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LG6210E
Maintenance Manual
山东临工工程机械有限公司
Shandong Lingong Construction Machinery Co, Ltd
Related Manuals for SDLG LG6210E
Summary of Contents for SDLG LG6210E
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Page 1
LG6210E Maintenance Manual 山东临工工程机械有限公司 Shandong Lingong Construction Machinery Co, Ltd… -
Page 2
Maintenance Manual──LG6210E Hydraulic Excavator Forward This maintenance manual includes the Safety specifications, function information of systems and units, maintenance instructions, checking and adjustment methods, schematic diagrams and wiring diagrams. Please refer to «Safety” for safety notes for Overall maintenance operation on the machine. -
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Service Manual──LG6210E Hydraulic Excavator PREFACE …………………………..I SECURITY …………………………..1 Common precaution ……………………… 1 Security precautions …………………………1 Safety Devices …………………………… 1 Clothing and Personal Protective Items……………………1 Emergency matters preparation ……………………..2 Fire Prevention for Oil and Fuel ……………………..2 Properly dispose of scrap liquid …………………….. -
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Maintenance Manual──LG6210E Hydraulic Excavator Rotary gear ring，specifications ……………………33 Regulator, specifications ……………………….. 34 Cab specifications …………………………34 Operator seat specifications ……………………..35 Recommended hydraulic oil specifications ………………….. 35 Hydraulic oil, specifications ……………………..36 Hydraulic pressure，specifications ……………………36 Hydraulic tank, specifications ……………………..36 Air conditioning unit，specifications ……………………. -
Page 5
Maintenance Manual──LG6210E Hydraulic Excavator Draining …………………………..69 Filling oil …………………………..70 Fuel filter, replacing ……………………….. 70 Additional fuel filter (oil-water separator core), checking / draining …………… 71 Water separator filter element, replacing ………………….71 Fuel tank sediment, draining ……………………..72 Fuel tank ventilation filter, replacing …………………… -
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Maintenance Manual──LG6210E Hydraulic Excavator ……………………..107 VERVIEW OF THE ENGINE BF6M2012C Engine ……………………….107 Engine characteristics curves ……………………… 110 BF6M2012C engine ……………………….110 Basic examination, engine ……………………..110 Purpose of the basic examination ……………………110 Testing of the basic examination ……………………111 Troubleshooting ………………………… -
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Maintenance Manual──LG6210E Hydraulic Excavator 5.1 Overview ……………………….142 Cooling System,instruction ……………………..142 Cooling system, operating ……………………..143 Coolant …………………………..143 Draining the cooling system ……………………..145 5.2 Radiator, including assembly and connection …………….145 Coolant, replacing ………………………… 145 Draining the coolant ……………………….145 Filling the coolant in the cooling system …………………. -
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Maintenance Manual──LG6210E Hydraulic Excavator 2.1 Hydraulic motor 1, travel motor …………………. 197 Travel motor,instruction ………………………. 197 Operating, the hydraulic motor ……………………200 Operating, brake valve……………………….. 201 Operating, parking brake ……………………..202 Operating, displacement conversion valve …………………. 203 Travel motor, operation precautions …………………… 205 Installing ………………………….. -
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Maintenance Manual──LG6210E Hydraulic Excavator Rotating joints description ………………………. 262 Rotary joints,assembly ……………………….263 Rotary joints, tools ……………………….. 264 Common tools …………………………264 Special tools …………………………265 Rotary joint soft hose (valve — rotary joints), replacing ………………. 266 Rotary joint hose (Rotary joints — motor), replacing ………………267 Rotary joints, dismantling …………………….. -
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Maintenance Manual──LG6210E Hydraulic Excavator Installation …………………………..311 2.5 Bottom roller ……………………….. 312 Bearing wheel specification ……………………..312 Bearing wheel,wear limitation ……………………… 313 Measure the wear of outside diameter of roller thread………………. 314 Measure the wear of flange width of roller ………………….. 314 Bearing wheel, installing ……………………… -
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Maintenance Manual──LG6210E Hydraulic Excavator Actuator, air mixing valve driver ……………………356 Water temperature sensor ……………………..357 Pipe temperature sensor ……………………… 358 Temperature sensor inside the vehicle ………………….359 Air conditioning units, maintenance……………………. 359 Periodic inspection ……………………….359 Inspection items …………………………359 Ambient temperature sensor …………………….. -
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Maintenance Manual──LG6210E Hydraulic Excavator Solenoid valve troubleshooting ……………………407 ) …………..407 AIN CONTROL VALVE IRECTIONAL VALVE CONTROL VALVE Hydraulic circuit, valve ……………………….407 Description of the main control valve………………….. 409 Main control valve, partial view ……………………413 General notes …………………………416 Notice for disassembly ……………………….. -
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Maintenance Manual──LG6210E Hydraulic Excavator Pump instructions ………………………… 460 Pump, partial view ……………………….462 Pump, exploded view……………………….463 Operation principle of pump ……………………..464 Maximum oil flow adjustment ……………………… 466 Minimum oil flow adjustment ……………………..466 Pumps, maintenance standards ……………………466 Precaution for use ………………………. -
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Maintenance Manual──LG6210E Hydraulic Excavator Troubleshooting …………………………513 4. R ) …………….514 EMOTE CONTROL VALVE ONTROL PRESSURE VALVE 4.1 Remote control valve(Operation lever)………………. 514 Remote control valve(Operation lever),specification ………………514 Remote control valve (Operation lever), instruction ………………515 Maintenance standard of remote valve(operation lever) …………….522 Remote control valve（operation lever）,removing ……………… -
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Maintenance Manual──LG6210E Hydraulic Excavator Check valve …………………………… 624 6.2 Machinery Equipment / Additional Equipment …………….624 Hydraulic Quick Installation, instruction ………………….624 Hydraulic quick installation, adjusting ………………….629 ) …………..631 ROUBLESHOOTING ORKING HYDRAULIC SERVO HYDRAULIC Troubleshooting diagnostics procedures ………………….631 Examples of hydraulic system failure …………………. -
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Maintenance Manual──LG6210E Hydraulic Excavator ……………………….709 TARTING SYSTEM 4.1Overview …………………………… 709 Starting operations …………………………. 709 4.2 Starting motor including coil …………………… 711 Starting engine , indication ……………………… 711 Battery relay instructions ……………………….711 Safety starting relay, instructions …………………….. 712 Starting relay, replacing ……………………….712 4.3 Electronic air preheater, not including components Warm-up, indication …….. -
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Maintenance Manual──LG6210E Hydraulic Excavator SCH14 ……………………………. 752 SCH15 ……………………………. 754 SCH16 ……………………………. 755 SCH17 ……………………………. 758 SCH18 ……………………………. 759 ……………………760 RELAY CIRCUIT CUT 2.1 Fuse …………………………760 Fuse,instruction …………………………760 Slow-melt fuse,instruction ……………………..761 Replacement process of fuse …………………….. 762 Relay box,specification………………………. -
Page 18
Service Manual──LG6210E Hydraulic Excavator Preface Repair Manual contains specification, function introduction of the system and components, repair instruction, the method to check and adjust, Security diagram and circuits. ⅠWhole machine instruction The safety regulations about maintaining on the Ⅱ Repair and maintenance machine refer to SAFE PART. -
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Maintenance Manual──LG6210E Hydraulic Excavator Security Common precaution Warning! Please comply with the following rules for the security. Security precautions l If you have been drinking, eating some pills or other narcotics, do not operate the machine. l Only trained and authorized people can be permitted to Conform to safety operate and maintain the machine. -
Page 20
Maintenance Manual──LG6210E Hydraulic Excavator Emergency matters preparation l Know the position of fire-fighting equipmentsand how to use them. l Keep the emergency box and the tool used to wash the eyes in the working site. l Keep the phone number of doctor, emergency car,hospital and the fire department. -
Page 21
Maintenance Manual──LG6210E Hydraulic Excavator Working in the dusty environmental Dust impurities in the work environment • After the machine works in the environmetn containing asbestos dust, or other hazardous impurities, put the used cab and engine air filter into a sealed bag before placing it… -
Page 22
Maintenance Manual──LG6210E Hydraulic Excavator Reasonably and safely use of tools • Only use the tools in accordance with the designed purpose of tools • Keep all tools in good condition, and understand their proper uses. • Set a place at the repair site used to store special tools and removed parts. -
Page 23
Maintenance Manual──LG6210E Hydraulic Excavator .Use handrails or ladders l Never jump on or off the machine. Never get on or off a moving machine. l When getting on or off the machine, face the machine and use the handrails and pedals to ensure that you support yourself. -
Page 24
Maintenance Manual──LG6210E Hydraulic Excavator all the pipes leading to the engine and heater. Contacting with these parts can cause serious burns. • Hot coolant can cause burns. • Only the engine is stopped and the temperature of the radiator pressure cap is so low that it can be removed by hand, you can check the coolant level. -
Page 25
Maintenance Manual──LG6210E Hydraulic Excavator The assembly position of the components should be right. l Use a crane or a crane slowly to prevent the compoments from hitting other parts. l When disassembling or assembling, use wedges, jack and frames to support the machine. -
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Maintenance Manual──LG6210E Hydraulic Excavator l Do not make fire, lit matches and open flames near the top of the battery, in case that the battery (hydrogen) is exploded. l If the battery electrode or wire touch with metal objects, short circuit may occur, which may cause your harm. -
Page 27
Maintenance Manual──LG6210E Hydraulic Excavator 3 Do not weld near the ring near the welded joints in the cylinder.Dsitance between the ring and the welding point of welding plates is 100 mm. 4 Do not weld at the bend part of a metal plate. -
Page 28
Maintenance Manual──LG6210E Hydraulic Excavator Be careful when removing or installing the track of the machine. When removing the track pin, the track will be suddenly separated, so do not let anyone stand on either side of track. Always do good protection at both ends of the track, in case of suddenly controlled actions to cause unnecessary harm. -
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Maintenance Manual──LG6210E Hydraulic Excavator Ⅰ.Whole machine description 1. Summary Components position Fig.1 Components position Boom Engine hood Tension spring Bucket arm cylinder Balancing weight Guiding wheel Boom cylinder Hydraulic pump Control panel(Forward) Operation lever Track motor and gears Operator seat… -
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Maintenance Manual──LG6210E Hydraulic Excavator 2. Specification Standard tightening torque The following table offers the standard tightening torque of the screws and the nuts. Additional circumstance will be shown in “Disassembly or assembly”. Table1 Tightening torque (m) Grade 4.8T 8.8T 10.9T,12.9 T… -
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Maintenance Manual──LG6210E Hydraulic Excavator Table2.Tghtening torque(inch) Grade 4.8T 8.8T 10.9T,12.9 T Size Tightening torque Tightening torque Tightening torque 9.80 ±0.98 23.53±2.35 16.67 ±1.96 5/16 11.76±1.17 19.61±1.96 29.42±2.94 19.61±1.96 40.20±3.92 54.91±4.90 7/16 31.38±3.13 59.82 ±5.88 87.27 ± 8.82 46.09±4.60 100.02 ±9.80 131.40 ±12.74… -
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Maintenance Manual──LG6210E Hydraulic Excavator Tightening torque of hydraulic plug with O ring Fig.2 Hydraulic plug with O ring 1. O ring 2. Plug Pf screw Table 4. Tghtening torque (Hydraulic plug) Thread Plug number Tightening torque Nm 9415–11012 24.51 ±1.96 9415–11022… -
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Maintenance Manual──LG6210E Hydraulic Excavator Table 5.Tghtening torque of rotating nut device with O ring Outer diameter of pipe Screw size(inch) Tightening torque Nm UN 13/16 – 16 93.16 ±9.31 UN 1 3/16 – 12 176.52 ±17.65 UN 1 7/16 – 12 205.94 ±20.59… -
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Maintenance Manual──LG6210E Hydraulic Excavator Engine, specifications Table 7 Specification Program Unit Specification Fuel injection pump BOSCH Fuel pump setup, B.T.D.C Injector,starting pressure Oil consumption ratio g/kW·h 216 at1900 r/min Fuel tank Capacity Filter Valve clearance, specifications Table 8 Specification Engine model… -
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Maintenance Manual──LG6210E Hydraulic Excavator Coolant, specifications Table11. Specification Items Unit Specification Radiator Axle core model 4-CF(Wave-shape plates) Radiator core volume（W × H × 720 × 293 × 145.4 D） Dry weight Hydraulic Axle core model 1-CF(Wave-shape cooler plates) Radiator core volume（W × H ×… -
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Maintenance Manual──LG6210E Hydraulic Excavator Engine control, specifications Table14. -
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Maintenance Manual──LG6210E Hydraulic Excavator Gauge control unit I-ECU, specifications Table15. Gauge control unit, I-ECU connector, specification Connector Attached connector House：AMP 174657-2 House：AMP 174655-2 Terminal：AMP 171661-1 Terminal：AMP 171662-1 Wire sealing：AMP 172888-2 Wire sealing：AMP 172888-2 Connecting pins, specifications Table15. Gauge control unit, I-ECU connector, specification No. -
Page 38
Maintenance Manual──LG6210E Hydraulic Excavator Engine control unit E-ECU (EMR2 ), specification Table15. E-ECU (EMR2 ) pin, specification Specifications Specifications No connection ECU grounding No connection ECU grounding No connection No connection No connection No connection No connection No connection No connection… -
Page 39
Maintenance Manual──LG6210E Hydraulic Excavator Vehicle control unit V-ECU, specifications (I-ECU has been assembled.) Table18. Vehicle control unit , V-ECU,, specification Item Connector Housing Tiny timer & JPT 70Pin AMP 1-963484-1，Terminal JPT（X10） connector AMP 929939-1，JPT Wire sealing AMP 828904-1，Terminal MT-2（X60） AMP 962876-1，MT-2 Wire sealing… -
Page 40
Maintenance Manual──LG6210E Hydraulic Excavator Fig.6 VECU, connector Table20. Connector (JB) pins , specification specifications No. specifications No connecting No connecting flow control proportional valve Attached pressure sensor grounding EMR2 power checking Hammer pressure switch Floating position pressure switch No connecting… -
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Maintenance Manual──LG6210E Hydraulic Excavator specifications No. specifications High speed selecting switch Rapid assembly ending switch Preheating relay grounding No connecting Speed solenoid valve No connecting Preheating relay Overloading warning selecting switch Speed control signal 1 Speed control signal 2 Speed control signal 3… -
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Maintenance Manual──LG6210E Hydraulic Excavator Battery, specifications Table21.Battery, specifications Items Specifications Number 2 series Voltage of battery(Rated) Min12.65V / .Battery Max12.95V / .Battery Capacity 150A/h, .Battery Battery disconnector Connecting to “-” Density of sour liquid at 27°C（81°F） MIN 1.265 g/ccm MAX1.300 g/ccm AC generator, specifications Table22. -
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Maintenance Manual──LG6210E Hydraulic Excavator Battery relay, specifications Table24. Specifications Items Specifications Rated voltage DC 24V Rated loading 100A (Continuous), 1000 A (30s) Exciting current 0.5A or less（24 V，20°C） Voltage of open circuit DC 9V or less Min. working voltage DC 20V or less ≥1 MΩ… -
Page 44
Maintenance Manual──LG6210E Hydraulic Excavator Traveling warning, specifications Table28. Specifications Items Specifications Working voltage DC 18~32V Current 0.4A Sound pressure 115 ± 5Hz Operating temperature -20 — 50 °C Upper wiper motor, specifications Table29. Specifications without loading Items Specifications ＜2.5kgNm Starting torque… -
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Maintenance Manual──LG6210E Hydraulic Excavator Security lever switch, specifications Table32. AC generator, specifications Items Specifications Manufacuturer OMRON Model and name D2VW-5L2A-1M Operating force 230 gf Reaction force 20 gf Rated voltage DC 30 V，5 A Environmental -40 — 90 °C temperature Rated current 1500 rpm—为… -
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Maintenance Manual──LG6210E Hydraulic Excavator Fuse specifications Capacity and marks related to circuits. Energy Application/circuit Energy Application/circuit 10 A I-ECU F 16 15 A Starting switch 10 A Working lamp（Cab roof） F 17 Cab lamps 15 A Working lamp（Boom） F 18… -
