spring stop
dog [203] in the valve bushing [202], and tighten
the plug [204] in specified torque.
Caution:
Apply hydraulic oil on the periphery of valve [201],

and then install it in the valve bushing [202].
During the installation of valve bushing, the axes

of valve bushing shall be aligned to the axes of
valve. Protect the valve seal from being damaged
by contact.
The pressure of the component to be removed is

debugged, so the whole of safety valve gp shall
be replaced if one of the above-mentioned
components is needed to be replaced.
In order to avoid falling off, apply grease on both

face of the shim, adhere it to the plug and then
install the plug in the valve sleeve.
Tightening torque (98.1±19.6) N.m (72.3 ± 14.5)

lbf·ft
7-227
Figure Steps
7-228
2. Assembly of speed reducer and hydraulic motor

During the reassembly after component replacement, two parts require the intermittent adjusting. Bearing
pretightening adjusting and washer S adjusting Make sure whether the following components are replaced with
new ones before assembly.
Component
replacement
No Yes
Replace the Replace the

component component
housing [1] Rotating shaft
Rotating shaft assembly
assembly Redution gear
Ball bearing [21] assembly
[A] Perform the [C] Adjust the

assembling in [B] Adjust the
ball bearing radial clearnace
accordance with of cone bearing
following steps.
When the above components are assembled after verification, they must be used after being adjusted one by
one. If components are used without adjustment, it may lead to poor operation and early damage of travel
motor assembly.
7-229
Figure Steps
1. Assembly of housing [1]
1) The housing [1] is lifted in operation platform with
the opening upwards, and tighten 3 screws
uniformly.
2) Install the periphery of ball bearing [21] into the
housing [1] with press-in tool and hammer.
Hammer
3) Install floating seal [31] in the housing [1] with
Press-in tool press-in clamp [I] [II].
Ball bear ing
Caution:
Hub
The O-ring of floating seal [31] cannot be applied
with lubricant.
Install the floating seal in housing in the following

sequence: press-in clamp [I], float seal, and then
use the press-in clamp [II]. Press the press-in
clamp [II] until it contacts the press-in clamp [I].
Check and make sure that the O-ring is installed

in housing [1] correctly.
Press-in clamp [I]

Press-in clamp [II]
2. Assemble spindle [2].
1) Use press-in clamp [II], [III] to install the floating
seal [31] in the floating seal slot of spindle [2].
Caution:
The O-ring of floating seal [31] cannot be applied

with lubricant.
Install the floating seal in housing in the following

sequence: press-in clamp [III], float seal, and then
use the press-in clamp [II]. Press the press-in
clamp [II] until it contacts the press-in clamp [III].
Check and make sure that the O-ring is installed

in housing [1] correctly.
Press-in clamp [II]

Press-in clamp [III]
7-230
Figure Steps
3. Assemble housing [1] and spindle [2]
1) 3.1 Install two lifting ring on the symmetric
position of the spindle [2].
2) 3.2 Hitch the hook, and put the spindle [2] in the
housing [1] slowly.
2 lifting rings
Lifting tool
3) Remove the lifting ring, fix the housing [1] and

spindle [2] with 2 fixing clamps in symmetric
positions.
4) Overturn the workbench and make the cover
upwards.
Caution: Overturn it by 180 degree.
2 fixing clamps
Hexagonal rod wrench
5) Align the periphery of cone bearing [22] (three) to
the periphery hole on spindle [2], and then install
them.
7-231
Figure Steps
4. Assemble speed reducer assembly.
1) Install the sling (II) in the center hole of the speed
reducer assembly.
2) Lift and hold the speed reducer assembly and
align it to the position on spindle [2], and install
the speed reducer assembly to spindle [2] slowly.
3) Install pin [17] (24 pins) in the slot pin between
speed reducer A [4], B[5] and housing [1].
Caution: Apply gear oil on each pin.
Sling (II)
5. Assemble the ball bearing [21]
Hammer
1) Place the ball bearing [21] in housing [1], and
knock the press-in tool with hammer to press-in
Press-in tool the ball bearing.
2) Install the periphery of the 3 cone bearings.
Angoiar ball Caution: Knock the periphery with hammer to
bear ing verify that the ball bearing is installed into the
housing.
Hammer
Press-in tool
6. Assemble the support flange [3]

1) Install the support flange [3] to ball bearing of
spindle [2].
Caution: Assemble it in accordance with the
joint mark on the spindle [2], support flange [3]
and planetary carrier drive shaft.
7-232
Figure Steps
7. Assemble parallel pin [34] and tighten hex screw.
1) Apply Loctite on the thread position of screw [19],
and put the washer in three holes.
2) Tighten the 3 hex socket screws with the
tightening torque of 20N.m.
3) Insert the parallel pin in the hole and drive them
in the pin hole one by one with force gun.
Caution:
If there is oil or grease on pin and hex screw,

degrease them with degreasant, and then dry
them.
Never mistake the direction and position of

periphery.
Torque wrench
Hexagon joint
Force gun
Compressed air5~6 kgf/cm² (72.5~87 psi)
Press-in tool
Hammer
4) Tighten 3 hex screws with the torque wrench
Tightening torque (72.3±11) Nm (53.3±8.1) lbf·ft
Torque wrench
If the following part is to be replaced,

• S pin as
• Speed reducer assembly
Adjust it referring to "[c] Adjust axial clearance of cone bearing", and then carry out the following operation.
7-233
If no component is required to be replaced, carry out the following operation directly.
Figure Steps
8. Assemble elastic snap ring and distance piece
1) Install the distance piece [13] into the support
flange.
2) Install elastic snap ring [20] to elastic snap ring
slot in the support flange [3].
Caution: During the assembly of 3 distance
pieces [13] and elastic snap ring [20], align the
marks made during the disassembly of support
flange [3], and then install them in the same
position as that before disassembly.
Retainer pliers
9. Assemble the gear bracket

1) Install 3 gear brackets [7] to planetary gear drive
shaft R [9] .
Caution: During the assembly of 3 gear
brackets, align the marks made during the
disassembly of support flange [3], and then install
them in the same position as that before
disassembly.
Retainer pliers
2) Install 3 elastic snap rings [25] in the elastic snap

ring slot of planetary drive shaft [9].
Caution: The spring backup ring may fly out.
Make the side of sharp corner on spring backup
ring upwards.
Retainer pliers
7-234
Figure Steps
10. Assemble oil seal
1) Turn over the travel motor assembly
2) Install the oil seal [132] in the oil seal hole on
spindle [2].
Caution: Apply white vaseline or lubricant on
the lip of oil seal [132].
Hammer
Press-in tool (III)
11. Assemble drive shaft [102]

Install ball bearing [102] to the drive shaft [169]
Caution: Wear the leather glove and then
install the bearing. Ensure that the cone of ball
bearing is compressed to the seat.
Heating groove
Leather gloves
12. Install plunger assembly ([161] [162])
1) The spring [193] is installed in piston as [161
[162] and the piston hole in the spindle [2].
2) Install in the spindle [2].
Caution: The spring is adhered with grease
and apply hydraulic oil on external diameter of
piston group.
13. Assemble the fulcrum shaft [167]

1) Insert the 2 pins [171] in the spindle [2].
2) Install the 2 fulcrum shafts [167] to the pins.
Caution: Apply grease on the junction
surface of the fulcrum shaft.
7-235
Figure Steps
14. Assemble the cylinder block
1) Install the washer [110], spring [114], and washer
[110] in the drive shaft hole of cylinder block [104]
in order.
2) Place the cylinder block [104] on the compressor
to compress the spring [114].
Pressure workbench
3) Place keeper [?] on the last washer, switch it on

and press the pressure head until the backup ring
slot in the drive shaft hole of cylinder block [104]
can be seen clearly. Install spring backup ring in
the slot and then release the pressure.
Caution: Cover the drive working surface of
the cylinder block with plastic film.
Caution: The spring backup ring may fly out.
Refer to the left figure for how to install washer

[110], and elastic snap ring [145].
Pressure workbench
Press-in tool (I)
Retainer pliers
15. Assemble the motor assembly

1) 15.1 Insert 5 needle rollers [151] in the pin of
cylinder block [104].
2) Install washers in each end surface of 5 rollers.
3) Install the thrust steel ball [108] to washer [111].
Caution: Soak the components as a whole in
hydraulic oil.
7-236
Figure Steps
4) Install plunger assembly [105] [106] to the thrust
plate [107].
5) Insert the above components in the hole of
cylinder block [104]
6) Upon the assembly of drive shaft [102],

Lifting sling (I) swashplate [103], oil distribution plate [153],
thrust steel ball [108], washer [111], thrust plate
[107], ball bearing [151], cylinder block [104], and
piston assembly, install it on the drive shaft
lengthways with lifting clamp.
Crane
Sling [I]
7-237
Figure Steps
16. Assemble the assembly components
1) Lift the motor assembly with the sling [I], and then
install it in the spindle [2].
2) Upon the installation, remove the sling [I].
Caution:
Fit the fulcrum shaft hole on swashplate [103] and

fulcrum shaft.
Avoid bumping while installing it into the spindle

[2].
Upon the installation of motor assembly, turn the

cylinder block with hands to ensure that it cannot
stagnate, remove it to check and then install it
again.
7-238
[A] Adjustment of ball bearing