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Maintenance Manual──LG6210E Hydraulic Excavator Relay box, specifications Table 35.Relay code of relay box Relay Name Description Type number RE3611 Speaker Always open, NO RE3501 Front work lights Always open, NO RE3301 Starter Always closed, NC RE9106 X3/quick install safety devices Always open, NO… -
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Maintenance Manual──LG6210E Hydraulic Excavator Radio with cassette or CD player specifications CD and MP3 player with recorder Table 39.Specifications Items Specifications Rated voltage DC 14V（negative grounding） Operating temperature -30 — 75℃ Output 20W×2EA Frequency range EU:MW531-1602KHZ/FM87.5-108MHZ/LW153-279KHZ NA:FM87.7-107.9MHZ/AM530-1710KHZ 80PF 75 W… -
Page 49
Maintenance Manual──LG6210E Hydraulic Excavator Travel motor, specifications Table 43.Travel motor, specifications Items Unit specifications Travel Model EM140V Motor Type Variable swash plate piston hydraulic motor Displacement cm³/rev 82.4/140.5 Pressure reducing (Standard value / 39.2+2.9/-1 when 15 l/min reconstructed value) Pressure reducing (Maintenance limit 39.2+2.9/-2 when 15 l/min… -
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Maintenance Manual──LG6210E Hydraulic Excavator Rotary unit specifications Table 44. Specifications Items Unit Specification Model M5X130CHB Fixed swash plate ， Type piston motor Pressure reducing valve— model KRD22EK10C Rebound damping valve— model 2KAR6P72 Displacement cm³/rev 121.6 Rated pressure 34.3 Theoretical output torque… -
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Maintenance Manual──LG6210E Hydraulic Excavator Attention！ For contact pressure of the ground，refer to the Operator Manual Rotary gear ring，specifications Table 46. Specifications Items Unit Specification Type Ball bearings with internal gear Teeth Weight Outer diameter 1327 Height Bearing Material SUJ-2 Outer ball diameter 31.75… -
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Maintenance Manual──LG6210E Hydraulic Excavator Regulator, specifications Table.47. Specifications Items Unit specifications Model KR3G-9N2A Maximum input torque kef m 60.9 Maximum oil output rate L/min 2×200 Minimum oil output rate L/min 2×38 Cab specifications Table.48 specifications Items Unit Specifications Length 1800… -
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Maintenance Manual──LG6210E Hydraulic Excavator Operator seat specifications Table.49 specifications Items Unit Specification suspension ， tilt Type Adjustable backrest handrail with backrest 。 Base Setting Headrest Forward 。 Backrest Forward back 。 Handrail below Height below Suspension Stroke ±35 Load 50～130… -
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Maintenance Manual──LG6210E Hydraulic Excavator Attention! I *：is installed at the factory * ISO：International Organization for Standardization *HV：High viscosity Hydraulic oil, specifications Table 51：Specification Items Unit Specification Type Anti-wear mineral oil used in high-pressure hydraulic system Level ISO VG46 Viscosity at 40℃… -
Page 55
Maintenance Manual──LG6210E Hydraulic Excavator Size: Height×width×depth mm 399×732×19 Compressor Model SD7H15WZ8045 Type Swing plate Number cylinders-diameter 7-φ29.3×39.8 stroke， mm Displacement，cc 154.9 Pressure of e pressure reducing 38±2 valve Maximum permissible continuous 5000r/min speed Maximum downshift speed 5000r/min Lubricating oil capacity, cc… -
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Maintenance Manual──LG6210E Hydraulic Excavator Table 54.Tightening torque Items kgf.m nut ， electromagnetic Central clutch （SD7H15） Install screws of valve cover Oil filling plug Hose connector Expansion valve Proportional solenoid calve specifications Table 55. Specification Category Unit Value Conditions of Maximum supply pressure kgf/cm²… -
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Maintenance Manual──LG6210E Hydraulic Excavator Table 57.Specification limit ， Component Mode Standard/reconstruction Maintenance value，unit：Mpa unit：Mpa Main Main pressure 32.4+1.5/-1 at 200l/min 32.4+1.5/-2 control reducing valve 200l/min valve High 34.3+1.5/-1 at 200l/min 34.3+1.5/-2 200l/min Boom throttle Raising 35.8+1.5/-1 at 28l/min 35.8+1.5/-2 at 28l/min… -
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Maintenance Manual──LG6210E Hydraulic Excavator machine.When the measured pressure value does not meet the maintenance tolerance limit, the worn or defective parts should be checked, or adjusted the pressure. 4 Main throttle pressure reducing valve is affected by the following 5 factors, so the pressure measurement conditions should be ensured strictly.And if measured… -
Page 59
Maintenance Manual──LG6210E Hydraulic Excavator Servo pump specifications Table 59.Specification Items Unit Model ZX10LGRZ1-07A Type Fixed gear Displacement cc/rev Oil flow l/min Release pressure kgf/cm² Accumulator specifications Table 60.Specification Description Unit Specification Type of gas Gas volume Boost pressure of gas 1.47±0.1… -
Page 60
Maintenance Manual──LG6210E Hydraulic Excavator Solenoid valve, specifications X1, solenoid valve 3 section Fig.9 X1, solenoid valve 3 section Table 61. X1, solenoid valve 3 section, specifications Instructions Unit Specification Maximum operating kgf/cm² pressure Maximum flow l/min ℃ Range of temperature -20～95… -
Page 61
Maintenance Manual──LG6210E Hydraulic Excavator Remote control valve （lever）specifications Table 62. Specification Items Unit Specification Remote control valve（bar）,left type Hydraulic Remote control valve （bar） ,right Type hydraulic Operating angle Degree 19(throttle 1-3),25(throttle 2-4) Hydraulic oil Mineral hydraulic oil ℃ Engine oil temperature range -20～95… -
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Maintenance Manual──LG6210E Hydraulic Excavator Table 64. Straight moving pedal, specification Items Unit Instruction Type Mineral hydraulic oil Operating angle Degree Backward：12.4，forward： 12.4 ℃ Engine oil temperature range -20～90 Main operating pressure 3.2+0.2 Weight Hydraulic oil cooling system, specifications Refer to cooling systems, specifications… -
Page 63
Maintenance Manual──LG6210E Hydraulic Excavator Table 65.Specification，2 pump oil flow selector valve Instruction Unit Specification Normal operating pressure 34.32 Normal flow l/min Maximum oil flow at 140 kgf/cm² in section C cc/min Maximum pressure loss when flow rate is 0.07 100lpm Minimum cracking pressure of spool 0.69… -
Page 64
Maintenance Manual──LG6210E Hydraulic Excavator Rotary solenoid valve Fig. 12 Rotary solenoid valve Table 67.Specification，solenoid valve Instruction Unit Specification Maximum operating pressure kgf/cm² Operating flow Allowed regressive pressure kgf/cm² Internal leakage at pressure 140 kgf/cm² and Cc/min viscosity 20 cSt ℃… -
Page 65
Maintenance Manual──LG6210E Hydraulic Excavator Solenoid valve, specifications Table 68.Solenoid valve block 1 Items Specification Maximum pressure 50 kgf/cm² Maximum oil flow and The direction of oil flow Maximum oil Pressure loss pressure loss (viscosity flow l/min kgf/cm² P1→A1 20 cSt) 5 maximum （A1→T）… -
Page 66
Maintenance Manual──LG6210E Hydraulic Excavator Table 70. Specification，boom Items Unit 5.7m HD Length 5700 5910 1585 Width Weight 1890 Boom cylinder specifications Table 71. Specification Items Unit Specification Boom cylinder Quantity Φ125×φ80×1235 Inner diameter ×live bar × stroke Align the center Fully retracted（A）… -
Page 67
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm, specifications Fig.15 Bucket arm Table 72. Size，arm Items Unit 2.9 m HD Length 2900 3910 Width Weight 1085 Bucket arm cylinder, specifications Table 73.Specification Items Unit Specification Stick cylinder Quantity φ135×φ95×1540 Internal diameter ×live lever ×… -
Page 68
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 16 Cylinder length A Retracted length B Stretched length Bucket cylinder, specifications Table 74. Specification Items Unit Specification Bucket cylinder Quantity φ120×φ80×1065 Internal diameter ×live lever × stroke Make the center Fully retracted（A） 1655±2 distance of the pin Fully stretched（B）… -
Page 69
Maintenance Manual──LG6210E Hydraulic Excavator Fig.17.Cylinder length A Retracted length B Stretched length 3 Tools NET 8940-00200 remote control valve connector replacement tools Fig. 18 Remote control valve connector replacement tools Items Quantity Name remarks Socket wrench SAE 4130（QT） Baffle SAE 4130（QT）… -
Page 70
Maintenance Manual──LG6210E Hydraulic Excavator NET 8940-00190 Moving motor guide pins Fig. 9 Moving motor guide pins Items Quantity Name Remarks Guide bar SAE 4130（25～35 HRC） Screw M8×16 NET 8940-00270 rotating ring replacement tool Fig. 20 Rotary ring replacement tool Items… -
Page 71
Maintenance Manual──LG6210E Hydraulic Excavator NET 8940-00290 alignment pins of track motor Fig. 21 Track motor, pins Items Quantity Name Remarks Guide bar SAE 4130（25～35 HRC） Screw M8×16 NET 8940-00300 Rotary gear alignment pins Fig.22 Rotating gear ring, guide pin Items… -
Page 72
Maintenance Manual──LG6210E Hydraulic Excavator 4 Maintenance instructions；Security instructions Maintenance position Park the machine in a horizontal solid place. The appropriate positions of machine are described in a variety of maintenance instructions. Fig.23 Maintenance position A Fig.24 Maintenance position B Fig. 25 Maintenance position C… -
Page 73
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 27 Maintenance position E Fig. 28 Maintenance position F… -
Page 74
Maintenance Manual──LG6210E Hydraulic Excavator Ⅱ Repair and maintenance 1 Lubricating; fuel; other liquids 1.1 Overview Recommend lubricants Note! 1) Recommended engine oil level (VDS-3, or Global DHD-1 +VDS-2, or ACEA-E5 + VDS-2, or API CH-4 + VDS-2) Note! *: is installed in the factory. -
Page 75
Maintenance Manual──LG6210E Hydraulic Excavator • ISO: International Organization for Standardization • API: American Petroleum Institute Table 2. Filling capacity Tank Type of fluid About filling capacity Liters Engine oil disc with filter Engine oil 19.5 Hydraulic oil tank Hydraulic oil… -
Page 76
Maintenance Manual──LG6210E Hydraulic Excavator adaptation temperature requirements), ASTM D 975 No 1D and 2D, JIS KK 2204. Note! Please use the API level of CF or CG as the engine oil. If the API Level is CD, then the replacement intervals of engine oil should be half. -
Page 77
Maintenance Manual──LG6210E Hydraulic Excavator 10 Battery status, checking 11 Seat belts and tension of seat belt, checking, replacing it if necessary 12 Coolant freezing point, checking 13 Lubrication, refer to the lubrication chart 14 Oil level of rotating gearbox, checking… -
Page 78
Maintenance Manual──LG6210E Hydraulic Excavator 23 Rotary gearbox oil level, checking 24 Rotary motor gear box, changing the oil 25 Rotating ring gear bearings, lubrication 26 Rotary oil bath grease, checking 27 Cab; door, lid, hinges, fittings and locks, lubricating 28 Track board bolts, checking… -
Page 79
Maintenance Manual──LG6210E Hydraulic Excavator 2 Machine, check the external damage, cracking and worn damage 3 Cleanser level, checking 4 Coolant level, checking 5 Additional fuel filter (oil-water separator core), checking / draining 6 Track plate bolts, checking 7 Engine, oil level, checking Maintenance every 50 hours Maintenance points marked as «Optional equipment»… -
Page 80
Maintenance Manual──LG6210E Hydraulic Excavator 8 Main filter element of air filter, cleaning 9 Battery status, checking 10.Cab,pre-filter,cleaning 11 Lubrication, refer to the lubrication chart 12 Rotary gearbox oil level, checking 13 Rotating ring gear bearings, lubricating 15 X1 oil return filter (optional equipment), replacing Maintenance every 500 hours Maintenance points marked as «Optional equipment»… -
Page 81
Maintenance Manual──LG6210E Hydraulic Excavator 2 Machine, check the external damage, cracking and worn damage 3 Cleanser level, checking 4 Coolant level, checking 5 Hydraulic oil level, checking 6 Replace the fuel of engine. 7.Fuel filter,replacing 8 Oil-water separator filter element, replacing 9. -
Page 82
Maintenance Manual──LG6210E Hydraulic Excavator 3 Cleanser level, checking 4 Coolant level, checking 5 Hydraulic oil level, checking 6 Replace the fuel and filter of engine. 7.Fuel filter,replacing 8 Oil-water separator filter element, replacing 9. Fuel tank, draining 10 Ventilation filter of fuel tank, replacing 11Hydraulic oil servo filter, replacing 12.Main filter of air filter, cleaning… -
Page 83
Maintenance Manual──LG6210E Hydraulic Excavator 1 Try to run and check 2 Machine, check the external damage, cracking and worn damage 3 Cleanser level, checking 4 Coolant level, checking 5 Hydraulic oil level, checking 6 Replace the fuel and filter of engine. -
Page 84
Maintenance Manual──LG6210E Hydraulic Excavator Maintenance every 6000 hours Maintenance points marked as «Optional equipment» is not included in the calculated maintenance interval. 1 Try to run and check 2 Machine, check the external damage, cracking and worn damage 3 Cleanser level, checking… -
Page 85
Maintenance Manual──LG6210E Hydraulic Excavator 33 Loose and missing bolts, checking 34 X1 oil return filter (optional equipment), replacing Test running and checking 1 Starting and stopping functions (including warm-up function) 2 Instruments 3 Lighting 4 Direction instruction 5 Danger flash lamp… -
Page 86
Maintenance Manual──LG6210E Hydraulic Excavator 2Check the cleanser level Add cleanser inside the cleaner. Fig.2 Engine oil level, checking 1 Open the hood. 2 Pull out the dipstick (1), wipe it with a clean cotton cloth. 3 Insert the dipstick, and then pull it out. -
Page 87
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic oil level, checking 1. Park the machine on hard ground. 2. Stop the machines in the repair location C. Refer to maintenance position. 3 Push the safety control lock lever down and fix it firmly in Fig.5… -
Page 88
Maintenance Manual──LG6210E Hydraulic Excavator 3 Open the right door on the machine. Fig.8 4 Replace oil filter with 9,996,672 wrench , fill the new oil filter with engine oil. Clean the base of filter housing. Make sure that all the old filter gaskets are removed. -
Page 89
Maintenance Manual──LG6210E Hydraulic Excavator 2 Use a 9,996,671 oil filter wrench to loosen the fuel filter, then remove it. 3 Clean the sealing surface of filter head. 4 Coat the new rubber seal of filter with a little oil, or make it wet with diesel fuel. -
Page 90
Maintenance Manual──LG6210E Hydraulic Excavator 2 Disconnect the cable connector (1). 3 Loosen the drain valve (2), and discharge the sediment from the oil-water separator tank (3). 4 Use an oil filter wrench to loosen 9996671 oil-water separator tank (3), then remove it. -
Page 91
Maintenance Manual──LG6210E Hydraulic Excavator 2 Remove the clamping screw (2) and air filter (1) of fuel tank. Fig.17 3 Install the new fuel tank air filter (1) and the rubber connector (2). 4 Install the clamping screw and the fuel tank air filter. -
Page 92
Maintenance Manual──LG6210E Hydraulic Excavator 3 Pull out the main filter element of air filter and place it in a soft, clean surface, Carefully beat the end of the main element. Fig.21 4 Use clean dry compressed air to clean the main filter,… -
Page 93
Maintenance Manual──LG6210E Hydraulic Excavator 5 Close the air filter cover and side door. Safety filter element of air filter, replacing Note! After replacing the main filter element every 3 times, security filter should be replaced, or at least once every two years. -
Page 94
Maintenance Manual──LG6210E Hydraulic Excavator 2 Remove the battery cover. Fig.28 Removing the battery 3 Remove the battery cover (1). Electrolyte level should be approximately exceeding the panels about 10 mm. 4 When necessary, use distilled water to fill. 5 Operate the machine after filling fully, so that water can be mixed in the battery electrolyte, which is even more important in cold weather. -
Page 95
Maintenance Manual──LG6210E Hydraulic Excavator External radiator / oil cooler outside, cleaning WARNING! Compress air. Do not point directly to exposed skin. Use protective equipment. 1 Open the left door on the machine. Fig.31 2 Remove the screws (1), and open the radiator cap (2). -
Page 96
Maintenance Manual──LG6210E Hydraulic Excavator 4 Pull up the filter mesh and remove it 5 Blow the outside of the radiator / hydraulic oil cooler and inflatable cooler with compressed air or water flow net cleanly. Fig. 34 Filter Hydraulic tank, oil returning filter, replacing Note! When using a hydraulic hammer, refer to the table to replace the oil return filter. -
Page 97
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic oil draining filter, replacing Note! After 500 operating hours, replace the filter element of hydraulic oil draining filter, and then replace it every 1000 operating hours. 1 Put a container under the oil draining filter, turn the filter counterclockwise to remove it. -
Page 98
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic tank, replacing the ventilation filter Removing 1 Release the residue pressure in the hydraulic tank from the respirator. 2 Remove the rubber cover (1) and nut (2). Fig.40 Remove the rubber cap and nut 1. Rubber nut 2. Nut 3 Remove the cover by rotating respirator cover (3), and remove the filter components (4) of respirator. -
Page 99
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic tank, hydraulic oil replacing Important! Use the same hydraulic oil in the system. If you mix different brands of hydraulic oil, hydraulic system may be damaged. Note! Refer to the table below to replace the hydraulic oil. -
Page 100
Maintenance Manual──LG6210E Hydraulic Excavator Valve clearance, checking / adjusting Tool 9,998,681 Rotary tool 885,812 Timing Tool WARNING! Risk of burns — stop diesel engine and let it cool, then make the necessary operations. 1. Park the machine in the maintenance position B. Refer to maintenance position 2 Open the engine hood. -
Page 101
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the rocker cover (1). 7 Open the right side door on the machine. Fig.47 8 Removing gear cover (1) of camshaft, install the steering gear (2). Note! Steering gear must be fully meshed with the gear of camshaft. -
Page 102
Maintenance Manual──LG6210E Hydraulic Excavator Fig.50 Valve overlap Fig. 51 1,3,5,7,9 and 11 are exhaust valve 10 According to the black mark in the figure, adjust the valve clearance for each cylinder. Adjustment steps are as follows: 1 Loosen the locking bolts on the adjusting screw of the rocker. -
Page 103
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 53 1 885 812 timing tool 2 Adjustment screws 11 Rotate the crankshaft one full circle until the valves of cylinder overlap. According to the black mark in the figures, adjust the valve clearance of each cylinder. -
Page 104
Maintenance Manual──LG6210E Hydraulic Excavator Coolant, replacing WARNING! Risk of burns — stop diesel engine and let it cool, then make the necessary operations. WARNING! When the expansion tank cap (cooler cover) is opened, because of the high pressure of cooler within the system, it has the risk of scalding. -
Page 105
Maintenance Manual──LG6210E Hydraulic Excavator Note! Do not fill the cold coolant when the engine is warming up, which may cause cracks of engine body and cylinder heads. Main filter of air conditioning, cleaning 1 Move driver’s seat to the front position and fold the backrest forward front. -
Page 106
Maintenance Manual──LG6210E Hydraulic Excavator Note! When removing the lid, refer to the method of top lid. Fig.62 6 Remove the filter and blow the filter with compressed air —- maximum pressure of 0.2 Mpa. 7 Restore the machine to the operating state. -
Page 107
Maintenance Manual──LG6210E Hydraulic Excavator 5 Disconnect the wiring harness (4) of air actuator. Remove the pipe (1) of air conditioning and the upper shell (3). . Fig. 67 1 Pipeline 2 Open method of housing 3 Upper shell 4 Wire harness Note! When removing the lid, refer to the method of top lid. -
Page 108
Maintenance Manual──LG6210E Hydraulic Excavator 3.Remove the filter and blow the filter with compressed air —- maximum pressure of 0.2 Mpa. Note! If the air filter is clogged, airflow reduces, and cooling and heating capacity will decrease. Therefore, clean regularly. Fig.71… -
Page 109
Maintenance Manual──LG6210E Hydraulic Excavator 2 Check the gear oil level and fill it fully as needed. Note! After adding gear oil, wait about 5 minutes, then check the gear oil level. Fig.75 Rotary motor gear box, changing the oil Important! Drain when the gear oil is heated to rush out the dirt. -
Page 110
Maintenance Manual──LG6210E Hydraulic Excavator 3 After lubrication, thoroughly clean the excessive grease. Rotary oil bath grease, checking 1 Open the battery cover on the right side of the machine. 2 Remove the lid. Fig.79 3 Check the grease level. Note! If the grease is contaminated, or water is under discoloration, grease should be replaced. -
Page 111
Maintenance Manual──LG6210E Hydraulic Excavator Fig.82 2 Rotate the superstructure to one side , and fall the boom to lift the track. Rotate the track plate forward and backward several times slowly. Check whether the track plates and screws are loose or missing or damaged. -
Page 112
Maintenance Manual──LG6210E Hydraulic Excavator Fig.85 2 Rotate the track plate forward and backward several times slowly. Check whether the track plates and screws are loose or missing or damaged. Stop the track when rotating back. 3 Measure the track tension between the track plate in the center of track frame and the assembling surface of track bearing wheel.. -
Page 113
Maintenance Manual──LG6210E Hydraulic Excavator Oil level of track gearbox, checking 1 Put the machine on a hard ground. 2 Rotate the gearbox as shown in the figure. Remove the cover on the plug (2), check if there is gear oil spilling. -
Page 114
Maintenance Manual──LG6210E Hydraulic Excavator 2 Check the loose and missing assembly bolts of the seal cap visually. 3 Check whether the bolts of the hydraulic pump, motor, main control valve are loose or missing. Hydraulic pressure, checking 1 Measure the hydraulic pressure with pressure gauge, and adjust it if necessary, refer to main pressure reducing valve adjustment. -
Page 115
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm cylinder • Bucket cylinder is completely extended. Fig.91 Measurement conditions, bucket arm cylinder A B→A: Arm is retracted B A→B: Arm is extended Bucket cylinder Fig.92 Measurement conditions, bucket arm cylinder A B→A: Bending out… -
Page 116
Maintenance Manual──LG6210E Hydraulic Excavator Measuring • Operate the control lever with full stroke • Measure the time of full stroke of cylinder with a watch. • Measure 3 times and calculate the mean. Operating Standar Allowable Remarks value Boom Lifting 2.6±0.3… -
Page 117
Maintenance Manual──LG6210E Hydraulic Excavator • After measurement, remove the tape and carefully clean Fig.94 Measurement conditions, peristaltic 1 Tape 3 Piston rod 5 Retracted (L = A — a) 2 Seal sleeve of cylinder 4 Starting position 6 Extending (H = b — A) -
Page 118
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 95 Measurement conditions, rotation speed Rotation towards left/right at idle Preparation • Bucket is with full load. • Bucket arm cylinder is completely retracted. • Bucket cylinder is completely extended. • Make the mark (A) on the outer bearing sleeve of rotary bearing, and mark (B) on the chassis under it directly. -
Page 119
Maintenance Manual──LG6210E Hydraulic Excavator Fig.97 Moment of inertia A Mark position (bearings) C Stopping position of rotary device E Starting rotation device B Mark position (chassis frame) D Moment of inertia F 180 ° rotation Measuring clearance of bearing Removable status Standard 0.05 ~ 0.2… -
Page 120
Maintenance Manual──LG6210E Hydraulic Excavator Installation conditions Clean the bearing sleeve and lower part of chassis of outer rotary gear. Wear of rotary gear are uneven on the entire circumference. To obtain accurate results, measure twice and rotate the upper structure around the axis 90 °. -
Page 121
Maintenance Manual──LG6210E Hydraulic Excavator Allowed spacing Measure the gap twice in each location and record in the following table. Superstructure in the 1st At the 2nd reading of the reading of the gap position position superstructure A (1st measurement) B (2nd measurement) -
Page 122
Maintenance Manual──LG6210E Hydraulic Excavator Travel time Standard Allowed value Maximum 1 Speed 2 Speed Performance of moving straight Preparation • Bucket cylinder / bucket arm cylinder are fully extended • Fix the excavating device to the move gesture. Fig.102 Measurement conditions, performance of moving straight Measuring 1 Operate two travelling control lever with full-stroke. -
Page 123
Maintenance Manual──LG6210E Hydraulic Excavator Track running speed Preparation • Mark any of the track piece in the test side. • Top up the track to be tested. Fig.104 measurement conditions, track speed Measuring • Accelerate the engine to maximum speed. -
Page 124
Maintenance Manual──LG6210E Hydraulic Excavator • When another machine is starting, do not make two machines contact with each other. Connect the actuating cable as follows: 1 Connect the clamp (1) of the actuating cable (A) with (+) pole of battery on the machine that is started with actuator. -
Page 125
Maintenance Manual──LG6210E Hydraulic Excavator Ⅲ Engine system 1 Overview of the engine BF6M2012C Engine The engine is 4- stroke, six-cylinder, turbocharged, direct injection, water-cooled diesel engine, equipped with inflatable cooling and wet replaceable cylinder. The electronically controlled diesel engine is controlled by the electronic control unit (EMR2) software of engine. -
Page 126
Maintenance Manual──LG6210E Hydraulic Excavator Cylinder is coded from the flywheel end. Engine Rotation direction of engine is counterclockwise seen from the flywheel side. Fig. 2 Engine, side view of starting motor 1 Fuel intake throttle 2 Single injection pump 3 Fan drive… -
Page 127
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 3 Engine, side view of air heater 1 Coolant inlet (from radiator) 2 Coolant exit (to the radiator) 3 Coolant supplement throttle 4 Air inlet (from the air filter) 5 Turbocharger 6 Intake manifold 7 Exhaust manifold… -
Page 128
Maintenance Manual──LG6210E Hydraulic Excavator Engine characteristics curves BF6M2012C engine Fig.4 Engine characteristics curve Basic examination, engine Note! Some testing and safety inspection is carried out when the lock lever is not locked. If the lock lever is not locked in a safe situation, ensure that the machine will not be operated accidentally. -
Page 129
Maintenance Manual──LG6210E Hydraulic Excavator Testing of the basic examination Basic examination divided into the following test items should be done after reading the fault code and checking parameters. Troubleshooting Troubleshooting overview If a function has been felt to fail, it is very important to identify the cause as soon as possible. -
Page 130
Maintenance Manual──LG6210E Hydraulic Excavator Contain design information of error code, all fault codes table and each fault code information. 5 Components, repair and specifications Contain troubleshooting methods and numerical measurements of components. Also contain some circuits and certain regulations 6 Parameters Wrong setting of parameters will result in the failure symptoms. -
Page 131
Maintenance Manual──LG6210E Hydraulic Excavator Fig.5 Valve • Each cylinder of engine has one intake valve and an exhaust valve. Guide lever of the valve guide is retracted in the cylinder cover. Valve embedded body is made of high-quality steel and also is retracted in the cylinder cover. -
Page 132
Maintenance Manual──LG6210E Hydraulic Excavator • Measuring projection of piston needs a dial indicator of locator. • Piston is located on the dead point position on the surface of the piston. Fig. 6 Measurement, piston projection 1 Dial indicator A. Set the dial indicator on the surface of cylinder to «zero». -
Page 133
Maintenance Manual──LG6210E Hydraulic Excavator • 3-hole = 1.4 mm Table 2 piston projection Piston projection Identification cylinder head gasket 0.33 ~ 0.55 mm 1 hole 0.56 ~ 0.65 mm 2 holes 0.66 ~ 0.76 mm 3 holes Installing cylinder cover… -
Page 134
Maintenance Manual──LG6210E Hydraulic Excavator 1.2 Pistons Piston, indication BF6M2012C Engine Piston is made from special aluminum alloy. Combustion chamber of position is located slightly off-center relative to the piston (eccentric). Piston is equipped with three rings. The first ring has a ring prop made of cast iron. -
Page 135
Maintenance Manual──LG6210E Hydraulic Excavator Piston cooling Piston is cooled by spraying the oil to the inner part of the piston. Plastic 2-hole piston cooling nozzle is installed in the main bearing base. Fig. 10 Piston cooling 1.3 Valves mechanery Valves, indication… -
Page 136
Maintenance Manual──LG6210E Hydraulic Excavator 1.Park the machine in the maintenance position B. Refer to maintenance position 2 Open the engine hood. 3 Remove the turbocharger inlet pipe (1). 4 Remove the ventilation pipe (1) of crankcase. Fig.13 5 Remove the cable bracket (1). -
Page 137
Maintenance Manual──LG6210E Hydraulic Excavator Note! Steering gear must be fully meshed with the teeth of camshaft gear. 9 Set the overlap angle of engine valve Rotate the crankshaft using the steering gear 1 until it reaches the overlap angle of cylinder valve. -
Page 138
Maintenance Manual──LG6210E Hydraulic Excavator 10 According to the black mark in the figure, adjust the valve clearance for each cylinder. Adjustment steps are as follows: 1 Loosen the locking bolts on the adjusting screw of the rocker. 2 Install the protractor on adjustment screws. -
Page 139
Maintenance Manual──LG6210E Hydraulic Excavator 13 After the maintenance work is completed, start the engine, check for leakage and operation state. 1.5 Engine Assembly Engine Assembly Table 3 tightening torque, unit: kgf· m Installation location Tightening torque Screws (fan and flywheel side) 70±7… -
Page 140
Maintenance Manual──LG6210E Hydraulic Excavator 2 Lubrication system Lubrication system, indication •By the forced lubrication through the oil pump, engine oil is supplied to the rotating parts, such as the turbocharger, crankshaft, camshaft, pistons, intake / exhaust valves, rocker arms and the contact surface of timing gear. -
Page 141
Maintenance Manual──LG6210E Hydraulic Excavator Diagram, oil circuit Table 4 Specifications Items Explain Remarks Oil Pump Rotary pumps: Volume flow in the n = 2500 min-1: 65 l / min Oil radiator Oil cooler bypass valve Opening pressure: p = 2.1 ± 0.35 bar… -
Page 142
Maintenance Manual──LG6210E Hydraulic Excavator the oil cooler to the oil filter. These two parts are mounted on the oil cooler on the crankcase with flange. Downstream from the filter, oil flows into the main oil and secondary pipeline. From here, the oil pipeline will be guided to the lubrication points. -
Page 143
Maintenance Manual──LG6210E Hydraulic Excavator Oil cooling tank Pressure relief valve of oil cooling tank and oil cooler, cooperate with each other. Table 6 oil cooling tank Item Explain Remarks Oil filter Components: the filter shell, oil filter and filter element. -
Page 144
Maintenance Manual──LG6210E Hydraulic Excavator 3 Fuel system 3.1 Overview Fuel system, indication Fuel supply system is composed of a low and a high pressure circuit. Low pressure circuit Fuel comes out from the fuel tank, goes into fuel filter 5… -
Page 145
Maintenance Manual──LG6210E Hydraulic Excavator through a large number of fuel, with automatic exhaust function. Fuel flow system diagram Fuel flows from the pump (9) to the tank (2) to the supply pipe of each cylinder injection pump on the crankcase through a filter (7). -
Page 146
Maintenance Manual──LG6210E Hydraulic Excavator Fuel level sensor is installed in the fuel tank. When the fuel level gauge shows EMPTY, the tank there is about 40 liters of fuel left. Fuel injection system, indication • BF6M2012C works according to direct injection. -
Page 147
Maintenance Manual──LG6210E Hydraulic Excavator hand, which avoids the start-up procedure of engine. (Starting protection). Note! Do not reduce cross-section of pipe and connect to pump (refer to installation instructions), which will cause the engine power loss. Fig. 30 Oil supply pump… -
Page 148
Maintenance Manual──LG6210E Hydraulic Excavator 4 Turn on the power, start the engine, run the engine at low idle for several minutes. If the engine is difficult to start, and then use the main pump to exhaust. Note! The main pump can not be used with the engine running. -
Page 149
Maintenance Manual──LG6210E Hydraulic Excavator 5 Remove the pipes(1), screws (3) and fuel supply pump (2). Fig.35 1 Fuel input / output pipeline Note! Cover the port of hose, to prevent debris from 2 Fuel supply pump entering the fuel system. -
Page 150
Maintenance Manual──LG6210E Hydraulic Excavator 5 Tighten screw on the filter by hand until the seal contacts tightly, then turn a half circle. 6 Perform to exhaust air. Refer to fuel system, oil leakage Additional extra oil filter, replacing Tool 9996671 oil filter wrench… -
Page 151
Maintenance Manual──LG6210E Hydraulic Excavator 3.3 Fuel Tank Description of the fuel tank Fig.39 Structure, fuel tank 1 fuel tank 2 mesh filter 3 fuel tank lid 4 emissions knob 5 handle 6 oil output throttle 7 screws 8 shims 9 flat gasket10 spring washers… -
Page 152
Maintenance Manual──LG6210E Hydraulic Excavator 3.4 Injectors; oil supply pipelines Injector, indication Injection nozzle has 6 holes, which is designed to provide a fixed standard of the injection surface shape, regardless of the angle of injector and injector nozzles. Fig. 40… -
Page 153
Maintenance Manual──LG6210E Hydraulic Excavator Injector, replacing one 1 Park the machine in the maintenance position B, refer to maintenance position Important! Note to keep clean as far as possible! 2 Open the engine hood. 3 Remove the cable bracket (1) from the valve cover. -
Page 154
Maintenance Manual──LG6210E Hydraulic Excavator Engine starting conditions Note! This test can only be used for engine has problems about starting. 4 Remove the injectors cover (1) from the engine, disconnect all the cables (2)of injector. Note! Do separate the disconnected cables. -
Page 155
Maintenance Manual──LG6210E Hydraulic Excavator Note! If test results are not normal, check the fuel pressure sensor and the engine electronic control unit (EMR2). 11 Stop the engine. 12 Store the operation cards. The engine is running, but without load. 13.Begin the testing of SIEDIA engine. -