The ball bearing [22] must have proper pretighten- Torque lench
ing force to satisfy its life cycle requirement, and the
replacement of any one component influencing the
pretightening force of ball bearing must be carried Special nut
out in accordance with the following steps. Asjusting jig
• Ensure that all adjustments are correct during hub

the reassembly of the assembly. Incorrect Spindle
adjustment may lead to earlier damage.
• Components influencing the pretightening force
of the bearing include: housing [1], spindle
group and ball bearing [21].
• Ensure to adjust the pretightening force as fol- Depth micro-meter
lows:
Tool(s):
• Adjusting clamp used for pretightening force of
ball bearing Hub
Spindle
• Depth indicator
• Torque wrench
• Socket wrench 30mm (1.18In) Asjusting jig
1. Install the adjusting clamp used for pretightening

force of ball bearing on spindle [2], and then
tighten the nut in tightening torque specially set
to 12±2kgf-m, so as to compress the ball
bearing [21] installed in the housing.
2. Measure the size of "A" with depthometer from
the measuring hole on the adjusting clamp used
for pretightening force of ball bearing.
3. The "B" size of adjusting clamp used for
pretightening force of ball bearing is known, so
calculate the "C" size of clearance:
• “C”=“A”-“B”
• A = measured value B = clamp thickness size C
= clearance required
7-239
Ensure that all adjustments are correct during the

reassembly of the assembly. Incorrect adjustment
may lead to earlier damage.
Surface E
• If any above mentioned component is required
to be replaced, the axial clearance is required to
Hold flange be adjusted again.
• The steps to adjust the axial clearance of cone
bearing are as follows:
Retainer (IV)
4. Determine the size “D” of support flange [3]. Taper roller bearing
5. In accordance with the measuring result of (2)-
(4), adjust the support flange [3] following the
RV gear ass’y
steps below.
• Size "C" of support flange [3] is required to be
measured.
• "D" = "C" ±0.02, size "D" is adjusted to the equa-
tion size.
(a) If the actual size "D" of support flange [3] is less Tool(s):
than the specified size, Cut surface E of support
flange [3] to the specified size. • Press-in tool (IV)
(b) If the actual size of support flange [3] is within • Hammer

the tolerance, use it in the current situation. • Thickness gauge
(c) If the actual size "D" of support flange [3] is more 1. For the press-in toll (IV) on the periphery of cone
than the specified size, Replace new spindle gp bearing [22] on the planetary drive shaft [9]
[3]. Measure and adjust size "D" of support compressed in the speed reducer as, knock it
flange [3] again. gently with hammer.
6. Remove Adjusting clamp used for pretightening 2. Assemble the thinnest washer [13] in support
force of ball bearing from spindle [2]. flange [3].
[B] Adjust the axial clearance of cone bearing. 3. Knock the periphery of washer [20] gently with
If the aftermentioned components are required to be hammer and press-in tool (IV).
replaced, reselect the thickness of washer to adjust Ensure that the speed reducer gp has been
the axial clearance of cone bearing [22]: housing installed into the spindle.
[1], spindle group, speed reducer group and spring
4. Install elastic snap ring [20] in the slot of support
backup ring [20]. flange [3].
5. Measure the clearance between spring backup
ring [20] and cone bearing [22] with depth
gauge.
7-240
6. Verify whether the thickness of elastic snap ring Table of clearance adjustment components
is correct or not:
Washer [13]
Max.= thickness of plug gauge+ thickness S of
washer installed
Min.= thickness of plug gauge + thickness S of
washer installed - 0.05
7. Select another washer S in the following table to
install in the gap between washer S and spring
backup ring.
Mark of
Size, mm (In)
category
E 3.30~3.35mm(0.130~0.132 In)
F 3.35~3.40mm(0.132~0.134 In)
G 3.40~3.45mm(0.134~0.135 In)
H 3.45~3.50mm(0.135~0.138 In)
I 3.50~3.55mm(0.138~0.140 In)
J 3.55~3.60mm(0.140~0.142 In)
K 3.60~3.65mm(0.142~0.144 In)
L 3.65~3.70mm(0.144~0.146 In)
M 3.70~3.75mm(0.144~0.148 In)
N 3.75~3.80mm(0.148~0.150 In)
O 3.80~3.85mm(0.150~0.152 In)
P 3.85~3.90mm(0.152~0.154 In)
Q 3.90~3.95mm(0.154~0.156 In)
R 3.95~4.00mm(0.156~0.157 In)
S 4.00~4.05mm(0.157~0.160 In)
T 4.05~4.10mm(0.160~0.161 In)
U 4.10~4.15mm(0.161~0.164 In)
7-241
Figure Steps
1. Install sleeve [15] to the drive shaft.
2. Install sun gear [6] to sleeve [15], and then put the
steel ball [36] in the hole of sun gear [6].
Caution: Apply grease on the steel ball [36].
3. Install O-ring [30] to the slot of cover [8].

Caution: Apply grease on the O-ring [30].
4. Lift the mounting cover [8] to the spindle [2] with

sling, lifting ring and plastic hammer.
Caution: Protect the O-ring [30] from being
bumped.
Lifting tool
Lifting ring
Plastic hammer
Container, 8L (about 0.3cu ft)
5. Tighten 12 hex screws [35] to specified torque.

6. Pour the gear oil in housing [1].
Tightening torque 10.4±1.6Nm (7.67±1.2)lbf·ft
Torque wrench
Screw socket 10mm (0.39In)
Gear oil 5.4L (0.2cu ft)
7-242
Figure Steps
7. 23. Install the O-ring [43] to plug and then tighten
the plug [33] to specified torque. (3 gear oil ports)
Tightening torque: 25±5Nm (18.4±3.7)lbf·ft
8. Install the cylinder block [115] into spindle [2], and

then install return plate [116] to the cylinder block
[104]. The operation shall be carried out in order.
Caution: The cylinder block is required to be
soaked in hydraulic oil before installation.
Caution: Never mistake the installation

sequence of cylinder block [115] and return plate
[116]; otherwise; the brake torque may reduce.
9. Apply grease on O-ring [135] [139], and then

install them in the O-ring slot of piston [112].
10. Install the piston [112] into the spindle.
Caution: As the O-ring [112] contacts with pin
DLE [112], knock the piston [112] with plastic
hammer gently to install piston [112] smoothly
and uniformly. Protect O-ring [112] from being
damaged.
Plastic hammer
7-243
Figure Steps
11. Install the ball bearing [150], parallel pin [341],
thrust plate [109], 12 springs [113] to the rear
flange [301].
Caution: Apply hydraulic oil on the ball
bearing, and apply grease on the thrust plate and
12 springs.
Grease and hydraulic oil
12. 28. Pour hydraulic oil on the spindle [2], install O-

ring [27] [29] in the slot, fit the faces on the spindle
[2], do not apply grease on it, and insert 2 pins
[42] in the spindle [42]. Align the relief valve [301]
to pin [42] hole and install it to spindle [2].
Hydraulic oil is about 1.7L (0.06cu ft)
13. Tighten 12 hex screws [343] to specified torque.

Tightening torque: 25.7±4Nm (19±3)lbf·ft
14. Install O-ring [355] to plug [357] and tighten the
plug to specified torque.
Tightening torque: 10±2Nm (7.4±1.5)lbf·ft
Torque wrench
Screw socket 10, 14mm (0.39, 0.55In)
7-244
Figure Steps
15. Install safety valve to relief valve group [301].
16. Tighten the safety valve to the specified torque.
Tightening torque: 25±5Nm (18.4±3.7) Nm
Torque wrench
Screw socket 32mm (1.3In)
7-245
7.5.14 Removal and Installation of Slewing Motor & Speed Reducer

Removal
the hydraulic tank.
Figure Steps
1. Remove the oil filler pipe (1);
2. Remove hose (2) of main oil filler;
3. Remove the oil return pipe (3).
7-246
Figure Steps
4. Remove 2 pilot pipes (4) of time delay valve.
5. Remove the bottom plate (5).
6. Remove block (6).

7-247
Figure Steps
7. Remove the grease hose (7) on the bottom of
slewing motor speed reducer.
8. Remove the 12 fixing bolts (8);

9. Apply lubricant on pin (9), and then remove it.
10. Lift the motors with rope and hoisting equipment,

and then place them on a clean and safe position.
Lifting weight: 217kg (478.5lb)
11. Cover the installing port of the motor with
paperboard after it is lifted, so as to avoid foreign
matters falling into the port.
7-248
Installation
The installation is in the reverse order of removal.
Clean the threaded hole before the installation, and apply the anaerobic thread locker (TONSAN 1277) on the
bolt threads.
Check the hydraulic oil is sufficient.
• Tightening torque of mounting bolt M24-10.9: 600 ± 55Nm (442.5 ±40.6) Ibf·ft.
• Tightening torque of M16 pilot duct: 26± 2Nm (19.1 ±1.5) lbf·ft.
• Tightening torque of M22 oil return pipe: 47± 2Nm (34.7±1.5) lbf·ft.
• Tightening torque of M30 high-pressure pipe: 126±N.m (92.9±4.4)lbf·ft
• Tightening torque of M36 refilling pipe: 137± 6Nm (101±4.4) lbf·ft.
7-249
7.5.15 Disassembly and Assembly of Slewing Motor & Speed Reducer

Cross-section view of slewing motor & speed reducer
The part numbers involved in the paragraph please refer to the numbers in figure below.
Cross-section view of swing motor

马达部分剖面图
7-250
Cross-section view of reduction gear
Plugged for
transportation
Plugged for
transportation
7-251
Special tool 3. Install the clamp used for oil seal.