Page 156
Maintenance Manual──LG6210E Hydraulic Excavator 4 Air intake system; exhaust system 4.1 Overview Air intake system, instruction • Air used for combustion is filtered by pre-filter, air filter, then provide into the combustion chamber of engine through the air cooler. • To provide convenience to the operator, blocking of the intake system will be perceived and start a warning light on the gauge. -
Page 157
Maintenance Manual──LG6210E Hydraulic Excavator Exhaust System, instruction BF6M2012C engine 1 The exhaust system is designed to make noise is significantly reduced when the waste air goes through exhaust manifold and the muffler. Fig. 49 Installing, the muffler 1 turbocharger 2 pipes… -
Page 158
Maintenance Manual──LG6210E Hydraulic Excavator 4.2 Air cleaner with the connecting pipe; air preheater Preheating coil, replacing WARNING! Risk of burns — stop diesel engine and let it cool, then make the necessary operations. 1 Open the hood. 2 Remove the outlet pipe (1) and hose (2)of boost air cooler. -
Page 159
Maintenance Manual──LG6210E Hydraulic Excavator Intercooler reduces the air temperature about 100 ° C (212 ° F), which can increase engine power by about 10%. Torque of engine will increase, and fuel consumption is also reduced. Turbo diesel engine with inflation cooling (intercooling) is the most efficient during all diesel engines. -
Page 160
Maintenance Manual──LG6210E Hydraulic Excavator 5 Cooling System 5.1 Overview Cooling System,instruction Chamber and boxes of cooling unit are made of aluminum. Hydraulic oil cooler and boost air cooler is installed on the radiator frame. As the fan rotates, the air goes through the radiator, oil cooler and inflatable cooler ,and then be absorbed into the engine. -
Page 161
Maintenance Manual──LG6210E Hydraulic Excavator Cooling system, operating Fig.55 Cooling System (1) 1 cooling fan 2 radiator 3 vent hose 4 outlet hose of coolant 5 thermostat6 fan belt 7 cylinder cooling chamber 8 filters of engine and oil cooler 9 inlet hose of coolant 10 water pump 11 additional hose Note! Tightening torque (clip): 0.5 ~ 0.6 kgf ·… -
Page 162
When filling and replacing the coolant, only use the coolant VCS of SDLG. Do not mix different coolants or corrosion protection agent, as this may cause damage to engine. If you use the VCS coolant and pure water, the mixture should contain 40-60% concentrated coolant and 60-40% water. -
Page 163
Maintenance Manual──LG6210E Hydraulic Excavator concentrated coolant. Do not mix with other premixed coolant, which may cause the damage to engine. Important! Refrigerant of cooling system must be disposed according to environmental regulations. Draining the cooling system Draining To drain the cooling system, remove screw on the left crankcase, use the appropriate container to collect the coolant. -
Page 164
Maintenance Manual──LG6210E Hydraulic Excavator 3 Open the left side door on the machine. Open the coolant drain valve (1), and drain the coolant into a suitable container. Note! Prepare a suitable container. Note! After emptying the cooling system, do not prevent freezing. -
Page 165
Maintenance Manual──LG6210E Hydraulic Excavator 4 Remove the screws (2), and remove the thermostat housing (1) at the outlet hose (3) of the radiator. 5 Remove the cover from the engine cylinder thermostat (1). Fig.60 6 Install a new thermostat with a new gasket (2). -
Page 166
Maintenance Manual──LG6210E Hydraulic Excavator 2. Heat when measuring the water temperature, then see actions listed in the table. About operating temperature, refer to thermostats, specifications. Note! Opening temperature of valve is engraved on the flange. 3 Put the thermostat in a container filled with antifreeze or oil. -
Page 167
Maintenance Manual──LG6210E Hydraulic Excavator 4 Loosen two mounting screws for 2 laps. Fig.66 5 Use the belt adjusting nut (3) to remove the compressor belt (1). Note! Belt tension of adjuster is very strong. Therefore, after removing the belt, pay attention to injury. -
Page 168
Maintenance Manual──LG6210E Hydraulic Excavator 6 Use a socket wrench handle (1 / 2 «) rotate belt tension (3)clockwise, remove the belt (4), then install a new belt. Note! Belt tension of adjuster is very strong. Therefore, after removing the belt, pay attention to injury. -
Page 169
Maintenance Manual──LG6210E Hydraulic Excavator 6.2 Speed control Engine speed control switch description · VECU automatic operating position, the operator can easily control operation mode, the engine speed and maximum horsepower by the engine speed control switch. · Switch can control engine speed and maximum horsepower according to the programs of each mode of VECU. -
Page 170
Maintenance Manual──LG6210E Hydraulic Excavator Ⅳ Power transmission 1 Gear box 1.1 Track gearbox Track gearbox, instruction Track gear box is made up of 2 -order planetary gear devices, which can turn the high speed of hydraulic motor to low speed, high torque rotational force in the centre of sprocket teeth. -
Page 171
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 2 Port connector 1.Gear oil level checking throttle (PF 3 / 4) 2 Gear oil filling and discharge throttle (PF 3 / 4) 3 High-speed 4 Low-speed Table 1 Direction of rotation E-axis view Import… -
Page 172
Maintenance Manual──LG6210E Hydraulic Excavator Table 2 Throttle connection Throttle sign Dimension of the throttle Throttle （A）（B） PF 1 Oil supply(oil return) （P ）（P ） PT1/4 Pressure checking （P） PF1/4 Displacement conversion valve —oil supply （D ）（D ） PF1/4 Draining oil Fig.4 Track gear box, cross section… -
Page 173
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 5 Track gearbox, exploded view Power from the output shaft of hydraulic motor will be delivered to prime epicyclic gear (27) → No.1 bracket rack (19) →secondary epicyclic gear (20) →secondary planetary gear (12) → ring gear (8). -
Page 174
Maintenance Manual──LG6210E Hydraulic Excavator Tightening torque Table 4 tightening torque Deceleration screws (A) Quantity Thread Torque, kgf · m M16(P2.0) 27±3 Sprocket bolt (B) M16(P2.0) 27±3 Note! The intensity level of screws must be greater than 10.9 KS. Lubricating oil Important! Before operating the travel function, fill the gearbox to the correct level with the gear oil. -
Page 175
Maintenance Manual──LG6210E Hydraulic Excavator Operation Checking • Check the oil level before operating the travel function • Check whether gear box assemblies is leaked. • Check whether the mounting screws are tight. • Check whether there is abnormal sound or vibration during the operation. -
Page 176
Maintenance Manual──LG6210E Hydraulic Excavator Table 5 Components, replacement standard Items No. Component Status Allow value Ring gear There is dents or uneven wear on the Area ratio: No.2, planetary gear teeth surface. No.2 epicyclic gear Gear is broken. No.1 planetary gear No.1 epicyclic gear… -
Page 177
Maintenance Manual──LG6210E Hydraulic Excavator Special tools Table 7. Special tools Explain Size Quantity Bearing shim adjustors Refer to the next figure Gasket thickness measurement fixtures Fig.11 Gasket thickness, measurement tool Track gear box, removing 1 Remove cover screws (2), and remove the cover (1). -
Page 178
Maintenance Manual──LG6210E Hydraulic Excavator Fig.13 Remove the hydraulic hose and screw 6 Entangle around the gear box with a rope, and then lift it. Remove the motor. Then, push the gearbox out with the screws in the thread hole of the chassis. -
Page 179
Maintenance Manual──LG6210E Hydraulic Excavator Track gear box, replacing the lid 1.Park the machine in the maintenance position B, refer to maintenance position. Turn the gear box until the drain plug and level plug is located on the vertical axis. 2 Remove the two plugs (1,2)on the end cap and drain the gear oil into a suitable container. -
Page 180
Maintenance Manual──LG6210E Hydraulic Excavator Track gearbox removing Note •Before removing, completely clean the gear box components. • Choose a clean work area. • Make marks on the assembled components to note the correct position in order to facilitate assembly. • Be careful not to mix the secondary component parts, namely, the planetary gear bearings, gears and thrust washers. -
Page 181
Maintenance Manual──LG6210E Hydraulic Excavator 4 Remove No.1 planetary gear transmission equipment (18) from No.2 planetary gear (10). Remove No.1 planetary gear drive device. • Hit the spring pin (26) into the No. 1 pin (25). • Remove thrust washer (24), No.1 planetary(22) and needle roller bearings (23) gear from No.1 bracket (19). -
Page 182
Maintenance Manual──LG6210E Hydraulic Excavator 5 Remove No. 1 epicyclic gear (27) and coupling (9). Note! Remove 1 bracket (19) and remove the 2 and 1 star gear (20,27). WARNING! These parts are very heavy. Pay attention to the appropriate safety. -
Page 183
Maintenance Manual──LG6210E Hydraulic Excavator — Tools: Ring bolts (M10), plastic hammer Note! Mark the matching marks for the gear (12), pins (15) and bracket (11). Note! Do not mix gears, bearings, thrust washers and pin components. Note! Do not reuse the spring pin (16). -
Page 184
Maintenance Manual──LG6210E Hydraulic Excavator Note! When it is difficult to remove, lift of the parts vertically, and tap it with a plastic hammer. 10 Remove the seals (3) from the housing (1). Remove the seals (3) from motor housing (302 main shaft) on the removal of. -
Page 185
Maintenance Manual──LG6210E Hydraulic Excavator 1.Install the angular bearing (2) to the housing (1). — Tools: Plastic hammer, desktop presses. Note! Outer ring of angle of bearing should be completely aligned, full going to the bearing. Note! Press it with a hammer or press-fit. -
Page 186
Maintenance Manual──LG6210E Hydraulic Excavator Figure 36 Adjustment, shim 4 Install level pin (7) to the housing (1), calibrate the gear (8) correctly. — Tools: Plastic hammer Note! Coat the mating surface of ring gear (8)with Loctite # 5699 . Note! Temporary install four screws (30). -
Page 187
Maintenance Manual──LG6210E Hydraulic Excavator WARNING! These parts are very heavy. Pay attention to the appropriate safety notes. Note! Li pile technology: A solution using Loctite 6 No. 2 planetary gear transmission (10) is properly installed to the rack of the motor. -
Page 188
Maintenance Manual──LG6210E Hydraulic Excavator — Tools: plastic hammer Note! Align No. 1 bracket and hole of spring pin. Note! Piling technology: Note! Check whether the No. 1 planetary gears rotates smoothly. WARNING! These parts are very heavy. Pay attention to the appropriate safety notes. -
Page 189
Maintenance Manual──LG6210E Hydraulic Excavator 10 Insert a ring bolt into the oil level throttle and install the cover (28) to the ring gear (8). Install screws (31), screw (30) and tighten them to the specified torque. — Tools: Ring bolts (PT 1 / 2), L-shaped wrench 10 mm… -
Page 190
Maintenance Manual──LG6210E Hydraulic Excavator Track gearbox, troubleshooting Table 10 Troubleshooting of track gearbox Gearbox can’t Motor is overloading Reduce the load. rotate. Gearbox is damaged. Replace the gearbox. Mating surface Liquid washer is not Remove and reuse it. is leaking. -
Page 191
Maintenance Manual──LG6210E Hydraulic Excavator Abnormal Gear oil is not Refill the oil to the operating enough. specified level. temperature Bearing or gear is Replace the gearbox. damaged. Gear oil is mixed Replace the sealing with gear oil. ring of motor. -
Page 192
Maintenance Manual──LG6210E Hydraulic Excavator Rotary gear boxes, cross sections Fig.3 Rotary gear boxes, cross sections 1. No.2 planetary gear transmission 17 bearing 32 bearing 2. No.2 bracket 18 retaining ring 33 washers 3 No. 2 planetary gear 19 housing 34 washers 4 No. -
Page 193
Maintenance Manual──LG6210E Hydraulic Excavator Function 2—order planetary gear assembly converts speed / low output torque of the hydraulic motor into low speed / high torque, and then transfer to the inner gear of rotary ring through pinion gear to rotate upper structure. -
Page 194
Maintenance Manual──LG6210E Hydraulic Excavator Turn gearbox, lubricating Notes about lubrication • Before operating the rotary function, check the oil level. • Check whether the motor and gearbox assemblies leaks. • Check whether the mounting screws are tightened. • Check whether there is abnormal sound or vibration during rotation process. -
Page 195
Maintenance Manual──LG6210E Hydraulic Excavator Gear oil, replacing Note! Drain the gear oil when the oil can be decomposed into any impurities. • Open the cover (D) on the drain valve (C), and connect drain hose (E) to the drain valve (C), then drain the oil into a suitable container. -
Page 196
Maintenance Manual──LG6210E Hydraulic Excavator Table 11 standard replacement parts Item Part Name Status Standard values Allow the value epicyclic Erosion on the gear -Diameter Clearance: φ gear teeth. epicyclic 1mm (0.039 in) gear -Area ratio:＜5% No.1 planetary gear No.2 planetary… -
Page 197
Maintenance Manual──LG6210E Hydraulic Excavator General Tools Table 12 General Tools Explain Size Quantity Wrench 17 × 19 mm 24 × 27 mm Socket wrench General wrench 10 mm 14 mm Torque Wrench 3923 ~ 17652 Nm 11768 ~ 47072 Nm φ… -
Page 198
Maintenance Manual──LG6210E Hydraulic Excavator Special tools Table 13 special tools Explain Part Number Number Bearing assembly fixtures 8920-00280 Bearing assembly fixtures 8932-00600 Oil seal assembly fixtures 8920-00550 Oil seal assembly guide fixtures 8920-00570 seal 8920-00560 assembly guide fixtures… -
Page 199
Maintenance Manual──LG6210E Hydraulic Excavator Rotary gear box, replacement 1 Park the machine in the maintenance position C, refer to maintenance position. 2 • When the engine is running, the hydraulic pipelines are under high pressure. Stop the machine, drain the… -
Page 200
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the drain hose (2) of rotary motor. 7 Remove the feedback line hose (3)of rotary motor. 8 Remove the vice hose (4) of delay valve. 9 Remove the assembly screws (1) of rotary gear box, and remove the silica gel (2) from two rear holes. -
Page 201
Maintenance Manual──LG6210E Hydraulic Excavator 13 Transfer the drain hose (1) and pins (2) to the new rotary gear boxes. Fig.19 Transfer, oil drain hose and pins 1 oil drain hose 2 pin 14 Enhance the rotary units with the lifting device and install it on the machine. -
Page 202
Maintenance Manual──LG6210E Hydraulic Excavator 17 Install the vice delay hose (4) of valve. 18.Install drain hose (2 ) of rotary motor. 19.Install anti-cavitation hose (3). 20 Remove vacuum pump installed on the hydraulic tank. 21 Fill the gearbox oil from the oil filling pipe. -
Page 203
Maintenance Manual──LG6210E Hydraulic Excavator 5 Remove the screw (22). 6 Remove plate (23). Fig. 23 Removing, screws and plates 7 Remove No.1 epicyclic gear (37). Fig. 24 Removing, No.1 epicyclic gear 8 Remove the first planetary gear assembly (28) from the ring gear (20). -
Page 204
Maintenance Manual──LG6210E Hydraulic Excavator 9 Remove the ring gear (20) and connected pin (21). 10.Remove No.1 epicyclic gear (26) and thrust ring (25). Fig.27 Removing No.2 epicyclic gear 11 .Remove transmission device(1) of No.1 planetary gear from the shaft (10). -
Page 205
Maintenance Manual──LG6210E Hydraulic Excavator 16.Fix the reduction gear as shown in the picture. Press the shafts (10) from the boxes(19)out with press tool. Fig. 31 Removing, shaft 17 Remove the spherical bearing (16) and collar (11) from the shaft(10)with press tool. -
Page 206
Maintenance Manual──LG6210E Hydraulic Excavator 19 Push the spherical bearing (17) out of the tank (19) with the press tool. Note! Spherical bearing (17) can also be removed by work bench press tool. Fig. 34 Removing,, spherical Rotary gear box assembly Note •… -
Page 207
Maintenance Manual──LG6210E Hydraulic Excavator Assembly 1 Install the O-ring (13) to the collar (11), and then install it to the shaft (10). Note! Coat the O-ring (13) with grease (NLGI 2). Fig. 48 Installing, collar 2 Press the spherical bearing (16) down to the shaft (10) with press tool. -
Page 208
Maintenance Manual──LG6210E Hydraulic Excavator 3 Press the oil seal (14) into the cover (12) with press tool. Note! Coat the outer diameter of the oil seal with Loctite # 680. Be careful not to touch the oil seal lip chips. -
Page 209
Maintenance Manual──LG6210E Hydraulic Excavator 7.Fix the tank (19) as shown in the figure. 8 Press the spherical bearing (17) to the tank(19) with press tool. Note! Install the both internal and external bearing sleeve with press tool. Fig. 54 Installing, spherical bearings 9 Install spherical bearings (17), and install the retaining ring (18) on the shaft (10). -
Page 210
Maintenance Manual──LG6210E Hydraulic Excavator Note! Align the pin assembly (4) and spring pin hole of bracket(2). Install the thrust washers (8) attached with a small amount of grease to the gear (3). Install spring pin (9), with cutting edge towards the end of pin (5). -
Page 211
Maintenance Manual──LG6210E Hydraulic Excavator WARNING! The parts are heavy. When operating these components, should take appropriate safety precautions. Note! — Coat the mating surface of the tank (19) with Loctite 5699 silicone rubber. — Support the tank (19). Fig. 61 Installing, No. 2 planetary 13 Transmission device of No.1 planetary gear and… -