1. Remove the clamp used for bearing (401).
4. Special tool used to remove brake plunger

2. Remove the clamp used for bearing (402).
Disassembly
The chapter introduces the disassembly of slewing
motor & speed reducer in two parts, including:
1) Disassembly of the slewing motor
2) Disassembly of the speed reducer
Choose a clean location. The disassembly

platform shall be covered by rubber plate or
cloth, etc. in order to protect components from
being damaged.
7-252
Perforation
7-253
1. Disassembly of slewing motor

Remove the motor according to the following sequence. The number in the brackets following the component
name is the symbol shown in the installation profile view.
Figure Steps
1. Tie the periphery of motor with steel wire rope, lift
it by crane, and then clean it with colorless and
transparent light oil. Blow and dry it with
compressed air after the cleaning.
Caution: Protect the motor from foreign
matters entering its inside. Wash mud and dust
adhered to the motor, and seal each hole with
adhesive tape.
2. Drain the working oil out of the motor body via the
oil drain hole.
3. Put the shaft end of drive shaft (101) downwards,
and then fix it on the operation platform which is
easy to be disassembled. At this time, make the
mark at the junction position between motor body
(301) and valve body (303).
4. Loosen pressure-reducing valve (051) and
remove it from valve body (303).
Caution: O-ring may be destroyed while
loosening pressure-reducing valve, therefore, be
sure to replace the O-ring.
7-254
Figure Steps
5. Remove the ROMH oil drain plug (469) from valve
body (303), and then remove the spring (355) and
plunger (351).
Caution: Protect the plunger valve seat from
being damaged.
6. Unscrew hex bolt (401), and then remove valve

body (303) from motor body (301).
(Because of the elastic force of brake spring
(712), valve body (303) may pop from motor body
(301) after the removal of bolt.
Remove the valve block (131) from valve body
(303).
Caution: Carefully operate to protect the
valve plate from falling off from valve body.
(For some motor, valve block is installed on a side

of cylinder.)
When prying the junction surface with a screw-
driver, protect the junction surface from being
damaged.
7. Remove the brake spring (712) from the brake

plunger.
7-255
Figure Steps
8. Pull out the brake plunger (702) from motor body
(301) with remover.
Caution: Hook the slot of brake plunger using
the remover paw end, and then lift it vertically.
9. Level the motor again, and then pull out the

cylinder (111) from drive shaft (101). Pull out the
plunger (121), plate (123), plate spring and
plunger (124) in sequence.
Caution: Protect the revolving mating surface
of cylinder and plunger, etc. from being damaged.
When it is not available to move the plunger out,
do it in the #12 operation step.
10. Remove friction plate (742) and metal plate (743)

of separator from motor body (301).
7-256
Figure Steps
11. Remove drive shaft (101) and plunger (124).
Caution: The spline may destroy oil seal
during the removal of the drive shaft, so wrap the
spline part of drive shaft with the plastic adhesive
tape before the removal.
7-257
Figure Steps
12. Carry out the following operation steps in
accordance with the requirements.
Drive out the inner ring of cylindrical roller bearing
Punch press from drive shaft with press machine.
Caution: The inner ring of cylindrical roller
bearing can also be knocked by hammer and steel
Drive shaft bar, but it is needed to knock the inner ring
uniformly and protect the bearing from being
damaged.
The removed bearing cannot be reused.
13. Knock the outer ring of cylindrical roller bearing

gently with hammer and steel bar from one a side
of housing of oil seal (491), so as to remove it
from the motor body (301).
Caution: The removed bearing cannot be
reused.
14. Remove the cylindrical roller bearing (444) from

valve body (303) with sliding weight bearing
detacher.
Caution: The removed bearing cannot be
reused.
2. Disassembly of speed reducer

7-258
Figure Steps
1. Lift the speed reducer with lifting device, and then
lay the drive shaft on the level ground. Drain the
gear oil from oil drainage port on the gear.
2. Loosen hex screw (602) and remove the motor.
3. Remove No. 1 sun gear (211).
4. Remove No. 1 planetary carrier group
Caution: Collect the gear oil with a clean
container, and check the oil for wear powder.
5. Disassembly of No. 1 planetary carrier group.

Caution: It is not required to disassemble No.
1 steering carrier further hereto, so please check
the components in accordance with the guidance
mentioned by maintenance criteria.
6. Lift the gear ring (202) and remove it.

7. Remove No. 2 sun gear.
8. Remove No. 2 planetary carrier group
7-259
Figure Steps
9. Disassembly of No. 2 planetary carrier group.
Caution: It is not required to disassemble No.
2 planetary carrier group hereto.
Check the components carefully according to the

guidance mentioned by maintenance criteria. We
recommend to replace No.2 planetary carrier
group in set as possible as you can. But if the
replacement of some part is inevitable, please
operate in accordance with the following steps.
1) Remove the innermost spring pin (910) and No. 2
spring pin (282).
2) Remove the No. 2 planetary gear (203) from the

side.
10. Remove the elastic snap ring (913) from the drive
shaft (201).
Caution: Mark the gear and pin to avoid
mistake during the installation.
Caution: If No.2 spring pin (282) is removed,

never reuse it.
7-260
Figure Steps
11. Place the speed reducer erectly. Support the
periphery of housing, make the drive shaft surface
downward, and knock the center of shaft with
plastic hammer to remove the shaft from the
housing.
Caution: Hereto, check the drive shaft, and if
there is no abnormality, it is not required to
disassemble it further. Check the components
carefully according to the guidance mentioned by
maintenance criteria. We recommend to replace
in set as possible as you can. But if the
replacement of some part is inevitable, please
operate in accordance with the following steps.
12. As it is shown in the figure, remove bearing seal

ring (915) and the bearing (401) from the drive
shaft bearing.
13. Remove oil seal (401) from the housing (102).
Caution: While removing the drive shaft from
the housing, protect it from being damaged.
Caution: If the bearing seal (915) and oil seal

(801) are removed, never reuse them.
Assembly
The chapter introduces the assembly of slewing motor & speed reducer in two parts, including:
1. Assembly of slewing motor
2. Assembly of speed reducer
7-261
The assembly sequence is opposite to that of disassembly, so please pay attention to the following points.
Protect the components from being damaged
Before the assembly, please check each component in accordance with maintenance criteria.
Each component shall be cleaned with detergent and then blow it dry with compressed air.
Before the assembly, revolving junction part and bearing, etc. must be applied with clean working oil.
Seals such as O-ring and oil seal shall be replaced in principle.
Tighten the fixing bolts and oil drain plug, etc. with torque wrench according to the tightening torque
shown in the following table.
If the liquid filling material is used. Peel the surface of the component with knife or similar objects. and
grind the surface with oilstone.
7-262
Table of specification and tightening torque of bolt

If it does not conform to the above part number, please refer to the assembly profile view.
Applicable part
Bolt size Name Tightening torque
number
M20 Hexagon socket bolt 431Nm(317.9lbf·ft) 401
M33xP1.5 Pressure reducing valve 177Nm(130.5lbf·ft) 051
M30xP1.5 ROMH oil drain plug 334Nm(246.3lbf·ft) 469
PF1/4 ROM oil drain plug 36Nm(26.6lbf·ft) 467
12mm(0.47In) Hexagon socket bolt 102Nm(75.2 lbf·ft) 602
10mm(0.39In) Plug 65Nm(47.9 lbf·ft) 901
1. Assembly of slewing motor
Figure Steps
1. Place the motor body (301) on the platform
suitable for operation with one side of the valve
body (303) upwards.
2. (This step can not be executed until the cylindrical
roller bearing is removed.)
Install the inner ring of cylindrical roller bearing
(443) into the drive shaft (101) in the shrink-on
method.
Caution: Pay attention to the direction of the
dowel pin of cylindrical roller bearing.
3. Install the inner ring of cylindrical roller bearing

(444) into the drive shaft (101) in the shrink-on
method.
4. Install the oil seal (491) in the motor body (301)
with tool.
Caution: Pay attention to the direction of the
oil seal.
(Refer to the assembly profile view.)
Apply a thin layer of grease on the sealing part of

oil seal.
One side of the output shaft

Caution: Knock it uniformly to protect the
periphery from being damaged.
7-263
Figure Steps
5. Knock it gently with hammer and steel bar to
install the cylindrical roller bearing (443) on the
motor body (301).
6. Install the drive shaft on the motor body (301).

Caution: Install it carefully to protect the
sealing part of oil seal from being damaged.
Caution: Twine the spline of the shaft with

plastic adhesive tape.
7. Place the motor body (301) flatly, and then insert

the plunger (124).
Caution: Revolve the side with big chamfer of
plunger into the motor body.
Caution: Apply a layer of grease on it in order

to avoid it falling off from the junction surface.
7-264
Figure Steps
8. Assemble the plate (123) and plate spring, and
then assemble them and piston group (121, 122).
9. Install the plunger group (121, 122) assembled on

plate (123) on the cylinder (111), and install it
together with drive shaft (101) cooperatively.
7-265
Figure Steps
10. Reset the motor body (301) with the oil seal
downward, and then install separator metal plate
(743) and friction plate (742) into the motor body
(301) in sequence.
Install 4 separator metal plates and 3 friction
plates in total.
11. Install O-ring (706) (707) in the motor body (301).

Caution: The O-ring is difficult to be broken
off when it is installed on the brake plunger if it is
applied a layer of grease.
7-266
Figure Steps
12. Install the brake plunger (702) in the motor body
(301).
13. Install brake spring (712) in brake plunger (702).
14. (This step can be implemented only when

removing cylindrical roller bearing (444)).
Install the outer ring of the cylindrical roller bearing
(444) into valve body (303) while knock it gently
with hammer and steel bar.
Caution: Knock on the periphery of outer ring
evenly till it is completely installed into clamp slot
of valve body.
7-267
Figure Steps
15. Install valve plate (131) into valve body (303), and
then into O-ring.
Caution: Apply a thin layer of grease on the
joint surface of valve plate. (Prevent falling off)
16. Install valve body (303) on motor body (301), and

then tighten it with hex bolt.
Caution: Pay attention to the installation
direction of the valve body. (Refer to external
dimension figure)
Pay attention to avoiding falling-off of valve plate.
Pay attention to avoiding falling-down of brake

spring.
Hex bolt shall be tightened evenly.

7-268
Figure Steps
17. Install the plunger (351) and spring (355) into
valve body (303), and then install the ROMH oil
drain plug (469) equipped with O-ring (488) into
valve body (303).
Caution: Check whether the plunger moves
smoothly.
18. Install pressure-reducing valve (051) into valve

body (303).
2. Assembly of speed reducer

7-269
Figure Steps
1. Assembling the drive shaft assembly
1) Install bearing seal ring (915) into drive shaft
(201).
2) Apply the grease inside of bearing (401), and
press it into drive shat.
Caution: Before assembly, apply the grease
on both sides of bearing.
7-270
Figure Steps
3) Apply the grease on the bearing.
Grease
7-271
Figure Steps
2. Place the housing (102) on horizontal operation
platform
3. Install oil seal (801) in front of housing (102) with
the clamp.
4. Lift up drive shaft assembly with threaded hole in
front end of drive shaft, and then install it into
housing.
Caution: Apply sealant (LOCKTITE No.222)
on the outer surface
Caution: Do not install forcibly, and do not

damage the lip of oil seal carefully with the clamp
in 5.3.4.
7-272
Figure Steps
5. Lift the speed reducer erectly, and make drive
shaft downward.
6. Install the bearing (402) with clamp.
7. Install the elastic snap ring (913).
8. Fill the grease into housing from grease filler.
Caution: Test the installation depth of drive
shaft from bearing surface with the clamp
according to the requirements in 5.3.4.
7-273
Figure Steps
9. Install No. 2 planetary carrier group.
1) Install thrust washer (286).
2) Insert planetary gear (203).
3) Gently knock No. 2 pin (282) into planetary gear
with plastic hammer.
7-274
Figure Steps
4) Install spring pin (910) into No. 2 planetary carrier
group (230), and knock on two ends of spring pin
tightly.
7-275
Figure Steps
10. Apply liquid seal on the joint surface of housing
(102).
11. Install No. 2 planetary gear group into housing
(102).
7-276
Figure Steps
12. Install gear ring (202) into housing (102).
Temporarily fix the gear ring with four screws.
Caution: pay attention to use a washer to
avoid housing damage when screwing.
13. Install No. 1 planetary carrier group.

7-277
Figure Steps
14. Install No.1 sun gear (211)
15. Temporarily remove the bolt, and apply liquid seal
on the installation surface of housing (102).
16. Install rear housing (104) to gear ring (202), and
tighten hex bolt.
17. Fill gear oil into speed reducer from the filler,
temporarily install the dipstick, and test gear oil
capacity.
7-278
7.6 Work Implement

7.6.1 Removal and Installation of Bucket
Removal
Figure Steps
1. Start the engine, operate the machine to make
bucket back lie on the ground, and then shutdown
the engine;
Caution: A rubber mat shall be placed in the
location between bucket and floor.
2. Remove fixing bolt and gasket (1);

3. Remove fixing bolt and gasket (2);
7-279
September 15, 2020 7.6 Work Implement
Figure Steps
4. Remove the pin shaft (3) with copper hammer and
raping bar;
Caution: Two workers are needed: one
worker hammers the pin shaft out of pin hole from
one end of the pin shaft with a copper hammer
and raping bar, and the other worker holds the pin
shaft on the other end.
Caution: The pin shaft weighs 21.5Kg (47.41

lb).
Caution: O-ring, which is installed between

front bracket of arm and the bucket, needs to be
removed and put at a safe place.
raping bar
Caution: Two workers are needed: one
worker hammers the pin shaft out of pin hole from
one end of the pin shaft with a copper hammer
and raping bar, and the other worker holds the pin
shaft on the other end.
Caution: The pin shaft weighs 21.5Kg (47.41

lb).
Caution: the O-ring, which is installed

between of the arm and bucket, needs to be
removed and put in a safe place.
6. Start the engine to lift and slewing the boom, and
then remove the bucket (5).
7-280
Installation
Installation steps
• Tightening torque for pin shaft fixing bolt(1)(2): M20: 600±55 N·m {442.5±40.6 lbf·ft}, the distance from the
nut close to the locating sleeve to the locating sleeve: 1-1.5mm (0.0394-0.0591 In).
• Clean up the thread part of bolt and nut before assembling, and apply the anaerobic thread locker (Tonsan
1277) on the thread surface.
• Clean up the pin hole and pin shaft surface before installing pin shaft.
• If it is difficult to knock the pin shaft, adjust the installation position of the bucket, and knock it again.
• Do not damage or lose O-rings and dust ring during installation.
• Add grease after installation.
7-281
7.6.2 Removal and Installation of Link and Lever

Removal
Figure Steps
1. Remove the bucket. See "the removal and
installation of bucket" for details.
2. Retract arm cylinder completely, retract boom
cylinder to make work implement drop until the
front bracket of arm falls onto the ground, select
proper state to place sleeper between link (1) and
arm as well as between bucket cylinder block and
arm during the process.
3. Remove fixing bolt and nut (1).

4. Remove fixing bolt and nut (2).
7-282
Figure Steps
5. Install the rapping bar into axle hole of the link,
hook two ends of rapping rod with the sling, and
lift the link to vertical state with hoisting equipment
and sling.
6. Remove left lever (3).
Caution: The adjusting washers between the
lever and link, between the lever and middle
bracket of the arm shall be removed to a safe
place.
7. Place a sleeper between right lever and arm,

knock on small end of the pin shaft (4) with copper
hammer and rapping bar, push the pin shaft (4) to
right lever, and remove the pin shaft (4).
Caution: There are adjusting washers
between bucket cylinder and link, and between
the link and lever, and it is necessary to remove
and put them at a safe place.
8. Tighten the piston rod and the cylinder block with

wire rope.
7-283
Figure Steps
9. Rotate right lever (5) and drop its end on the
ground, and take off the sleeper. Knock small end
of the pin shaft (6) with cooper hammer and
rapping rod, push the pin shaft (6) to the direction
of right lever, and remove the pin shaft (6) and
right lever (5) at the same time.
Caution: There are adjusting washers
between the lever and middle bracket of the arm,
and it is necessary to remove and put them at a
safe place.
10. Remove the link (7), and convey it to safe place

for storage.
Installation
• Tightening torque for pin shaft fixing bolt (1) (2): M20: 600±55N·m {442.5±40.6 lbf·ft}; distance from the nut
close to the locating sleeve to the locating sleeve: 1-1.5mm {0.0394-0.0591 In}.
• Clean up the pin hole and pin shaft surface before installation.
• If it's difficult to knock in the pin shaft, adjust the mounting position of the lever and link, and knock it again.
• Do not damage or lose dust ring and adjusting shim during the installation.
7-284
7.6.3 Removal and Installation of Arm

Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the bucket
and the ground about 300~400mm {11.81~15.75In }, shut down the engine, operate the lever to relieve
pressure, release the pressure of the accumulator, and loosen the hydraulic oil tank cover slowly to
release the pressure in the hydraulic oil tank.
Figure Steps
1. Remove the bucket. See the Removal and
Installation of Bucket for details in this chapter
2. Remove link and lever. See Removal and
Installation of Link and Lever for details in this
chapter.
3. Remove the bucket cylinder. See Removal and
Installation of Bucket Cylinder for details.
4. Start the engine, stretch the arm cylinder to the
most, operate boom cylinder, and put down work
implement to make front bracket of the arm fall on
the ground.
Caution: A rubber mat needs to be placed
between the arm and ground.
7-285
Figure Steps
5. Lift up arm cylinder with lifting rope and hoisting
equipment.
6. Remove the bolt, nut and plate (1) with spanner.
rapping rod.
Caution: There is an adjusting washer
between the arm cylinder and arm, and it needs to
be taken down and placed at a safe place.
8. Start the engine, retract arm cylinder piston rod,

and fasten piston rod with wire rope in case of
stretching out.
Caution: Do not release the pressure
9. Lift arm cylinder to certain space with hoisting

equipment, place the sleeper between arm
cylinder block and the boom, and put arm cylinder
on the sleeper.
10. Remove lifting rope on the cylinder.
11. Install the pin shaft (2) into pin hole, and lift the
arm (5) with lifting rope and hoisting equipment
through the pin shaft (2).
12. Remove the fixing bolt, nut and plate (3) from the
boom front bracket hinge pin shaft.
13. Remove hinge pin shaft (4) with copper hammer
and rapping rod.
14. Slowly put the bucket arm on the ground with the
sling.
Caution: The crosstie needs to be placed
between the arm and ground.
15. Start the engine, and lift and slewing the boom to
remove the arm.
7-286
Installation
• Tightening torque of pin shaft fixing bolt: M12: 120±10N·m {88.5±7.4 lbf·ft}; M20:600±55N·m {442.5±40.6
lbf·ft}
7-287
7.6.4 Removal and Installation of Boom