Page 212
Maintenance Manual──LG6210E Hydraulic Excavator 14 Install the plate (23) to the ring gear (20), and then install the screws (22). Fig. 64 Installing, the board A Plug hole Note! Align the mating marks on tank(19), the ring gear (20) and plate (23). -
Page 213
Maintenance Manual──LG6210E Hydraulic Excavator 16 Tighten the drain valve (43) to the pipe (44), and then tighten the pipe (44) to the tank (19). 17 Install the pipe (40) to the motor, and then insert the level gauge (39). Note! Make the oil drain throttle of the pipe toward side. -
Page 214
Maintenance Manual──LG6210E Hydraulic Excavator Housing is Cracks or pin hole Replace the housing. leaking. leaks. Cover is damaged. Replace the cover. Shaft is Replace sealing O-ring is is worn. leaking. gasket. Contacting surface Replace or repair the of seal is damaged. -
Page 215
Maintenance Manual──LG6210E Hydraulic Excavator 2 Hydrostatic drive (Hydraulic motor, including the operating system) 2.1 Hydraulic motor 1, travel motor Travel motor,instruction • Hydraulic motor: the hydraulic motor is the design based on the variable impact and axial piston, including the paring brake valve assembly and the parking brake. -
Page 216
Maintenance Manual──LG6210E Hydraulic Excavator Fig.47 Travel motor structure 1 High-speed 2 Low-speed Table 11 Throttle connecting Throttle sign Throttle size Throttle (A), (B) Oil supply(oil return) (P1) ~ (P4) PT1 / 4 Pressure checking (P5) PT 1 / 8 Oil supply of displacement… -
Page 217
Maintenance Manual──LG6210E Hydraulic Excavator Fig.48 Travel motor, cylinder and piston 2-shaft 3 swash plate 4 cylinder 5 piston 6 piston sets 7 fixed plate 8 thrust ball 9 valve plate 10 washers 11 roller 12 brake piston 13 brake springs… -
Page 218
Maintenance Manual──LG6210E Hydraulic Excavator Operating, the hydraulic motor Pressurized oil is sent from the hydraulic pump through the control valve into the throttle on the rear flange (201) and flows to the half part of cylinder body (4) through the valve (9). -
Page 219
Maintenance Manual──LG6210E Hydraulic Excavator Operating, brake valve Operations (Brake release) When pressurized oil is supplied to the throttle (A), it opens the check valve (227) and flows into inlet throttle (C) of the hydraulic motor. Meanwhile, the pressurized oil goes into the chamber (b) through the channel (a) and through a small hole of the balance spool (223). -
Page 220
Maintenance Manual──LG6210E Hydraulic Excavator When the piston reaches the end of stroke, the pressure of chamber(g and f) begins to rise and react on the valve piston (101). At this point, open pressure of release valve is higher than the normal release set pressure. This process is used to buffer the pressure spikes when the valve is open. -
Page 221
Maintenance Manual──LG6210E Hydraulic Excavator When the oil pressure gets to about 6 kgf/cm , it starts to push brake piston (12) into the rear flange (201) to overcome the force of brake spring (13). At the same time, the piston moves away from the friction plate (15) and the mating piece (16) to separate them, and release the braking force of the control cylinder (4). -
Page 222
Maintenance Manual──LG6210E Hydraulic Excavator High speed When the solenoid valve is connected (ph), servo-hydraulic oil will flow to the throttle (D). Hydraulic flow (40kgf/cm2) of the throttle (D) overcomes the spring (266) force to move the spool (263) down and overcomes hydraulic oil pressure the throttle (A, B) to open the throttle (C). -
Page 223
Maintenance Manual──LG6210E Hydraulic Excavator Travel motor, operation precautions Installing • Check that the mating surface is clean. • Check that the motor is positioned in the frame correctly • If the gear that will be installed to the frame is very tight, install the components into frame evenly with the mounting screws. -
Page 224
Maintenance Manual──LG6210E Hydraulic Excavator The following standard about components maintenance capability can be decided according to the measurement before disassembly. However, they are general standards, and when the parts presents excessive external damage or discoloration, the primary thing is to determine the extent of replacement based on the average residual life span of parts and components. -
Page 225
Maintenance Manual──LG6210E Hydraulic Excavator kgf · m pieces Plate is bent. kgf • m Bearing Pitting / lobes appear on the bearing sleeve or ball or roller. Manual rotation is not smooth. Piston of Sliding surface is damaged. release valve Well Surface of base is damaged. -
Page 226
Maintenance Manual──LG6210E Hydraulic Excavator Table16.General tool Explain Size Quantity General wrench 5 mm、10 mm、8 mm、14 mm 1/2″ drive，3/4″ drive Torque Wrench About 280 n·m About 850 n·m Socket wrench 32、41 mm L-shape Socket 5、6、8、10、14、19 mm wrench Hammer Calibrated 12# Plastic hammer… -
Page 227
Maintenance Manual──LG6210E Hydraulic Excavator Table17.Special tool Instruction Quantity Quantity Ⅰ Fixer( ) 4Elevator Serial number:8932 — 00160 Ⅱ Fixer( ) Serial number:8932 — 00210 Serial number:8932 — 00150 Ⅲ Fixer( ) Serial number: 8933 — 00320 Pressure relief valve of travel motor, replacing 1. -
Page 228
Maintenance Manual──LG6210E Hydraulic Excavator 4 Remove pressure relief valve (1)of track motor. 5 Install the new pressure relief valve 6 Check pressure relief valve (1)of track motor, if necessary, adjust it. 7 Install the motor cover. Fig.60 Removing, valve Travel motor, disasembly Note •… -
Page 229
Maintenance Manual──LG6210E Hydraulic Excavator 3 Remove the screw (243). Fig.63 Screws, removing 4 Remove the flange (201) from the main shaft (302). Note! Be careful not to remove the shaft (2). Fig. 64 Rear flange, removing 5 Gearbox / hydraulic motor shaft and oil seal. -
Page 230
Maintenance Manual──LG6210E Hydraulic Excavator Brake valve 6 Removal of balanced spool. • Remove the plug (224) from rear flange (201). • Remove the O-ring (236) from the plug (224). Note! Do not reuse O-ring (236) after removal. • Remove the spring (228), locking device(225) and the balance spool (223)from rear flange (201). -
Page 231
Maintenance Manual──LG6210E Hydraulic Excavator 8 Double-speed valve, removing • Remove the plug (257) from rear flange (201). • Remove the spring (266) and spool (263)from rear flange (201). •Remove the O-ring (295) from the plug (257).. Fig. 70 Plug, removing Note! Do not reuse O-ring (295)after removal. -
Page 232
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 75 Ball, removing 10. Release valve, removing • Remove the plug (104) and remove the well (102). Note! Do not replace two pressure relief valve with each other. •Remove the O-ring (110) from the plug (104). -
Page 233
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 80 Release valve piston, removing Removing the hydraulic motor 11. Remove parking brake. WARNING! Sudden injection of compressed may result in pop-up of air piston. To ensure your safety, install a protective cover on the piston cover. -
Page 234
Maintenance Manual──LG6210E Hydraulic Excavator Note! Carefully remove the cylinder, do not let the piston and the needle (51) fall into the main shaft. •Grasp the cylinder (4) with two hands to remove it from the main shaft302). •Remove swash plate (3), ball (67) from the main shaft (302). -
Page 235
Maintenance Manual──LG6210E Hydraulic Excavator 16 Remove steel ball (67) and parallel pin (71)from the main shaft (302). WARNING! Sudden injection of compressed may result in pop-up of air piston. To ensure your safety, install a protective cover on the piston cover. -
Page 236
Maintenance Manual──LG6210E Hydraulic Excavator Note! Use a rubber pad to protect the sliding surface of the cylinder body. Note! Only it is needed to replace the spring (14). WARNING! Do not suddenly release the press tool. Spring may pop up and cause damage. -
Page 237
Maintenance Manual──LG6210E Hydraulic Excavator Brake, assembly 1.Check valve • Install the O-ring (237) to the plug (226). • Install the spring (230) and check valve (227) to the plug (226), then coat the springs and valve assembly with Fig. 93 Plug, installing grease. -
Page 238
Maintenance Manual──LG6210E Hydraulic Excavator • Tighten the plug (257) into the rear flange (201) to the required torque Torque (10±2 kgf·m). Fig. 97 Plug, installing 4 Impact release valve components. • Embed the ball (285) into the rear flange (201). -
Page 239
Maintenance Manual──LG6210E Hydraulic Excavator Note! Piston seals (120) includes O-ring and Teflon ring. Note! Coat the two side of the piston seal (120) withthe grease. Install O-ring, then Teflon ring. • Install the piston (101), spring (106), the spring positioning piece (103) and gasket (105) with a plug (104), then tighten to the required torque (10±2 kgf·m) -
Page 240
Maintenance Manual──LG6210E Hydraulic Excavator Note! Be careful, when shrunk to install ball bearing (49), do not heat the main shaft (2). 8 Assemble piston assembly (61), (62). •Coat the spring (93) with grease and install it on the piston assembly. -
Page 241
Maintenance Manual──LG6210E Hydraulic Excavator 11 Motor components. • Install needle (51) to the cylinder (4), and then put the collar (11) and thrust ball (8) into the cylinder. •Insert the piston assembly (5), (6) into the bearing plate (7). •Coat piston with hydraulic oil, and then install it into the cylinder body (4). -
Page 242
Maintenance Manual──LG6210E Hydraulic Excavator 13 Install the friction plate and the engagement piece (16) to the cylinder body (4) in sequence (15). Note! Immerse the friction plate (15) in hydraulic oil. Fig112 Brake, installing 14 Install the O-ring (35), (39) and assemble the piston (12) to the main shaft (2). -
Page 243
Maintenance Manual──LG6210E Hydraulic Excavator 17 Fill with hydraulic oil. • Oil Capacity: 1.7 liters Fig.116 Hydraulic oil, using 18 Insert O-ring (329), (327) and (342) into the main shaft (302), and install the rear flange (201). Note! Do not coat O-ring (329), or mating surface with any grease. -
Page 244
Maintenance Manual──LG6210E Hydraulic Excavator 21 Install the relief valve to the rear flange (201). Tighten to the required torque. — Tightening torque: 25±5 kgf·m Fig119 Relief valve, installing Troubleshooting of track motor Table 20. Road motor does not rotate Main pressure relief… -
Page 245
Maintenance Manual──LG6210E Hydraulic Excavator Table21.Oil leaks Mating surface is Remove the scars Mating surface damaged. with sandpaper. Tighten it to Screw is loose. specified torque. Plug is loose. Tighten it to Tank leaks. specified torque. Cracking or pin hole Replace the gearbox leaks. -
Page 246
Maintenance Manual──LG6210E Hydraulic Excavator Table22.Travel motor can’t work on the slope. Volume efficiency is Replace hydraulic motor Motor rotates.. low. assembly. Inner part of brake Replace rear flange valve leaks. assembly. Parking brake Spring is damaged. Replace all the springs. -
Page 247
Maintenance Manual──LG6210E Hydraulic Excavator Table24.Speed doesn’t increase. Check P1/P2 pump Output of Flow leading to flow.Check the flow left/right motor is pump is low. through central different.. channel. Displacement of left/right motor is Replace hydraulic different. motor assembly. Table25.Abnormal sound… -
Page 248
Maintenance Manual──LG6210E Hydraulic Excavator 2.2 Hydraulic motor 2, rotary motor Rotary motor instruction Rotation group is comprised by cylinder (III) and 9 piston assemblies(II) located in the cylinder. Two ends of cylinder (III) is supported by bearing (443) and (444). Piston… -
Page 249
Maintenance Manual──LG6210E Hydraulic Excavator Rotary motor, structure Fig88 Rotary motor, structure Table 27.Direction of rotation Import Export X-axis view Clockwise Counterclockwise Table28.Throttle dimension and torque,Nm（lbf ft） Throttle Sign Screw dimension and depth Torqu 1 5/16-12 UN-2B-19 Main pump 1 5/16-12 UN-2B-19 Anti-cavitation 9/16-18 UNF-2B-12.7… -
Page 250
Maintenance Manual──LG6210E Hydraulic Excavator Fig.89 Rotary motor,cross sections 031 delay valve 121 piston 301 housing 401 screw 706 O-ring 031-1 plug 122 track plate 303valve housing437retaining ring 707 O-ring 033 screws 123 pushing plate305cover 443 roller bearing712 brake spring 051pressure relief valve… -
Page 251
Maintenance Manual──LG6210E Hydraulic Excavator Rotary motor working principle Hydraulic motor The high pressure oil from pump to be sent via the main control valve, into the throttle(A) of the valve (1) , gets to the half position of the pistons in the cylinder (4), and push the piston attached to the cylinder bore of the swash plate, which formed the axial force F. -
Page 252
Maintenance Manual──LG6210E Hydraulic Excavator Anti-cavitation valve Because there is no back pressure valve to prevent speeding, the motor will rotate faster than oil supply due to inertia flow. In order to prevent the cavitation of motor, add enough oil flow from the anti-cavitation valve. -
Page 253
Maintenance Manual──LG6210E Hydraulic Excavator Pressure of valve chamber g acts on the area (A3 — A4)of piston (302). If the fluid pressure is greater than the spring (321) force, the piston starts to move to the left. At this point, valve chambers h acts as a damping valve… -
Page 254
Maintenance Manual──LG6210E Hydraulic Excavator Fig.101 Operating, pressure reducing valve Rebound damping valve Rebound damping valve makes the acceleration and delay of superstructure rapid / responsive, smooth / gentle, no bumps or shocks, which greatly reduces the mechanical stress on rotating machinery, and extends the life span of components. -
Page 255
Maintenance Manual──LG6210E Hydraulic Excavator Fig.102 Operating, rebound damping valve R rebound damping valve T time P pressure Figure (3) shows the valve condition when inertia load moves and the braking pressure decreases [Y point in Figure (4)]. When the pressure (P) is less than the force… -
Page 256
Maintenance Manual──LG6210E Hydraulic Excavator chamber (P) flows through the narrow channel (g), resulting in a damping function. The delay makes the base (t) open and connects a channel from throttle (A) to throttle (B). The path is (l → t → r → k), which can balance pressure of throttle (A) and (B) [Z-point in Figure (4)].The… -
Page 257
Maintenance Manual──LG6210E Hydraulic Excavator Maintenance standards of rotary motor Lubrication and exhaust of rotary motor • After repairing or replacing the rotary motor components, it is necessary to pre-lubricate internal components to prevent scratches / scratching on the bearings and sliding parts. -
Page 258
Maintenance Manual──LG6210E Hydraulic Excavator Replace the oil seals and O-ring, although they did not seem damaged. Replacement standards of parts Replace all damaged parts or those not within the range of values. Table51 Items Standard Recommended Remedy size replacement value Gap between piston and cylinder 0.027… -
Page 259
Maintenance Manual──LG6210E Hydraulic Excavator Standard about repairing sliding surface If the surface roughness of sliding surface is exceeding the following standard, please repair or replace the part. Table52.Sliding surface Part Standard surface roughness Standard surface roughness to be repaired 3 — Z（Ra=0.8）… -
Page 260
Maintenance Manual──LG6210E Hydraulic Excavator General Tools Table 54 General Tools Tool Dimension Component and remarks General tool 14mm RO plug（496） 17mm Screw(401) Wrench, socket wrench 41mm Pressure reducing valve(051) Hammer Plastic and steel hammer Bearing(443， 444） ， pin （451） Steel linkage 10 ×… -
Page 261
Maintenance Manual──LG6210E Hydraulic Excavator Fig.108 Removing, hose 1. Anti-cavitation hose 4 Remove the drain hose (2) of rotary motor. 2 Drain hose 5 Remove the feedback line hose (3) of rotary motor. 3 Feedback line hose 6 Remove the vice hose (4) of delay valve. -
Page 262
Maintenance Manual──LG6210E Hydraulic Excavator 17 Before the operation, exhaust the air in the hydraulic circuit of the rotary motor. 18 After the maintenance work is completed, start the engine, check for leakage. Rotary motor has been removed, replacing the seals… -
Page 263
Maintenance Manual──LG6210E Hydraulic Excavator 5 Install the sealing cover (1) on the rotary motor housing. Fig114 Installing,sealing cover 1 cover 6 Install the retaining ring (1,2). Fig.115 Installing, positioning ring 1 Retaining ring Rotary motor, replacing the brake piston seals 2 Retaining ring 1. -
Page 264
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the two valves from the valve body (1). 7 Remove the mounting screws (2). 8 Enhance the rotary motor cover (3). Fig.117 Remove the motor cover 1 Valve 2 Screws 3 Rotary motor cover 9 Remove the spring from the brake piston (1), remove the cylinder on the plate (2). -
Page 265
Maintenance Manual──LG6210E Hydraulic Excavator 11 Replace O-ring(1,2) inside the housing. Fig.120 Replacing, O-ring 1 O-ring 2 O-ring 12 Use a special tool, install the brake piston outside housings. — Tool/Part Number (1): 14559282 13 Install the spring on brake piston. -
Page 266
Maintenance Manual──LG6210E Hydraulic Excavator Rotary motor, disassembly 1 Before disassembly, make sure the motor is clean and without dust and debris. Note! All the throttles have to be plugged to prevent external dust from entering the throttles. 2 Remove the drain plug and drain the oil from the housing (301). -
Page 267