Removal
Before removal of oil pipe, open the arm and bucket completely, keep the distance between the bucket
and the ground about 300~400mm {11.81~15.75In }, shut down the engine, operate the lever to relieve
pressure, release the pressure of the accumulator, and loosen the hydraulic oil tank cover slowly to
release the pressure in the hydraulic oil tank.
Before removing pipelines and fittings, it is necessary to clean the assembled oil port.
Figure Steps
1. Start the engine, operate the machine to make
arm cylinder and bucket cylinder stretch out, and
operate boom cylinder to make the lever fall on
ground.
2. Release the residual pressure in hydraulic oil line.
(See release of residual pressure in hydraulic oil
line in “Test and Adjustment” for details)
7-288
Figure Steps
3. Remove hydraulic hose (1) on both ends of
bucket cylinder with hexagon socket wrench, and
pay attention to wrapping the connector with a
towel or cloth to prevent oil splashing. Fasten the
hose on boom tube with the strap
Caution: Collect the hydraulic oil leaked from
the line with a barrel to prevent contaminating the
ground.
4. Refer to “Removal and Installation of Arm” in this

chapter for removal of arm assembly (2), (arm
assembly includes arm, bucket, link, lever and pin
shaft)
Caution: The crosstie needs to be placed
between arm and ground.
5. Start the engine, and slewing the machine until

there is enough space for removing the boom.
7-289
Figure Steps
6. Operate the machine to place the boom on the
ground.
Caution: The pad needs to be placed between
front bracket of the boom and ground.
7. Disconnect the connection of grease line (3) and

boom cylinder.
8. Remove fixed sleeve (4) between boom cylinder
and boom hinge pin and its accessory bolt and pin
shaft.
between the locating sleeve and cylinder, which
needs to be taken down and placed at a safe
place.
9. Remove the fixed sleeve, bolt and nut on the right

side of boom cylinder with the method in article 8.
10. Lift the left boom cylinder (5) with lifting rope and
equipment.
11. Push boom cylinder and hinge pin shaft (6) of
boom to the position that does not affect the
moving of boom cylinder (5) with copper hammer
and rapping rod.
7-290
Figure Steps
12. Start the engine, retract piston rod of left boom
cylinder, and fasten piston rod with wire rope to
prevent stretching out. Lower left boom cylinder to
revolving frame, and place the sleeper between
the cylinder and frame.
13. Lower the right boom cylinder (7) with the same
method.
14. Lift the stretching part on both ends of the boom
middle bracket pin shaft with lifting rope and
equipment.

16. Disconnect the harness (8) and fix it on the boom
with a strap.
17. Disconnect the connection between hose (9) and
boom tube.
Caution: Wrap the connector with a towel or
cloth to prevent oil splashing.
Caution: Pay attention to collect the

hydraulic oil leaked from the line with a collecting
equipment to prevent contamination.
18. Remove fixed plate (10) of boom and frame hinge
pin and its bolt and washer.
7-291
Figure Steps
19. Remove boom and frame hinge pin (11) with
special tools.
20. Operate hoisting equipment to remove the boom.
Installation
• Tightening torque of pin shaft fixing bolt: M12: 120±10N·m {88.5±7.4 lbf·ft}?M20: 600±55N·m {442.5±40.6
lbf·ft}
• The distance between the locating sleeve and its nearest nut is 1~1.5mm {0.0394-0.0591 In}.
7-292
7.6.5 Removal and Installation of Work Implement Assembly

Removal
Figure Steps
1. Remove the bucket. See the “Removal and
Installation of Bucket” section for details in this
chapter;
2. Start the engine, operate the machine to retract
arm cylinder and bucket cylinder completely, and
operate boom cylinder to make work implement
fall on the ground.
3. Remove fixed sleeve (1) between boom cylinder

and boom hinge pin and its accessory bolt and pin
shaft.
between the locating sleeve and cylinder, which
needs to be taken down and placed at a safe
place.
4. Remove the fixed sleeve, bolt and nut on the right

side of boom cylinder with the method in article 2.
7-293
Figure Steps
5. Lift the left boom cylinder (2) with lifting rope and
equipment.
6. Push boom cylinder and hinge pin shaft (3) of
boom to the position that does not affect the
moving of left boom cylinder (2) with copper
hammer and rapping rod.
7. Start the engine, retract piston rod of left boom
cylinder, and fasten piston rod with wire rope to
prevent stretching out. Lower left boom cylinder to
revolving frame, and place the sleeper between
the cylinder and frame.
8. Lower the right boom cylinder (4) with the same
method

10. Disconnect the harness (8) and fix it on the boom
with a strap.
11. Disconnect the connection between hose (9) and
boom tube.
Caution: Pay attention to collect the

hydraulic oil leaked from the line with a collecting
equipment to prevent contamination.
7-294
Figure Steps
12. Remove fixed plate (7) of boom and frame hinge
pin and its bolt and washer.
13. Remove the boom and frame hinge pin (8) with
special tools (9).
14. Install front bracket pin shaft of bucket arm back

into its front bracket. 15. Use two sets of hoisting
equipments for coordination, one lifts stretching
part on both ends of boom middle bracket pin
shaft, the other lifts stretching part of arm front
bracket pin shaft, and operate two sets of hoisting
equipments to remove work implement assembly
(10).
7-295
Installation
Tightening torque of pin shaft fixing bolt: M12: 120±10N·m {88.5±7.4 lbf·ft}?M20: 600±55N·m {442.5±40.6
lbf·ft}
• The distance between the locating sleeve and its nearest nut is 1~1.5mm {0.0394-0.0591 In}.
7-296
7.6.6 Removal and Installation of Bucket Cylinder Assembly

Removal
the hydraulic tank.
Apply more lifting points as many as possible. Lifting ring is not allowed to bear any shear force. If
there is no appropriate lifting point, a wide lifting rope that can bear enough weight shall be used.
Figure Steps
1. Referring to "the removal and installation of
bucket" & "the removal and installation of link and
lever" in this chapter, remove the bucket, link and
lever
2. Operate the machine to lower arm end to the
ground.
Caution: Separate the cylinder from the arm
with crosstie, and avoid direct touch and bump to
cause appearance wear.
7-297
Figure Steps
3. Retract bucket cylinder, and fix piston rod with
wire rope to prevent it from stretching out.
4. Disconnect the hydraulic hose on both ends of the

bucket cylinder
5. Remove fixing bolt of bucket cylinder pin plate,

and take down the plate.
6. Lift bucket cylinder with strap and hoisting

equipment.
Caution: fix the piston rod in the shortest and
safe state, and then lift it.
7-298
Figure Steps
7. Knock the little end of pin with copper bar and take
it out.
Caution: Do not stand at the receding side of
the pin shaft; otherwise; the sudden falling of the
pin shaft will cause personal injury.
8. Take down bucket cylinder and horizontally place

it on the sleeper.
Installation
Welding is not allowed to operate on the cylinder, and the cylinder is not allowed to be used as the
ground wire for welding, to avoid the damages to parts in case of electric arcs between the piston rod
and cylinder head, and piston and cylinder tube.
Installation sequence is in the reverse order of removal.
Clean the threaded hole before installation, and apply anaerobic thread locker (TONSAN 1277) on the thread
surface.
• Tightening torque of the pin shaft fixing bolt: M12 :(120±10)Nm (88.5±7.4lbf·ft)
7-299
• Tightening torque of the oil pipe flange fixing bolt: M10 : (73.5±3.5)Nm (54.2±2.6lbf·ft);
Clean up the pin hole and pin shaft surface before installation.
If it is difficult to knock the pin shaft, adjust the installation position of the bucket, and knock it again.
Protect the seal ring from being damaged during the installation.
Add grease after installation.
Check the surface of the piston rod, and it is not allowed to have tape, paint, concrete, etc. to adhere
on the surface of the piston rod in case of damaging seal ring during action
Any dirt is not allowed to enter into hydraulic system during the operation of the hydraulic cylinder. Oil
port must be sealed reliably. For example: rubber cap or sealing plug.
Hydraulic cylinder shall not bear abnormal stress after installation, and be guaranteed not to bear
unnecessary load. Otherwise, this will affect the service life of cylinder.
7-300
7.6.7 Removal and Installation of Arm Cylinder Assembly

Removal
the hydraulic tank.
Figure Steps
1. Lift the arm cylinder steadily with nylon strap and
hoisting equipment.
7-301
Figure Steps
2. Remove the fixing bolt of piston rod pin shaft, and
remove the plate (1)
it out.
4. Operate the machine to retract the arm bucket

piston rod completely, and fix the piston rod with
wire rope to prevent stretching out.
Caution: fix the piston rod in the shortest and
safe state, and then lift it.
5. Remove two hydraulic hoses (2) with arm cylinder.