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the screw (401), remove the valve body (303) on the housing (301), then remove the valve pieces (131). Note! When screw is loose, the valve box will be (712) slightly lifted by spring brake. -
Page 268
Maintenance Manual──LG6210E Hydraulic Excavator Remove the 9 pistons (121) and plate (123) as a whole from the cylinder. Separate the piston assembly from the board. Note! Be careful not to damage locator plate (122) or the sliding surface on the track. -
Page 269
Maintenance Manual──LG6210E Hydraulic Excavator Note! If the bearings have been removed, do re-install with a new bearing. Rotating motor assembly Cleanliness is the main way to ensure a satisfactory service life of the motor, and it is same as the new units and repaired units. -
Page 270
Maintenance Manual──LG6210E Hydraulic Excavator Note! Do not exceed 110 ° C. 4．Coat the seals (491) with grease and install seals on the housing(301). Note! Note the direction of oil seal. Seal lip must be facing the housing (301). Note! Be careful not to damage the oil seal lip. -
Page 271
Maintenance Manual──LG6210E Hydraulic Excavator 8. Put the thrust plate (123) on the spring plate (114), install the piston assembly (121,122) on the thrust plate (123). 9. Installed the piston assembly into the cylinder (111). Install the rotation group in the housing (301). -
Page 272
Maintenance Manual──LG6210E Hydraulic Excavator 11. Install the O-ring (707) and O-ring (706) in the housing (301). Note! Before installation, coat the O-ring with grease. Fig.163.Installing, O-ring 12 Use a plastic hammer to hit the pistons, install the brake piston (702) in the correct location of the housing (301). -
Page 273
Maintenance Manual──LG6210E Hydraulic Excavator Fig.167.Installing, valve plate and O-ring 16 Install the valve box (303) and four screws (401) on the housing (301). Fig.168.Installing,valve housing 17 Install the spool (351) and spring (355) in the valve box (303), and install the the plug (469) of O-ring (488) in the valve box (303). -
Page 274
Maintenance Manual──LG6210E Hydraulic Excavator Rotary motor troubleshooting The measures should be taken that you find abnormalities in the operation of hydraulic motor ,as given below: Determine the possible causes Before continuing work, try to determine the nature of the fault, check all operating systems andd discuss the fault with operator. -
Page 275
Maintenance Manual──LG6210E Hydraulic Excavator Operate the rotary control lever to make the rotary motor with full load. Discharge of the oil flow in the normal state is lower than about 25 l / min(Pressure 270 kgf/cm2: Temperature 100° C). Motor can’t rotate Table66. -
Page 276
Maintenance Manual──LG6210E Hydraulic Excavator Rotation speed is not up to the set value. Table68. Troubleshooting Fault Reason Remedial measures Rotation speed is not 1. Lack of oil supply. 1. Check the oil flow of oil pump up to the set value. -
Page 277
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic is leak from the seals. Table71. Troubleshooting Fault Reason Remedial measures Hydraulic is leak from 1. Lips catch dirt particles, with 1. Replace the hydraulic oil the seals. damage. seals. Shaft is with scratches or 2. -
Page 278
Maintenance Manual──LG6210E Hydraulic Excavator 2.3 Hydraulic pump includes couplers, running including the operation system. Flexible coupling Flexible couplings consist of gear rack, insert and single part, and transfer engine power to the hydraulic pumpm and buffer rotational vibration. Engine torque is transferred to the connection ring connecting to the engine flywheel→… -
Page 279
Maintenance Manual──LG6210E Hydraulic Excavator Flexible coupling, removing Note! Release any residual pressure in the system, the method is to turn off the engine, return the key to the ON position, and remove RCV. Release residual pressure from the hydraulic tank, the method is to use exhaust devices. -
Page 280
Maintenance Manual──LG6210E Hydraulic Excavator 2.4.Rotary joints; pipeline Rotating joints description Rotating joints contain shaft (1), axis (2), sealing gasket (5), cover (3), plug (13), spacer (8) and screw (9). Shaft contains groove for oil flow. Axis has channel to supply oil to the shaft. Shaft seals and shaft to prevent oil leakage. -
Page 281
Maintenance Manual──LG6210E Hydraulic Excavator Table 75. Trottle-valve connection Rotary joints,assembly Fig.196 Rotary joints, assembly Table 76. Tightening torque,unit: kgf·m Specification Torque Specification Torque Specification Torque Clearance 15mm Axis L Upper frame Blocking device Screw J Screw 26.7 ±2.7 24.7±2.5 G Screw 1.0 ±0.1 K Bottom frame… -
Page 282
Maintenance Manual──LG6210E Hydraulic Excavator Rotary joints, tools Common tools Tool Notes Hammer 1. Steel hammer 2. Wooden or splasic hammer Rubber pad More than 500mm Wrench 1. Universal wrench 2. Double-end wrench 3. Single-end wrench Torque wrench 100 kgf·m A.Grind –“Finger” tip,make its shape as screwdriver. -
Page 283
Maintenance Manual──LG6210E Hydraulic Excavator Special tools Dry bearing assembler Table 78 .Special tools(Unit:mm) ΦA ΦB ΦC ΦD Components 100 30Thru 25 33 45 103 8920-01520 Fig.197 Dimension, special tools Plug dimension and tightening torque Table 79.Tightening torque,unit: kgf·m… -
Page 284
Maintenance Manual──LG6210E Hydraulic Excavator Rotary joint soft hose (valve — rotary joints), replacing 1. Park the machine in the maintenance position C, refer to P45, maintenance position. 2. When engine is running, hydraulic lines are under high pressure. Stop the machine and drain the residual pressure within the hydraulic lines.The method is that:… -
Page 285
Maintenance Manual──LG6210E Hydraulic Excavator Rotary joint hose (Rotary joints — motor), replacing 1. Park the machine in the maintenance position C, refer to P45, maintenance position. 2. When engine is running, hydraulic lines are under high pressure. Stop the machine and drain the residual pressure within the hydraulic lines.The… -
Page 286
Maintenance Manual──LG6210E Hydraulic Excavator Rotary joints, dismantling Warning! careful about heavy plate, take appropriate safety precautions. Note!Cleaning the outside of rotary joints with hot water or steam. Note! Plug the throttle valve, clean the central channel. Note! Mark each hose assembly to identify its position on the rotary joints. -
Page 287
Maintenance Manual──LG6210E Hydraulic Excavator 11. Pull out the O-ring (7), remove the screw (9), washers (10) and spacer(8). 12. Remove shaft (2) and axis (1). Fig.206 Remove the spacer. Fig.207 Shaft and axis, removing 13.Remove the O-ring (6) from the shaft (1). -
Page 288
Maintenance Manual──LG6210E Hydraulic Excavator 15 Remove seal gasket (5) assembled in the axis with a sharp pin. Note! Be careful not to damage the seal groove (1) of shaft. 16 Check each component, and repair or replace defective or worn parts. -
Page 289
Maintenance Manual──LG6210E Hydraulic Excavator 4.Before installing the gasket (5) and O-ring (6), coat seal groove with hydraulic oil (2 or 3 times). Note! Be careful not to twist or damage the gasket. Note! Check the assembly conditions of seal. Note! Ensure that the gasket is not damaged or reverse, and then put the seal inside the assembly by hand as close as possible to the cylinder conditions. -
Page 290
Maintenance Manual──LG6210E Hydraulic Excavator 10．Tighten the spacer (8) on the shaft (2) end and tighten the screws (9) to the specified torque with lock washers (10). Note!Spacer should conact with the shaft fully. If not, check the bushing is fully installed. -
Page 291
Maintenance Manual──LG6210E Hydraulic Excavator Note! When assembling pipe (4) to the central channel (5), pay attention that O-ring (1) and washers (2) should be installed close to the nut (3). Fig.221 Elbow, assembly Rotary joint,checking and troubleshooting Table83. Checking method… -
Page 292
Maintenance Manual──LG6210E Hydraulic Excavator Table 84.Wear limit Component Normality Allowance Replacement When measured Axis There is no visible wear depth fingernail (When this is not wear sealing contact surface is possible, you can visually check), if the wear of sealing contact surface within more than 0.1mm. -
Page 293
Maintenance Manual──LG6210E Hydraulic Excavator Inspection after assembly After assembly, check for leakage and pressure tests, as shown. High-pressure throttle valve Install the change-over valve and pressure gauge to the shaft throttle valve and axis throttle valve, and then observe the pressure gauge installed in the axis (high pressure), adjust high-pressure relief valve (7), gradually increase the pressure at the same time. -
Page 294
Maintenance Manual──LG6210E Hydraulic Excavator Troubleshooting Table86. Troubleshooting Faults Reasons Remedies Internal / external leak, Pressure between the pump Check the circuit between the pump the machine can not and valve decreases, and and valves, repair or replace them. move in a straight line alve circuit has problem. -
Page 295
Maintenance Manual──LG6210E Hydraulic Excavator 3 Upper rotary system Rotary Gear Description Rotary seal ring is a single-row ball bearings, support the superstructure on the chassis, and makes the upper structure rotate stable. Sleeve of outside bearing is fixed on the upper structure with screws, while sleeve of inner bearing sleeve (with inner gear) is mounted on the chassis with screws. -
Page 296
Maintenance Manual──LG6210E Hydraulic Excavator Ring gear lubricating pipe, replacing 1.Park the machine in maintenance position B, refer to maintenance position. 2 Remove the screws (2), and release the nuts (1,3). Remove the grease pipe of ring gear. Fig.224Replacing, grease pipe of ring gear 3 Remove the reverse order to install a new ring gear grease tube. -
Page 297
Maintenance Manual──LG6210E Hydraulic Excavator Ⅶ Frame and track equipment 1 Frame 1.1 Overview Upper structure, dissembbly Warning! Upper structure is heavy. Before removing or installing the all around the crane. Note! Upper structure weight: 4~7 tons, not including balance weight and mining devices. -
Page 298
Maintenance Manual──LG6210E Hydraulic Excavator Note! Lower the upper structure to connect the rotary gear and rotary gear rim together. Note! Tightening torque refers to the tightening torque table. Note! Tight across the corresponding screw. 4. Connect the hose, fastenting screws and the central channel sealed cover when removing. -
Page 299
Maintenance Manual──LG6210E Hydraulic Excavator 4. Remove 2 covers and one bolt from the balancing weight. 5.Aa shown in the picture,after fixing the hug bolt(C) Connect the cable with sufficient strength in the lifting position (A). 6.. Remove the four bolts (B). -
Page 300
Maintenance Manual──LG6210E Hydraulic Excavator 1.3 Frame, the lower part of body Underframe / chassis, indication Chassis consists of the guide wheel, springs, upperframe and supporting wheels, sprockets teech, track pin, underframe and unit protection devices. Fig.9 Structure, chassis 1 Underframe 4.Track pin 7 Supporting wheels… -
Page 301
Maintenance Manual──LG6210E Hydraulic Excavator Type «B» and «C» is the wide track plate, so their use is limited. Therefore, before use, check the use restrictions and conditions of use carefully before choosing an appropriate width of track plate. If necessary, construct the user. -
Page 302
Maintenance Manual──LG6210E Hydraulic Excavator 2.1.Front idle control, including the front fork Guiding wheel, specification Fig.10 structure, guide wheel 1 Guiding wheel 6 O-ring 2 Shaft 7 Pin 3 Support 8 Plug 4 Bushing 9 O-ring (shaft) 5 Seal ring… -
Page 303
Maintenance Manual──LG6210E Hydraulic Excavator Guiding wheel, measuring Fig11.Measure,the wear of guiding wheel… -
Page 304
Maintenance Manual──LG6210E Hydraulic Excavator Table3 Wear limitation,unit:mm No. Exam items Standard dimension Repair limitation Remedial measures Outside diameter Fixing or of flange replacing. Outside diameter of thread 2-1 Thread depth Flange width Thread total width 170 Thread width 43.5 Clearence… -
Page 305
Maintenance Manual──LG6210E Hydraulic Excavator 4. Measure right and left by turns.. If necessary, repair or replace them. Fig13 Measure，flange wear Guiding wheel,dissembly or assembly tools Table.4 Tools Symbol Tools Note Press tool Gease gun Torque wrench 60 kgf·m Pin fixture… -
Page 306
Maintenance Manual──LG6210E Hydraulic Excavator 3. Put the pin fixture on the pin (7), and hit the fixture with a hammer to get the pin out. Fig.15Pin, removing Fig14 Spring,dissembly Fig15 Pin,dissembly 4. Put the guide wheels (1) on the guide wheel support block (f).Put the shaft dissembly fixture (G) on the axis… -
Page 307
Maintenance Manual──LG6210E Hydraulic Excavator Guide wheel assembly Note! Assemble according to the reverse order of disassembly. 1. Put sleeve (4) o8n the guide wheel (1); and use the fixture (e)and (h), install with press tools. Fig.19 Bushing, assembly Fig19 Sleeve, assembly 2. -
Page 308
Maintenance Manual──LG6210E Hydraulic Excavator 11. Confirm there is no oil leakage around the gasket (5,6) and plug (8). 12. Assemble guide wheel components and spring plate of track. After assembly, make sure that guide wheel can rotate despite of the resistance. (More than 10 times). -
Page 309
Maintenance Manual──LG6210E Hydraulic Excavator 5. Support it on a platform. Disassemble the bolts connecting guide wheel and the spring tension of track.Replace guide wheel unit, and install the entire assembly. — Tightening torque of screw connection: 265 ± 29 Nm Note! When installing the connection screws, please coat the screw thread with Loctite liquid # 277. -
Page 310
Maintenance Manual──LG6210E Hydraulic Excavator Measure the profile of sprocket tooth 1. Clean the sprocket teeth. 2. Align P1, P2, P3 of sprocket tooth wear measurements (1), and the grinding line of sprocket teeth (3). — — Part number of sprocket tooth wear measuremeter:14516700 3. -
Page 311
Maintenance Manual──LG6210E Hydraulic Excavator 3. . Remove screws (5) of rotating sprocket (4), carefully remove the sprocket (4). 4. Install a new sprocket, tighten the screws in several steps. — Tightening torque of connection screw: 265 ± 29 Nm Note! When installing the connection screws, please coat the screw thread with Loctite liquid # 277. -
Page 312
Maintenance Manual──LG6210E Hydraulic Excavator Note! If the piston in track adjusting cylinder can not move, replace the valve assembly, and repair or replace the cylinder. 5. According to soil conditions, adjust the tension of workplace track. Refer to the table below. -
Page 313
Maintenance Manual──LG6210E Hydraulic Excavator Table7. Wear limitation,unit:mm Exam items Standard dimension Repair limitation Remedial measures Connection 190.3 194.8 Rotate or clearance replace Outside bushing or diameter of bushsing Track plate Welding or height replace Connection Replace height Clearence Standard Allowed deviation… -
Page 314
Maintenance Manual──LG6210E Hydraulic Excavator Table8. Wear limitation,unit:mm Wear limitation Wear limitation 124.2 ~ 124.6 62 ± 0.1 φ20.2 ~ 20.4 160.2 ~ 160.6 Track chain，wear measurement Measure the wear of track connection pitch 1. Put pin (3) between the sprocket teeth and the track frame, and then slowly start the machine backwards to tighten the track connection. -
Page 315
Maintenance Manual──LG6210E Hydraulic Excavator Measure the left and right by turns. — Tools: Vernier caliper 3. If the measured value exceeds the wear limitation, repair or replace bushing. Fig.38 Outside diameter of bushing, wear measurement 1. Pin 4.Vernier caliper 2. Bushing 5.Main connection… -
Page 316
Maintenance Manual──LG6210E Hydraulic Excavator Fig.39 Connection height, wear measurement 1.Flooer plate 2 Connection 3 Vernier caliper4 Connection height Measure the wear of the height track plate 1. Clean track plate. 2. Use the depth gauge (3) to measure height (4)of track plates (2). -
Page 317
Maintenance Manual──LG6210E Hydraulic Excavator Track chain, removing Tool 1. Each track is installed by a main pin. Move the machine so that the main pin is in the position as is shown by the arrow. Fig.42 Position, main pin 2 Loosen regulating valve of the track tension, and discharge the grease from cylinder to relax track tension. -
Page 318
Maintenance Manual──LG6210E Hydraulic Excavator 4. Remove the main pin (2)with the hydraulic press tool (1). (Remove the track plates around the main pin then remove the main pin.) Fig.44 Removing, main pin 5 Repeat the above steps to remove the other side of the track. -
Page 319
Maintenance Manual──LG6210E Hydraulic Excavator Main pin ,assembly Fig.48 Main pin and spacer,assembly Fig.48 Main shaft and spacer, assembly 3 Install spacer (10) to the hole (15)of the main connection (3,4). Note the direction of the interval. 4.Connect the main connection (3,4) and ordinary connection (1,2).Align the pin hole (16) of the main… -
Page 320
Maintenance Manual──LG6210E Hydraulic Excavator Track chain assembly, removing Tool 14290046 Track pin press tool Warning! Work includes heavy parts, if you do not concentrate, it can cause serious injury. 1．Put the machine in service position F, where there is enough space to roll out the track. Refer to P45,… -
Page 321