6. Disconnect grease hose (3);
7. Remove fixing bolt of piston rod pin, and remove
the plate (4).
7-302
Figure Steps
it out.
9. Slowly lift arm cylinder and place it on the sleeper.
Installation
surface.
7-303
7-304
7.6.8 Removal and Installation of Boom Cylinder Assembly

Removal
the hydraulic tank.
Figure Steps
1. Fix the boom cylinder (1) with nylon sling and
travel crane.
7-305
Figure Steps
2. Remove the fixing bolt of piston rod pin and take
down the sleeve (2).
3. Remove grease line (3).
it out.
5. Operate the excavator to retract boom cylinder

piston rod completely. Fix the piston rod with wire
rope to prevent it from stretching out. Place a
wood block under the boom cylinder so as to
lower the cylinder gently.
7-306
Figure Steps
6. Disconnect hydraulic hose (4) of boom cylinder.
7. Remove fixing bolt of boom cylinder block pin, and

take pin plate out (5).
8. Remove boom cylinder block pin (6).
9. Lift boom cylinder as out and place it on sleeper.

Caution: Be sure to fix the piston rod in the
shortest and safe state, and then lift it.
Installation
7-307
surface.
7-308
7.6.9 Disassembly and Assembly of Cylinder

Method for disassembly and assembly of the cylinder introduced in the chapter is common approach of
excavator cylinder. Refer to the following figure for component names involved in the text. Different cylinders
may have some differences.
1. Piston rod 15. Dust ring 29. Steel ball

2. End cover 16. Seal ring for shaft 30. Buffer ring
3. Cylinder block group 17. Split washer 31. Dust ring
4. Cushion collar 18. Buffer ring 32. C-bushing
5. Piston 19. Hex socket screw 33. Hex socket screw
6. Clip 20. Slide bushing 34. O-ring
7. Rear cushion collar 21. Steel wire snap ring 35. Bolt
8. Check ring 22. O-ring 36. Spring washer
9. Oil pipe group A 23. O-ring backup 37. Bolt
10. Oil pipe group B 24. Buffer ring 38. Spring washer
11. Clamp group 25. Dirt rings 39. Oil port cover
12. Pressure plate 26. Molding guide ring 40. Rubber gasket
13. Oil ring 27. Seal ring for hole 41. Hexagon socket bolt
14. Retainer ring 28. Flat end set screw
7-309
Disassembly
Preparations
1. Keep the operation area clean and tidy.
2. Estimate the total weight of the hydraulic cylinder and accessories, prepare appropriate lift equipment, and
the hook distribution shall keep the lifting stable.
The hydraulic cylinder oil ports shall be sealed with the rubber plugs or seal plugs to prevent the
hydraulic cylinder from being polluted by the foreign matters.
Protect the hydraulic cylinder assembly (piston rod in particular) from damage.
Figure Steps
1. Drain the oil from cylinder.
2. Fix the hydraulic cylinder.
2.1 Remove the pipe and other interferences before
the fixation.
2.2 Fix the hydraulic cylinder on the vertical or
horizontal position.
2.3 Locate the pin shaft hole with the cylinder bottom.
Fixed 3. Remove the cover.
device
Thread type: remove by using a hook head
wrench.
4. Pull out the piston rod
4.1 Confirm that the pipes, etc. have been removed.
4.2 Prepare the appliance for collecting the hydraulic
oil from the hole of telescope side (the end cover
CLG922E930E07530 side).
4.3 Pull out the piston rod to the longest position, and
then loosen and pull out the end cover slowly.
4.4 Pull out the piston rod with the end cover together,
place it on the crosstie.
7-310
Figure Steps
5. Fix the piston rod with the pin hole and the flat part
of piston rod lifting eye.
6. Remove the piston nut.
6.1 Remove the setscrew.
There are two chisel seams at the outside of set-
screw; they’re used for riveting on the cushion
head. Remove the riveting parts with hand drill,
and then remove the setscrew.
6.2 Remove the steel ball from setscrew.
CLG922E930E07531 6.3 Remove the piston nut.
7. Remove the parts such as piston, etc.
Remove the components according to the
sequence: Nuts→ Pistons → Cushion Collars →
End Covers.
8. Remove the cushion collars of telescope side.
8.1 Remove the piston nut.
8.2 Knock down the elastic snap ring with plastic
Thread hammer or other tools to remove it without damaging
piston rod and cushion collar.
Piston rod 8.3 Slide the cushion collar towards the piston rod
screw, and then the (double-slice type) retainer ring
will fall off.
Buffer ring with Cushion Baffle ring 8.4 Remove the cushion collar. There is a gap on the
Snap ring
one notch collar (two-piece) buffer ring, then remove the buffer ring by using the
gap.
9. Removal of piston seal.
CLG922E930E07532
9.1 The guide rings and dirt rings shall be removed
simply by hands.
9.2 Make the straight screwdriver up-right with the
seal ring and knock it with a hammer, then cut off and
remove it.
9.3 Take out the O-rings with the iron needle.
7-311
Figure Steps
10. Remove the end cover seal.
10.1 Remove the primary seal: Put iron needle
against the upper edge of the seal ring and extend the
iron needle to the bottom of seal ring, and run through
the primary sealing element, then tip and pry the
entire sealing element for removing
10.2 Remove the buffer ring: firstly remove the buffer
ring retainer (black), and the following removal is
same as the removal of primary seal.
11. Remove the dust ring and circlip
11.1 When removing the dust ring, put the screw
Press driver against the opening of the dust ring cir-clip,
knock the bottom of circlip, and then pry the circlip for
taking out.
Mounting clamp 11.2 Continue to knock the screw driver until it runs
through the whole dust ring, then tip and pry the entire
Bushing dust ring for removing.
12. Remove the slide bushing
12.1 Find the juncture of the slide bushing.
12.2 Support the upper end of the slide bushing
opening with a screwdriver, and then knock the
CLG922E930E07533 screwdriver with a hammer until it passes through the
whole slide bushing.
12.3 Remove the entire slide bushing with a
screwdriver.
13. Remove the lifting eye dust ring and the bushing.
13.1 Remove the dust ring from the lifting eye hole.
Same as the removal of the end cover dust ring,
remove it with a screwdriver or other tools.
13.2 Remove the bushing with a heel block as shown
in figure.
7-312
Installation
Figure Steps
1. Install the lifting eye dust ring and bushing.
1.1 Press it into the piston rod axle hole with the
Press mounting clamp.
1.2 Install the dust ring with a heel block.
Mounting clamp
Bushing
CLG922E930E07533
Heel block
Piston rod
Dust ring
Bushing
CLG922E930E07534
7-313
Figure Steps
2. Assembly of end cover parts.
2.1 Press the slide bushing with the press-in clamp.
2.2 Install the steel snap ring into the snap ring slot of
slide bushing.
Recheck the slide bushing for the scratch.
Dust ring and snap ring Caution: Do not scratch the slide bushing
during the assembly.
Main seal ring
2.3 Take out the O-ring backup ring from the heating
Buffer ring and snap ring box and assemble it, press the backup ring with iron
Slide bushing needle, and rotate it for one revolution around the ring
recess to transform it. Place the relevant O-ring into
O-ring retainer (white) the groove, install it with iron needle and rotate it for
O-ring (black)
one revolution to ensure that the assembly is
complete without turn-up.
2.4 Turn over the end cover by 180°.
CLG922E930E07535 2.5 Install the buffer ring into its groove.
Caution: When installing the small retainer
ring into the buffer ring, pay attention to the
direction that keep the its fillet side at the inner
Clamps side.
2.6 Install the primary seal ring into the seal ring
End
groove.
cover
Caution: Note the direction of the primary
seal ring, and install the snap ring firstly if exists
primary seal snap ring.
Slide bushing 2.7 Apply adhesive to the outside area of the dust
ring, place it on the dust ring groove. Then place and
CLG922E930E07536 press the guide sleeve under the pressure head.
2.8 Wipe the redundant adhesive around the dust ring
with paper, and then install the snap ring into its
groove.
2.9 Precautions for the installation of end cover
sealing elements.
7-314
Figure Steps
1. Check all parts are assembled

2. Check the mounting position is correct
3. Check all parts are installed in the correct direction
Main sealing ring

Do not confuse with the snap ring
Buffer ring and snap ring Slide bushing
No damage on the inner
surface
Install the buffer ring
and then the snap ring
(pay attention to the
direction)
Dust ring Retainer ring O-ring and snap ring

Install in place Install it in the groove. Piston rod may
be scratched if it slides out from the
groove.
Retainer
ring
No damage
O-ring
Qualified Unqualified Unqualified
O-ring Snap ring
protrudes sinks
upward downward
CLG908E07492
7-315
Figure Steps
3. Install the piston sealing elements.
3.1 Install the black lining ring into the seal ring
groove of the piston with iron needle (prevent the
Heel block Please compress sealing elements from being scratched).
Please compress
using a compressor
using a compressor
3.2 Put the guide jig onto the piston.
Jig
3.3 Take out the primary seal ring from the heating
Correcting
clamp box and install it to the interior guide jig, and then
place the exterior pressing sleeve.
Jig
3.4 Press the external sleeve by the compressor.
Piston Press the seal ring into the groove, then remove the
sleeve and guide jig.
Seal ring Seal ring
3.5 Install snap ring of the seal ring for hole
Retainer ring Caution: The chamfering side faces outward
and the two gaps of the snap rings are not on the
CLG922E930E07538
same direction.
3.6 Both guide rings and dirt rings have openings.
Open the openings in the minimum limit by hands,
and then install it from the axial direction.
4. Install the piston rod assembly
4.1 Fix the piston rod side.
4.2 When installing the guide sleeve and piston rod,
the lip of the dust ring and the shaft ring shall not be
hooked by the shoulder parts. Install the guide sleeve
and piston rod according to the right figure.
CLG908E07493
4.3 For the piston rod with the front cushion

Flat wire Cushion collar, install the plane machining parts of the cushion
direction collar Piston
collar according to the right figure.
Thread
CLG922E930E07540
7-316
Figure Steps
4.4 For the piston rod with rear cushion collar,
install relevant components and parts according to the
following orders:
Thread 4.4.1 Install the gap direction of the buffer ring into the
ring recess towards the thread side.
Piston rod
4.4.2 Install the plane machining parts of the cushion
collar according to the following figure.
4.4.3 Put the (two) baffle rings into the groove.
Clip Buffering Buffer Baffle ring
(two-
4.4.4 Press the cushion collar towards the baffle ring
ring with bearing
piece) sufficiently, and then install the clip. Knock it into the
notch bushing
groove gently with hammer, not damaging the piston
CLG922E930E07541 rod and cushion collar.
4.5 Tighten the piston nut
4.6 Install the setscrew and steel ball on nut.
After fastening piston nut, put steel ball in it, then
tighten setscrew. Rivet the two parts of the periphery
Riveting Punch with the cushion head.
5. Install the piston rod into the cylinder body.
Setscrew
5.1 Fix the cylinder body vertically or horizontally.
Steel ball 5.2 The vertical situation: install piston rod into the
cylinder body according to its dead-weight.
5.3 When the piston rod enter into the cylinder body,
protect the dirt ring and guide ring from falling off.
6. Tighten the end cover
CLG922E930E07542
Tighten it according to the required tightening torque
on the assembling drawing.
6.1 Thread type: tighten with the hook head wrench.
7-317
Figure Steps
7. Install the tubing.
7.1 Check the O-ring is installed into the groove
correctly.
7.2 Insert the oil pipe into the connector and tighten
the nut.
7.3 Adjust the position of the oil pipe and tighten the
clamp according to the requirements in the
assembling drawing.
7.4 Tighten the fastening nut.
8. Test run.
Note the O-rings 8.1 Conduct full-stroke movement for 6 times or more
slowly after the machine is installed to keep the
hydraulic cylinder is full of oil.
CLG922E930E07543 8.2 If install exhaust holes on the cylinder, try to
pressurize the exhaust hole side (return side) to
release the air.
8.3 Apply the grease or engine oil to the bushing at
both ends of the lifting eye.
7-318
7.7 A/C System

7.7.1 Removal and Installation of A/C Compressor Assembly
Removal
Before the removal of the air compressor assembly, recycle the refrigerant in the A/C system by using
the refrigerant auto filling and recovery device, ensure that there is no pressure in the A/C system, and
then remove it. When recycling the refrigerant, please wear the goggles correctly to prevent personal
injury.
During the removal and installation of pipeline, it is prohibited to wear cottony gloves for avoiding
refrigerant leakage caused by the foreign matters adhesion on the O-ring position.
Figure Steps
1. Remove 4 fixing bolts (1) of diesel engine fan
guard.
2. Move shield-lh of the fan (2).
7-319
September 15, 2020 7.7 A/C System
Figure Steps
3. Unscrew locking bolt (3) of A/C belt tension pulley.
4. Unscrew tension bolt (4) of A/C belt tension pulley

to the removable position of A/C belt.
5. Move the tension pulley along the guide groove of
compressor bracket and take down the A/C belt
(5).
6. Disconnect the harness connector (6) of the

machine that connecting with the compressor
clutch connector.
7-320
Figure Steps
7. Separately remove the fixing bolt (7) of A/C
refrigerating tube on the side of A/C compressor,
and then move the refrigerating tubes (8) and (9)
out.
8. Remove four fixing bolts (10) of A/C compressor

with wrench, and take down A/C compressor (11).
Weight of compressor assembly: 6Kg (13.2lb)
Installation
Installation is in reverse order of removal.
• Adjust the pretightening torque of A/C compressor pulley to 441±88.2N (99.1±19.8 lbf).
• Torque of pipe joint M6 bolts: 10±2Nm(7.4±1.5 lbf·ft).
• After the A/C compressor is assembled, it needs to use the refrigerant refill the equipment to vacuumize
the A/C system and refill it with refrigerant 950±50g (2.1±0.11 lb).
7-321
7.7.2 Removal and Installation of A/C Evaporator Assembly

Removal
Before the removal of the A/C evaporator assembly, recycle the refrigerant in the A/C system by using
the refrigerant auto filling and recovery device, ensure that there is no pressure in the A/C system, and
then remove it. When recycling the refrigerant, please wear the goggles correctly to prevent personal
injury.
During the removal and the installation of pipe line, it is prohibited to wear cottony gloves, in order to
avoid the refrigerant leakage caused by the foreign matter adhesion on the O-ring position.
When removing the A/C warm water pipe, please use special clamp or plug and seal the water pipe port
to protect the engine coolant from running off.
Figure Steps
1. Remove six fixing bolts (1) of bottom plate on
lower part of floor plate, and take down bottom
plate (2).
7-322
Figure Steps
2. Disconnect the connector (3) connecting with A/C
high-low pressure switch.
3. Remove fixing bolt (4) of A/C refrigerating tube

with spanner, and take down the fixed plate (5).
Move A/C refrigerating tubes (6) and (7) out at the
same time.
4. Remove the fixing clamp (8) of A/C water pipe.

5. Pull out the water pipes (9), (10).
7-323
Figure Steps
6. Open access door on driving side with the key,
and take out air filter (11) outside air conditioner.
7. Remove the fridge (12) and storage grid (13) on

the upper part of A/C hood in the cab.
8. Remove two fixing bolts (14) and three fastening

screws (15) of A/C hood upper cover and take
down the upper cover (16).
7-324
Figure Steps
9. Remove three fixing bolts (17) of lower cover, and
take down the lower cover (18).
10. Remove setscrew (19) of new air duct that has

butt joint with new vent of evaporator assembly to
extract new air duct (20) upward.
11. Remove the rear air ducts (21) and (22) on top of
evaporator assembly.
7-325
Figure Steps
12. Remove four air ducts (23)(24)(25) on the side of
13. Remove two fixing bolts (26) of air duct guard

plate on front lower part of evaporator assembly,
and take down air duct guard plate (27).
14. Push feet blow air duct (27) forward to separate it

from feet blow air duct of evaporator assembly.
7-326
Figure Steps
15. Remove the connectors (28) and (29) connected
with A/C harness and located on rear part of
16. Remove seven fixing bolts (30) of evaporator

assembly.
17. Move A/C evaporator assembly (31) away from
the floor.
Installation
Installation is in reverse order of removal.
• Torque requirements of the A/C cooling pipe connectors at the evaporator assembly side: M6, 10±2N.m
(7.4±1.5 lbf.ft).
• After the installation of the A/C evaporator assembly, it needs to use the refrigerant refill the equipment to
vacuumize the A/C system and refill it with refrigerant of 950±50g(2.1±0.11 lb).
• Pay attention to the orientation when installing air filter outside the air conditioner, suede side of evaporator
should face inward.
7-327
September 15, 2020 7.8 Cab
7.8 Cab
7.8.1 Removal and Installation of Cab
Removal
Figure Steps
1. Turn off the power
2. Remove the fridge (1), sundries box (3), upper
cover (4) and lower cover (5) behind the cab and
move them out;
Unlock two locks on rear cover (2), and take down
the cover.
3. Remove 4 air ducts (7) connected with A/C

evaporator (6);
7-328
7.8 Cab CLG920E/922E/923E
Figure Steps
4. Disconnect the connector (8) on right rear pillar of
the cab.
5. Disconnect the connector (9);
6. Disconnect nine-pin plug (10), and pull its harness
out, and place on the floor;
7. Disconnect two connectors connected with
controller (11);
8. Unplug two relays (12) on A/C harness from stop
plate of the cab;
9. Disconnect two connectors (13) connected with
fuse box;
10. Remove two fixed clips (14);
11. Disconnect the connector (15) connecting frame
harness and A/C harness and located on right
side of evaporator (6);
12. Remove the antislip step (16);
13. Remove the floor mat (17).
7-329
Figure Steps
14. Remove decoration plate (18) installed on the
floor;
15. Remove the decoration (19);
16. Remove the fixing bolt of the cover (21);
17. Disconnect the connector connected on sun
sensor (20), and pull out the harness connecting
the connector from the rear of the cab, and place
it on the evaporator.
18. Remove the 4 shock absorber bolts (22) on the 4