Maintenance Manual──LG6210E Hydraulic Excavator 5 Lift the machine, slowly run the track, until the main pin goes through the guide wheel, and then place a wooden block under the track. Note! Block: 110 x 110 mm Fig.55 Put a wooden block 6.Remove the main pin with special tool. -
Page 322
Maintenance Manual──LG6210E Hydraulic Excavator Note! Take care of the installation direction of track plates and chain. If they are installed reversely, it is very easy to wear track bearings. A. Traveling motor B. Front guide wheel side 1. Put the machine in service position F, where there is enough space to roll out the track. -
Page 323
Maintenance Manual──LG6210E Hydraulic Excavator 8. To increase tension, fill grease from the grease port on the tension cylinder. 9. Make the tension force uniformm.Method is to run the track forward or backward. 10. Measure the tension of track.Measure the maximum sagging. -
Page 324
Maintenance Manual──LG6210E Hydraulic Excavator Supporting sprocket; sliding rail Description of the top roller Fig.67 Structure, supporting sprocket 1.Roller shell 9 Locking plate 2.Cramshaft 10.O-ring 3.Cover 11Plug 4.Bushing 12Screw 5.Bushing 13Screw 6.Metal plate 14 Bushing ring 7Sealing 15 Spring washer 8O-ring Supporting sprocket;… -
Page 325
Maintenance Manual──LG6210E Hydraulic Excavator Table10. Wear limitation,unit:mm Exam items Standard dimension Repair limitation Remedial measures Outside diameter Welding of flange or replace Outside diameter of thread Flange width Clearence Standard Allowed deviation Clearence Replace between shaft dimension bushing Crankshaft Hole… -
Page 326
Maintenance Manual──LG6210E Hydraulic Excavator Measure the wear of flange width of supporting sprocket. 1. Clean the supporting sprocket. 2. Measure the wear of flange width of (1)of supporting sprocket thread with caliper (2). 3. Measure both left and right side by turns. -
Page 327
Maintenance Manual──LG6210E Hydraulic Excavator Top roller, dismantling 1. Remove the plug (11), and discharge oil. 2. Remove the screw(13), and spring washers (15). 3. Remove cover (3) and pull out the O-ring (10). When assembling,replace a new O-ring. 4. Straighten locking plates(9), and remove mounting Fig.72 Top roller,removing… -
Page 328
Maintenance Manual──LG6210E Hydraulic Excavator Assemble shaft assembly and collar into the vise vertically. Install the O-ring (8) and gasket (7) to the seal groove of the shaft and collar assembly (2,14). Install the O-ring (8) and gasket (7) to the seal groove of the roller housing (1). -
Page 329
Maintenance Manual──LG6210E Hydraulic Excavator Top roller, replacing one Warning! Work includes heavy parts, if you do not concentrate, it can cause serious injury. 1．Put the machine in service position F, where there is enough space to roll out the track. Refer to P45,… -
Page 330
Maintenance Manual──LG6210E Hydraulic Excavator 6.To increase tension, fill grease from the grease port on the tension cylinder. 7.Make the tension force uniformm.Method is to run the track forward or backward. 8.Measure the tension of track.Measure the maximum sagging. Table12. Adjust the tension of workplace track,unit:mm… -
Page 331
Maintenance Manual──LG6210E Hydraulic Excavator Bearing wheel,wear limitation Fig.84 Dimension, bearing wheel Table13. Wear limitation,unit:mm Exam items Standard dimension Repair limitation Remedial measures Outside Welding diameter of flange replace Outside diameter of thread Flange width 20.5 13.5 Clearence Standard Allowed deviation… -
Page 332
Maintenance Manual──LG6210E Hydraulic Excavator Measure the wear of outside diameter of roller thread. 1. Clean the bottom roller. 2. Measure wear outside diameter (2)of supporting sprocket thread with outside diameter caliper (1). 3. Read the value of the vernier caliper. -
Page 333
Maintenance Manual──LG6210E Hydraulic Excavator 3 Remove the screws and pull the bottom roller. Fig.88 Remove the screws Bearing wheel, installing 1. Find the front oil plug of the machine. 2. Coat the thread of bottom roller mounting screw with # 277 Loctite. -
Page 334
Maintenance Manual──LG6210E Hydraulic Excavator Bearing wheel, dissembly and assembly tools Table.14 Tools,unit:mm Symbol Tools Note Hammer Press tool Pin fixture Bottom roller supporting fixture Sleeve disassembler fixture Shaft pressing out fixture Sleeve disassembler fixture Rough grease 3 ~ 10 kgf·m… -
Page 335
Maintenance Manual──LG6210E Hydraulic Excavator 3 Put the bearing wheel shell (4) on support fixture (d),and put the shaft squeeze fixture (f) on the axis (6), and push the shaft with press tool(b). Fig.92 Remove the shaft 4 Remove seals (2) and O-ring (3)from the collar (1). -
Page 336
Maintenance Manual──LG6210E Hydraulic Excavator 7. Remove O-ring (7)from the shaft (6). 8 Confirm that there is no damage or rust on the sealing surface of the ring (2). 9 Confirm that the wear of the roller is in the allowable range. -
Page 337
Maintenance Manual──LG6210E Hydraulic Excavator seal ring (2) contacts with each other. Then, coat contact surface of the seal ring with a thin layer of engine oil. Press-fit collars (1) raidically. Fig.101 Assemble shaft ring Fig.101 Assembling, collar 9 Install collar (1) and shaft (6) while maintaining the wheel level. -
Page 338
Maintenance Manual──LG6210E Hydraulic Excavator Track plate, replacing one Warning! Work includes heavy parts, if you do not concentrate, it can cause serious injury. 1．Put the machine in service position F, where there is enough space to roll out the track. Refer to P45,… -
Page 339
Maintenance Manual──LG6210E Hydraulic Excavator Table17. Adjust the tension of workplace track,unit:mm Item Distance(A) Common soil 320~340 Ground with stones 300~320 Soft ground(Swamp,soil) 340~360t 2.7 Spring kit; tensioning device Spring group description Fig.107 Structure,spring group 1. Cylinder body 7 Washer 13Spring washer 2. -
Page 340
Maintenance Manual──LG6210E Hydraulic Excavator Spring group, dismantling Warning! Spring group bears a great force. Take particular care when dismantling. 1. Remove the screw (11), plate (10) and grease valve (4) from the piston (3) in order. Remove piston (3), gasket (9), bearing ring (8) and gasket (7) from the cylinder (1) in order. -
Page 341
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the locking screw (16) and rod (17). Fig.120 Remove screw and linkage 7.Confirm the inner part of cylinder and external part of piston without any damage or rust. 8. Replace the gaskets and seal washers. -
Page 342
Maintenance Manual──LG6210E Hydraulic Excavator Fig.122 Install screw and lock plates A.Screw bar B.Nut. C Metal D.Press tool 3. Install gasket (7), back-up rings (8) and seal gasket (9) to the cylinder (1). 4. Fill the cylinder body with grease (1) and promote the piston (3). -
Page 343
Maintenance Manual──LG6210E Hydraulic Excavator 2. Push the guide wheel assembly out of track frame with a crowbar. 3. Assemble hug bolts to a tension spring assembly of the track. Fig125 Ring bolts, assembly Fig.125 Install ring 4. Dissemble guide wheel and track tension spring assembly with lifting equipments. -
Page 344
Maintenance Manual──LG6210E Hydraulic Excavator Ⅷ .Cab and interior trimming 1. Cab Cab specifications (Refer to overview) Cab, removing 1. Connect cable to the hook of the cab, and lift the cab until the cable is not loosen 2. Remove the seven mounting screws (2,5) on the backing plate in the cab. -
Page 345
Maintenance Manual──LG6210E Hydraulic Excavator Fiber plastic device, description The backing plate that is installed on the cab is installed on five fiber plastic devices, and then assemble them to the platform. Fiber plastic device is designed to buffer the shock generated when operating the machine. -
Page 346
Maintenance Manual──LG6210E Hydraulic Excavator Fiber plastic device, installing 1. Tighten the screws (8), and install fiber plastic device on the platform. Tightening torque: 6.5 ± 0.7 kgf · m 2. Check whether the installation surface is damaged or with debris. -
Page 347
Maintenance Manual──LG6210E Hydraulic Excavator 2 Operator seat The operator seat specifications (Refer to Overview) Operator seat instructions Operator seat consists of headrest, backrest, handrail, seat belt, the upper and lower rails, suspension components, and control knobs. Fig.3 Operator seat 1. Level adjustment knob 10.Pillow… -
Page 348
Maintenance Manual──LG6210E Hydraulic Excavator Operator seat, tightening torque Fig.3 Operator seat, tightening torque A Screw 0.9 ± 0.1 G Screw 4.6 ± 0.5 B Screw 2.2 ± 0.2 H Screw 2.2 ± 0.2 C Screw 2.2 ± 0.2 I Screw 2.2 ± 0.2 D Lower rail knob J Cable E Screw 11.3 ±… -
Page 349
Maintenance Manual──LG6210E Hydraulic Excavator 6. Remove the operator seat from the machine. 7. Assemble the new operator seat to the machine. 8. Connect the sliding cable under the operator seat (Adjustable lumbar support).. 9. Tighten the mounting bolts of the front of the operator’s seat. -
Page 350
Maintenance Manual──LG6210E Hydraulic Excavator Air-cooling model Air-cooling model is only for refrigeration. If you need heating system, integrated system with cooling/heating. Air Conditioning (AC), basic principles Air-conditioning unit is to guide the hot air from the cab exhaust into the surrounding atmosphere. At the same time,… -
Page 351
Maintenance Manual──LG6210E Hydraulic Excavator placed. Two heat exchangers are connected to system with pipes. The system is filled with refrigerant, R134a, which flows through the entire system with the compressor pump. Cab fan exhausts the cab air through the evaporator, where the heat will be delivered to the refrigerant. -
Page 352
Maintenance Manual──LG6210E Hydraulic Excavator Figure 8 Component location A Ambient temperature sensor D Air conditioner control switch I Condensor L.Gas inlet pipe B Car inner temperature sensor E Ambient temperature sensor J.Inlet hose C Air conditioning F. Condensor K.Hose with liquid — Tightening torque: •… -
Page 353
Maintenance Manual──LG6210E Hydraulic Excavator Fig.9, Refrigerant process 1.Air conditioning unit 8 Ambient temperature sensor 15 Condenser 2 Blower motor 9 Evaporator 16 Pressure switch 3 Relay 10 Air mixture driver 17 Drier of liquid 4 Water temperature sensor 11.Core of eater… -
Page 354
Maintenance Manual──LG6210E Hydraulic Excavator Relay is located outside the air conditioning and driven by the blower motor and the electromagnetic clutch. 4. Cooler temperature sensor When cooler temperature is above 25 ° C (77 ° F), if it is equipped with auxiliary cab heater, the air conditioning will start the automatical adjustment. -
Page 355
Maintenance Manual──LG6210E Hydraulic Excavator the system conditions (ambient, indoor and setting temperature). 11. Core of heater Hot coolant releases the heat when it flows through the core of heater and before moving back to the engine. 12. Battery Battery provides power to the air conditioning system. -
Page 356
Maintenance Manual──LG6210E Hydraulic Excavator Service valve is installed on the compressor hose. This provides a method to check pressure of refrigerant. Air conditioning switch Automatic air conditioning switch Fig.10 Air switch A Positive B Back 1.Display window 6 Indoor / outdoor selecting switch 2. -
Page 357
Maintenance Manual──LG6210E Hydraulic Excavator Table1 Connector Connector111(12Pin) Connector112-1(12Pin) Connector112-2(12Pin) Specification Specification Specification Compressor ON / Drier switch OFF switch Fan speed 4- Shift 2 Ambient temperature sensor Fan speed 3- Shift 3 Face starting Ambient temperature sensor Battery+24V Left foot… -
Page 358
Maintenance Manual──LG6210E Hydraulic Excavator Manual mode can be used by the operator when it is needed. According to different options of temperature operation and display items, the switch displays the value of C4, C3, C2, C1, H0, H1, H2, H3 and H4. -
Page 359
Maintenance Manual──LG6210E Hydraulic Excavator — C1 ~ C4: Cooling mode — H1 ~ H4: Heating system model — H0: Intermediate mode • Emergency mode 1 ~9 can be adjusted. — 1 ~ 4: Cooling mode — 6 to 9: Heating model… -
Page 360
Maintenance Manual──LG6210E Hydraulic Excavator Control system, indication Automatic air conditioning system includes automatic and manual mode. When operating the switches excerpt for the temperature setting switch, check if the troubleshooting switch is in automatic mode, the control system will conver to manual mode. -
Page 361
Maintenance Manual──LG6210E Hydraulic Excavator Temperature setting Use a temperature selecting switch, set temperature of cab can be controlled at 16~32° C, set the interval as 1° C. Note! At initial installation, set the temperature to 25° C. Initial heating mode •… -
Page 362
Maintenance Manual──LG6210E Hydraulic Excavator — When the temperature is set to 16 ° C (61 ° F) or 32 ° C (90 ° F), air conditioning switch will set speed of blower to 4 shift. Model throttle control Table4 Starting ratio of model throttle… -
Page 363
Maintenance Manual──LG6210E Hydraulic Excavator Protection of compressor • Automatic mode — This is controlled automatically based on indoor, outdoor and setting temperature. — If the pipe temperature sensor is failing, switch will turn off compressor clutch. • Manual mode Self-diagnostics and instruction of system status •… -
Page 364
Maintenance Manual──LG6210E Hydraulic Excavator Table7 Instruction items of system condition Specification Code Display Unit Note Target 25 (77) °C (°F) Manual:C4~H4 temperature(Setting) Emergency mode:1~9 Ambient temperature A24 (A75) °C Fault code If there is no fault,skip it Water temperature c27 (c80) °C… -
Page 365
Maintenance Manual──LG6210E Hydraulic Excavator 5 Cleaner 12 Ring B.Leading to the evaporator 6 Ball valve 13 O-ring C.From the evaporator 7 Valve base 14. Crankshaft D.Leading to the compressor Expansion valve, operation Expansion valve is used to adjust refrigerant flowing into the evaporator.At this point of the system, high pressure /… -
Page 366
Maintenance Manual──LG6210E Hydraulic Excavator Evaporator Evaporator,instruction • Refrigerant is converted into low-pressure liquid and sprayed into the evaporator through the expansion valve. • Wet airflow getting through the central pipe system absorbs the hot of indoor / outdoor air and evaporated.In this process ,cool and dry the air. -
Page 367
Maintenance Manual──LG6210E Hydraulic Excavator Compressor chamber and valve boxes are made of aluminum, while the piston works directly in the compressor chamber. Fig.17 Structure,Compressor 1.AMP econo. Seal «J» series，connector (Labeled as II), cab frame 2P A.Clutch E Connector 2.AVX 1.25 (black) grounding B.Coils… -
Page 368
Maintenance Manual──LG6210E Hydraulic Excavator Condenser Condenser,instruction • Condenser consists of the pipes, the refrigerant and condensater chips, which can radiate quickly. • Condenser is cooled by the airflow from the fan of oil cooler, which condenses refrigerant high-pressure, high temperatur liquid into high-pressure liquid. -
Page 369
Maintenance Manual──LG6210E Hydraulic Excavator efficiency of work. Temperature and humidity is higher, and the system needs more refrigerant. More refrigerant is needed because expansion valve is opened greater to allow more refrigerant into the low pressure part of the system. -
Page 370
Maintenance Manual──LG6210E Hydraulic Excavator Drier, replacing If the system is opened for a lon time without protective plug, such as, in the case of hose is distributed to sub-lines, receiver drier must be replaced. If you suspect there is moisture in the system, replace the receiver dryer. -
Page 371
Maintenance Manual──LG6210E Hydraulic Excavator Fig.23 Refrigerant hose with joints A side B side 1.Hose Compressor Air conditioning unit 2 Hose Drier Air conditioning unit 3 Hose Compressor Condenser Blower motor It circulates the air in the cab, converting indoor and outdoor air to the cab. -
Page 372
Maintenance Manual──LG6210E Hydraulic Excavator Fig.24 Ceramic resistor View A View B Circuit diagram A Terminal «A» L 1 speed 1.4.4 ± 10% Ω B Terminal «B» ML 2-speed 2. 2.15 ± 10% Ω C Terminal «C» MH 3-speed 3. 0.85 ± 10% Ω… -
Page 373
Maintenance Manual──LG6210E Hydraulic Excavator Fig.25 Three-point relay A Air blower 1-speed blower 4 speed D B. Air blower 2-speed air blower C.Air blower 3-speed (relay only air-conditioning) D Air blower 4-speed Actuator, foot / face driver It is located in the air-conditioning unit and adjust the air flow in the cab. -
Page 374
Maintenance Manual──LG6210E Hydraulic Excavator Fig.26 Three-point relay 1.Air blower 1-speed blower 4 speed A.Controller 2. Air blower 2-speed air blower B.Closed 3.Air blower 3-speed (relay only air-conditioning) C.Face 4 Air blower 4-speed 5 Compressor ON / OFF relay Actuator, air mixing valve driver It is located in the air conditioning unit and adjust the appropriate temperature, cold / warm air. -
Page 375
Maintenance Manual──LG6210E Hydraulic Excavator Fig.27 Three-point relay 1.Air blower 1-speed 2.Air blower 2-speed 3.Air blower 3-speed 4 Air blower 4-speed 5 Compressor ON / OFF relay Water temperature sensor Table 13 Specification Items Specification Rate voltage DC24V Operation temperature -30 ~ 85 °C (-22 ~ 185 °F) 10 KΩ… -
Page 376
Maintenance Manual──LG6210E Hydraulic Excavator Pipe temperature sensor Pipe temperature sensor is installed in the core of , interval of evaporator 5 mm, and it is positioned 5 mm away from the evaporation plates. When a switch of the air conditioning is turned on, and the… -