corners of the cab;
19. Remove the 6 bolts (23) connecting the cab and
floor plate and located on cab bottom frame.
7-330
7.8 Cab CLG920E/922E/923E
Figure Steps
20. Disconnect water pipe (24) on washing end of
wiper washer reservoir in the rear of the cab from
washer reservoir (26);
21. Remove the clamp (25) from fixed water pipe (24);
22. Tidy water pipe (24) and fix on outer wall of the
cab, located at water pipe outlet on right rear side
of the cabin outside the cabin.
23. If it a non-FOPS cab, install 4 of M16 lifting eye

bolts (27) to the lifting hole (28) located on top of
29 the cab, and hook the two lifting-eye bolts at the
28
diagonal with a sling (29) to move the cab out of
the complete machine.
24. Start hoisting equipment, and slowly lift out the
cab.
27
Caution: The weight of standard cab is
395kg; the weight of cab with roll over protection
structure is 580kg, please choose the proper sling
Caution: please operate carefully. During

lifting, please be careful not to pull or intervene
CLG920, 922E07001 among the water pipes and harness and other
parts.
7-331
Figure Steps
25. If the cab is equipped with falling-object protective
31 structure, hook the circular tube beam (31) of
30
protective cover using sling (30);
26. Start hoisting equipment, and slowly lift out the
cab.
Caution: The cab weight is 680kg, so please
select an applicable sling
Caution: please operate carefully. During

lifting, please be careful not to pull or intervene
among the water pipes and harness and other
parts.
CLG920, 922E07002
7-332
7.8 Cab CLG920E/922E/923E
Installation
• Tightening torque of mounting bolt M12-10.9 of the cab: 120 ± 10 N.m;
• Tightening torque of mounting nut M20 of shock absorber is: 600±50 Nm,
• Apply thread locker (the code is anaerobic thread locker TONSAN 1277).
• Clean the thread hole before applying tread locker.
7-333
7.8.2 Removal and Installation of Floor Frame Assembly

Removal
When removing the hose, mark on the hose and connectors to facilitate matching when assembling;
Seal the removed connectors and hoses with covers or plugs to avoid of entering water, dust and
other dirt;
It is necessary to clean the periphery of the assembled oil port.
Figure Steps
1. Remove the cab. For detailed operations, please
refer to 7.8.1 Removal and Installation of Cab
2. Remove the boot (1);
3. Remove two fixing bolts (2) on front and rear part
of console upper cover (3) respectively
4. Move the console upper cover (3) upward, and
remove its internal electrical connectors;
5. Pull the harness out of left console;
6. By referring to above steps, pull the harness out of
right armrest.
7. Remove four clips (4) fixed on the floor;

8. Slide grommet (5) to the right off floor plate, and
move the harness (6) out of floor plate.
Caution: Wire harness (6) includes A/C
harness.
7-334
7.8 Cab CLG920E/922E/923E
Figure Steps
9. Remove the plate (7) and plate (8) on lower part of
the cab.
10. Disconnect two A/C water pipes (9) and

refrigerating tubes (10) located on lower part of A/
C evaporator assembly.
11. Disconnect 8 pilot pipes connectors (11) located

on the rear part of the cab;
12. Remove the clamps (12) and (13);
7-335
Figure Steps
13. Disconnect pilot clamp (14), clamp (15), clamp
(16), and clamp (18) at the bottom of floor plate;
14. Disconnect 4 pilot lines (17);
15. Disconnect the 6 pilot pipes (19) connecting with
the travel pilot valve (20)
16. Arrange 12 pilot hydraulic lines stretching out from
inside of the cab, and ensure there is no pulling
phenomenon with other parts during lifting
process.
17. Install the four M12 lifting eye bolts (20) to the
lifting holes at the four corners on the floor.
18. Hook the lifting eye bolts (20) with the 4 hangers
of the sling (21).
19. Start lifting device, and slowly hang from floor
plate.
Caution: The bearing capacity of the sling
shall not be less than 300 KG.
Caution: Please be careful to operate, and

pay attention to not make the pilot pipes shall
drag other components during the lifting process.
Installation
• Tightening torque of mounting nut of the cab shock absorber is 600 ± 50Nm, and apply oxygen-weary type
thread locker (TONSAN 1277) on the thread to prevent the looseness of nut.
7-336
7.8 Cab CLG920E/922E/923E
8-1
September 15, 2020 Attached drawing
CLG920E/922E/923E
8 Attached drawing
8.1 Hydraulic Schematic Diagram............................................................................................. 8-3

8.1.1 Schematic Diagram of the Kawasaki Hydraulic System .................................................. 8-3
8.1.2 Schematic Diagram of the Kawasaki Rexroth System..................................................... 8-4
8.2 Schematic Diagram of Electric System ............................................................................... 8-5
8.3 Schematic Diagram of A/C System..................................................................................... 8-6
8-2
Attached drawing September 15, 2020
CLG920E/922E/923E
8-3
CLG920E/922E/923E 8.1 Hydraulic Schematic Diagram
8.1 Hydraulic Schematic Diagram
8.1.1 Schematic Diagram of the Kawasaki Hydraulic System
破碎锤
HYDRAULIC HAMMER
液压回路图线条颜色、样式描述 HYDRAULIC LINES GROUP COLOR、PATTERNS DESCRIPIONS

左泵供油 LEET PUMP OUTPUT(P1)
右泵供油 RIGHT PUMP OUTPUT(P2)
先导泵供油 PILOT PUMP OUTPUT(P1)
主回油\泵吸油 RDTURN LINE(T)\PUMP SUPPLY LINE
泄油 DRAIN LINE(Dr)
液压元件
元件边界
CLG920E922E08001
8-4
CLG920E/922E/923E 8.1 Hydraulic Schematic Diagram
8.1.2 Schematic Diagram of the Kawasaki Rexroth System
动臂油缸
BOOM CYLINDER
B B
A A
CLG920E922E08002
8-5
CLG920E/922E/923E 8.2 Schematic Diagram of Electric System
8.2 Schematic Diagram of Electric System
Electrical schematic diagram for controller model CM3620
CLG920E922E08003
8-6
CLG920E/922E/923E 8.2 Schematic Diagram of Electric System
Electrical schematic diagram for controller model C101-D1
K4 K5 K6 K7 K8 MC K9 ECM K10 K11
50Y2316
8-7
CLG920E/922E/923E 8.3 Schematic Diagram of A/C System
8.3 Schematic Diagram of A/C System

AMP 174146-2 HVAC SG43200-719
040 36PM(黑)
9 10111213141516
12 3 4 5 6 7 8
AMP 174046-2 AMP 174047-2

040 16PF(黑） 040 20PF(黑）
/ / / /
/ / / / / / / / / / B B B B B B B B A A A A A A A A A
B B B B B B B B B B A A A A A A A A
M
077450-090 M
TH
90980-11060
M 090 2PM
2
1 TH
M 水温
170400-467
282500-148
P
机
077800-075
功率三极管
CLG920E922E08004
8-8
CLG920E/922E/923E 8.3 Schematic Diagram of A/C System

CLG920E, 922E, 923E (Cummins & ) Service Manual 202009002-En

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202009002

Applicable Model and Engine Model:

CLG920E/922E/Commins QSB7 (China II/ EU Stage II)

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

The meaning of the safety warning symbol is as follows:

1.1 Safety Precautions severe damage or even death.

Please read and be familiar with all safety precau-

The operator shall wear helmet and safety glasses

Do not operate the machine if you feel uncomfort-

Goggles, safety glasses or face shield can protect

your eyes from high-pressure fluid during the main-

tenance of the battery and the flying debris gener-

ated during the engine running and using tools.

Please wear the protection mask when removing

welding or cutting by using the welding gun.

Do not wear casual clothes, jewelry, ornaments, or

• Ensure that all guard plates and covers of the

If the pressured liquid is leaked, even if it is as small

Be careful to remove the hydraulic pipelines or

Please wear safety goggles and leather gloves

• Make sure there's no foreign matter in the vanes

Prevent Burn Oil

• Under working temperature, the hydraulic oil

• Clean and tighten all the electrode connectors.

Diethyl Ether Pipeline, Pipe and Hose

Fire Extinguisher and First-Aid Kit Preventing Thunder

Inner Space of Cab

7. Lifting angle, in principle, shall be under 60°.

Precautions for Operating Mobile

Precautions for Operating Bridge

Heavy objects that exceed 25 kg must be lifted

• Roll up the wire rope slowly until it is tensional.

13. If the crane stops operating due to power

Note: Allowable load value is 1/6 of the breaking

2.2 Marking of Revised Version

2.3 General Torque Specifications

Bolt Wrench Torque

Tightening torque of 24°cone with O-ring sealed pipe fittings

Hose Inner Tightening Torque

Tightening torque of flange sealing pipe fitting bolt

Bolt Performance Tightening Torque

Bolt Performance Tightening Torque

Tightening torque of thread angle sealing pipe fitting

Tightening torque of joints

2.4 Unit Conversion Table

Parameters Metric unit British unit Multiplier

2.5 Cable Identification Methods

Color abbreviation code

No. Wire type Wire name Description Heat resistance

Color Abbreviation Codes

Color English Abbreviation Color English Abbreviation

Remark: the code composed of two colors indicates double-color wire

Ambient 30°C 40°C 50°C 60°C 70°C

Circuit type and color abbreviation code

Circuit type Color Abbreviation Codes

2.6 Coating Materials

Name Specifications Main features and purposes

2.7 Weight Table

Components Weight (kg)