Page 377
Maintenance Manual──LG6210E Hydraulic Excavator Temperature sensor inside the vehicle It is installed between the left console and the driver’s seat and send signals to the controller (air conditioning switch) to set temperature by sensing the room temperature. Table 15 Specification… -
Page 378
Maintenance Manual──LG6210E Hydraulic Excavator to use the approved refrigerant recycling equipment to recycle. Important! Use the formal refrigerant recovery, recycling and filling station, do not mix to use these equipments. The recovery, recycling and filling stations of R134a and other refrigerant can not be replaced. Oil used in other systems is different from refrigerant R134a used in the system. -
Page 379
Maintenance Manual──LG6210E Hydraulic Excavator Table16. Periodic maintenance items Component Checking items Checking cycle(Month Compressor Operation condition Condensor Condensor Pollution Motor Operation condition Evaporator Pollution Refrigerant R-134 ） （ Charging capacity Guide wheel Operation condition V belt Loose,damage,aging Column Hose Aging… -
Page 380
Maintenance Manual──LG6210E Hydraulic Excavator normal circumstances, high-pressure pipe is hot, while low-pressure pipe is cold. Check the condenser. • When the condenser is contaminated, the effect of heat dissipation will be significantly reduced. Clean the condenser to improve the cooling effect. -
Page 381
Maintenance Manual──LG6210E Hydraulic Excavator Air conditioning unit, refrigerant inspecting and filling △ ! WARNING! Do not disassemble the relief valve of compressor. Refrigerant in the circuit may spray out and may cause injury. Special tools Fig.33 Refrigerant filling tool 1 Quick coupler… -
Page 382
Maintenance Manual──LG6210E Hydraulic Excavator • Connect the quick joints on the kit to the low-speed connection (inhalation) and high pressure (discharging) pressure parts of the compressor. • Connect central filling hose to the refrigerant tank. • Open (1 / 2 circle) and close each pressure valve to release the air in the hose and meter kit. -
Page 383
Maintenance Manual──LG6210E Hydraulic Excavator be closed Reading of pressure Probable reason • Low pressure gauge (blue), 1.Expansion valve does not work • High pressure gauge 2 Compressor does not work (red), Normal Fig.38. Reading of pressure gauge Reading of pressure Probable reason •… -
Page 384
Maintenance Manual──LG6210E Hydraulic Excavator • Low (blue) and high 1.Connector of compressor does pressure gauge (red) not work . indicates same 2.Compressor does not work pressure. 3.Electronic failure, circuit breaker or pressure switch do not work. Troubleshooting (the ambient temperature at air inlet is… -
Page 385
Maintenance Manual──LG6210E Hydraulic Excavator Table 24. Troubleshooting Refrigerant PressureMpa (kgf / cm Fault phenomenon Reason Check,repair High Normal 0.15~0.25 1.37~1.57 0.05~ 0.1 0.69~ 0.98 High / low pressure is low. Refrigerant Check and repair the Bubbles go through the sight is less and leakage of refrigerant. -
Page 386
Maintenance Manual──LG6210E Hydraulic Excavator Steps of refrigerant filling Important! Use refrigerant (R134a) only. Do not use any other refrigerant. Use the correct refrigerant pressure measuring devices. Do not use other refrigerant pressure gauge. Special tools Meter kit, vacuum pumps, refrigerant. -
Page 387
Maintenance Manual──LG6210E Hydraulic Excavator • When the reading of manifold meter gauge is 0 kgf / cm close the valve in both sides of the manifold and repair tank valve. Draining • Connect central filling hose to the vacuum pump. -
Page 388
Maintenance Manual──LG6210E Hydraulic Excavator • Open the valve in the low pressure side to completely fill the refrigerant system. • If the refrigerant is completely full, close the valve in the low pressure side. • Note the refrigerant flows in the mirror, check the pressure and view leakage. -
Page 389
Maintenance Manual──LG6210E Hydraulic Excavator Ⅸ .Hydraulic system, hydraulic work, other equipment Summary Instruction, summary Machine is equipped with a negative oil flow control system that the oil flow can be changed. With the system, working pump can send the oil flow according to the necessity. -
Page 390
Maintenance Manual──LG6210E Hydraulic Excavator 7. Retaining valve: all the locking valves used for boom and bucket arm to prevent the slipping of mining equipments. The main control valve includes the following features: — Boom -Bucket arm — Bucket — Rotation… -
Page 391
Maintenance Manual──LG6210E Hydraulic Excavator — Always clean the components handed in the «Clean room». If you use an alkaline detergent, it must contain anti-corrosive detergent . — Always plan the work of hydraulic system to make sure that it will not interrupted for a long time. -
Page 392
Maintenance Manual──LG6210E Hydraulic Excavator — All hydraulic components must be stored in plastic bags or film, and must be plugged. Package components can not be opened before use. — Innner instructure of maintenance service vehicles should be easy to maintain good order and cleanliness. -
Page 393
Maintenance Manual──LG6210E Hydraulic Excavator All hydraulic power transmission is working through the hydraulic oil in the working hydraulic system. A working pump supplies oil to the main valve. The main valve distributes oil to the four hydraulic cylinders and two hydraulic motors of excavating equipment (five booms). -
Page 394
Maintenance Manual──LG6210E Hydraulic Excavator Mechanical force from the engine is converted into hydraulic force by the main pump. Hydraulic force from the main pump is transmitted to the track motors, rotary motors and cylinder through the control valve, then converted to mechanical force to carry out straight action, rotating action and construction of exacavating unit. -
Page 395
Maintenance Manual──LG6210E Hydraulic Excavator pressurizes automaticaly. hydraulic oil, and pump suction • Suction port of filter force is enhanced • Oil returning pipeline: filter • Prevent damage to hydraulic and oil draining filter components, •Servo-hydraulic circuit: •Prevent contamination Pipeline filter hydraulic oil •… -
Page 396
Maintenance Manual──LG6210E Hydraulic Excavator and precision control. • During waiting period ,engine slows down to save fuel consumption reduce noise. 1.2 Fuel tank; pipeline; hydraulic oil cooling; filter; ventilation device 1.2.1 The fuel tank Hydraulic tank ,description Fig.2 Hydraulic tank ,structure… -
Page 397
Maintenance Manual──LG6210E Hydraulic Excavator l To check the hydraulic oil level, put the excavator parked on flat ground, retract the bucket arm cylinder,extend bucket cylinder, place the bucket to the ground,and turn off the engine. l All the (Mining and walking) operation levers should be extended in the end to release the remaining pressure l The neutral line of visible table means normal.Fill the… -
Page 398
Maintenance Manual──LG6210E Hydraulic Excavator To prevent excessive pressure inside the tank When the hydraulic actuators are operated, hydraulic oil level in hydraulic system will rise as the temperature increases. If the hydraulic pressure rises above the set pressure, SCBA will start to release the hydraulic pressure within the tank. -
Page 399
Maintenance Manual──LG6210E Hydraulic Excavator 3 Assemble adapter (2) and connect the hose (1) to the adapter. 4 Connect the plug to 24 volt outlet behind the operator cab. 5 Start the vacuum pump. 6 Run the pump 2-3 minutes, until a negative pressure -30 kPa can be read. -
Page 400
Maintenance Manual──LG6210E Hydraulic Excavator Tightening torque: 1.5 ± 0.2 kgf m 6 Assemble draining cap. 7 Re-add the hydraulic oil. Respirator, replacing 1 Release internal pressure within the hydraulic tank through vent. 2 Remove the mounting screws (2) of vent. -
Page 401
Maintenance Manual──LG6210E Hydraulic Excavator Servo-hydraulic selector valve, instructions Fig.13 Servo-hydraulic selector valve 1.Housing 6 Screw (M6 x 20) Tightening torque: 1.2 ~ 1.5 kgf · cm 2 Servo-hydraulic cap 7 Screws (M6 x 55) Tightening torque: 1.2 ~ 1.5 kgf · cm… -
Page 402
Maintenance Manual──LG6210E Hydraulic Excavator Check valve Fig.15 Check valve, structure 1 Screw 4 Spring 7 Nut 2 Valve body 5 Spring base 8 Sub-pin 3. Valve 6 Locking device A.Hydraulic oil flow Double-nut (7 — 1)— Tightening torque: 3.4 ~ 5.4 N m Operating pressure (Main control valve →hydraulic oil cooler… -
Page 403
Maintenance Manual──LG6210E Hydraulic Excavator Servo-hydraulic pipeline Note! About throttle connection, refer to P590, Hydraulic circuit, Standard Remote control valve (operation lever) pipeline Fig.16 Servo hydraulic pipelines, remote control valve (1) A Shuttle valve block (16) D valve block (31) B-B Shuttle line valve block (16) –Upper part E.Main control valve — front side… -
Page 404
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 17 Servo hydraulic pipelines, remote control valve (2) Table3 Valve connection Component Valve Component Valve Instruction Remote Shuttle valve block Inflection of bucket Boom descends valve(14)-rig (16) Boom extends ht side Boom is lifted Valve block (31) -
Page 405
Maintenance Manual──LG6210E Hydraulic Excavator Remote control valve (pedal) pipeline Note! About throttle connection, refer to P590, Hydraulic circuit, Standard Fig.18 Servo hydraulic pipelines, remote control valve (3) A.Main control valve — front side B. Main control valve — rear side C Valve blocks(31) -
Page 406
Maintenance Manual──LG6210E Hydraulic Excavator Solenoid valve pipeline Note! About throttle connection, refer to P590, Hydraulic circuit, Standard Fig.20 Solenoid valve pipeline A Main control valve – right DShuttle line valve block (16) G Accumulator valve block (9) B Main control valve — front Servo hydraulic selector valve(33) H Solenoid valve (12) C Main control valve –left… -
Page 407
Maintenance Manual──LG6210E Hydraulic Excavator Fig.21 Solenoid valve pipeline Table 5 Valve connection Component Valve Component Valve throttle throttle Valve block Battery battery(9)-ViewG Solenoid valve(11)-Detailed viewJ Solenoid valve(11)-Detailed viewJ Solenoid valve(11)-Detailed viewJ Rotary motor(3) Proportional solenoid valve(45) Servo-hydraulic selector valve (33 ‘) -
Page 408
Maintenance Manual──LG6210E Hydraulic Excavator Main valve(2)-View A Valve block (31)-Detailed view E Rapid assembly valve(36) Shuttle valve block (16) –View D Shuttle valve block (16) –View D Valve block (31)-Detailed view E Valve Hydraulic tank(21) –View F block(31)-Detaile d viewJ… -
Page 409
Maintenance Manual──LG6210E Hydraulic Excavator Filter draining Hydraulic tank(21) –View C oil(27)-Detailed view F Valve block of battery(9) Servo-hydraulic filter (8)- Detailed view D Solenoid (12)-ViewH Rapid coupler Central channel(17) Rotary motor(3)-Detailed viewK Fig.22 Hydraulic oil pipeline… -
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Maintenance Manual──LG6210E Hydraulic Excavator Fig.23 Hydraulic pump pipeline… -
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Maintenance Manual──LG6210E Hydraulic Excavator Main valve pipeline Note! About throttle connection, refer to P590, Hydraulic circuit, Standard Table 7 Valve connection Component Valve Component Valve throttle throttle Main valve(2)-View C Main valve(2)-ViewD Main valve(2)-View D Rotary motor(3) Main valve(2)-View B Hydraulic oil pump(1) –View H… -
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Maintenance Manual──LG6210E Hydraulic Excavator Fig.24 Main valve pipeline… -
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Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic main pipeline Note! About throttle connection, refer to P590, Hydraulic circuit, Standard Fig.25 Valve connection(Main pipeline) -
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Maintenance Manual──LG6210E Hydraulic Excavator Descending pipeline Fig.26 Valve connection(Low pipeline) Table 8 Valve connection Central channel Travelling motor Instruction Valve Direction Valve Left Left front Turn right Right front Left Left back Turn right Right back Left, right Speed control… -
Page 415
Maintenance Manual──LG6210E Hydraulic Excavator 1 Hose (Hydraulic Tank → Hydraulic oil cooler) 2 Hydraulic oil cooler 3 Pipe (main control valve → hydraulic oil cooler) 4 Pipe (main pump → main control valve) 5 Pipe (main pump → main control valve) 6 Pipe (the main control valve →… -
Page 416
Maintenance Manual──LG6210E Hydraulic Excavator Note! Check valve (12, 16) is installed in the pipe. Tightening torque: 2.0 ~ 2.5 kgf · m Fig.27 Oil returning pipeline and pump pipeline 1.2.3 Hydraulic oil cooling system Hydraulic oil cooling system,instruction Refer to cooling system,instruction 1.3 Servo-hydraulic system… -
Page 417
Maintenance Manual──LG6210E Hydraulic Excavator servo-hydraulic pressure to control valve to make it act and to allow excavation unit fall down with its own weight. Note! Servo hydraulic pressure within the accumulator can be used,only when the start switch is ON and the safety lever is open by lowering left console, Fig.29 Accumulator, structure… -
Page 418
Maintenance Manual──LG6210E Hydraulic Excavator Figure 31 Cross-section diagram of accumulator (Partial view) 1 valve block 7 plug 2 O-ring 8 spiral spring 3 plug 9 spring guide stopper 6 steel ball Table 9 Valve instruction Valve Instruction Valve Instruction Battery… -
Page 419
Maintenance Manual──LG6210E Hydraulic Excavator 3 Remove battery assembly (1). Fig.32 Removing, accumulator 4 Remove the connector (1)from the accumulator (2)with a vise . 5 Install the new connector on the new accumulator. Fig.33 Removing,connector 6 Install the accumulator (1) Note! Replace with new O-ring and copper gasket. -
Page 420
Maintenance Manual──LG6210E Hydraulic Excavator These solenoid valves play the following functions when they are started. Valve group1 (Hydraulic diagram # 11) Fig.35 Solenoid valve block 1Shell 7Solenoid conductor 13.Label 2 Spool 8 Electromagnetic coil 14 O-ring 3 Spring 9 Nut 15 O-ring… -
Page 421
Maintenance Manual──LG6210E Hydraulic Excavator When the booster switch of excavation unit is pressed, the solenoid valve A2 is started, and throttle P2 opens to throttle A2. The servohydraulic pressure from the throttle enhances thereleasing pressure of the main e release valve. -
Page 422
Maintenance Manual──LG6210E Hydraulic Excavator valve of the main control valve, only the fuel of P2 pump supplies to the boom. • Throttle «b» of central bypass valve of the main control valve is opened to the pipeline with negative pressure of pump P1 , thus this reduces the output of the oil pump P1. -
Page 423
Maintenance Manual──LG6210E Hydraulic Excavator Electrical 70 ± 5 conductor 27mm 55 ± 5 Dissembling Note • Thoroughly clean the external part of valve before removing . Removed components should be stored in a clean place. • All components are assembled very precisely, so that… -
Page 424
Maintenance Manual──LG6210E Hydraulic Excavator • Coat the O-ring without lubricant to maintain its rightful place in the assembly. • Lubricate spools before assembly. • When assembly is complete, plug the door all the throttles in order to avoid impurities into the valve. -
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Maintenance Manual──LG6210E Hydraulic Excavator 5 Remove the hose (2). 6 Remove the screw (3). 7 Transfer the fasteners from the old solenoid valve to a new solenoid valve . Note! Replace the new O-ring. 8 Install the solenoid valve. 9 Connected the solenoid valve on the hose. -
Page 426
Maintenance Manual──LG6210E Hydraulic Excavator Oil pump P1 throttle Travelling left throttle-forward Oil pump P2 throttle Travelling left servo-hydraulic throttle-backward Pressure source selecting Travelling right servo-hydraulic valve throttle-forward Travelling right servo-hydraulic throttle-backward Boom descending throttle(Small Bucket arm confluence signal chamber) throttle… -
Page 427
Maintenance Manual──LG6210E Hydraulic Excavator Rotary servo-hydraulic Oil drain port throttle(Turn right) Selecting(X1)shuttle valve block Rapid assembly valve throttle Selecting(X1)shuttle valve block Dening pump-control signal throttle throttle Boom descending servo-hydraulic Dening pump-control signal throttle throttle Boom ascending servo-hydraulic Bucket parallel throttle… -
Page 428
Maintenance Manual──LG6210E Hydraulic Excavator confluence checking, backward pressure checking, load checking . -
Page 429
Maintenance Manual──LG6210E Hydraulic Excavator 2.Boom ascending pressure throttle reducing valve ing valve. 4.Bucket arm retracting throttle pressure reducing valve ducing valve 6.Bucket inner bent throttle pressure reducing valve ng valve 8 Selecting throttle pressure reducing valve Fig.39 the main control valve, external view of a 1. -
Page 430
Maintenance Manual──LG6210E Hydraulic Excavator 、 、 Ø26 5 ± 0.5 PL BL3 （ ） M10x1.5 Ø23 AL1, BL1, AL2, BL2, AL3, AR1, BR1, AR2, （ ） M10x1.5 BR2, AR3, BR3, AL4, BL4 Ø38 10 ± 1 （ ） M12x1.75 21 ± 2 ，… -
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Maintenance Manual──LG6210E Hydraulic Excavator Main control valve, partial view Fig.41 Main control valve( Partial view1) -
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Maintenance Manual──LG6210E Hydraulic Excavator Fig.42 Main control valve(Partial view2) -
Page 433
Maintenance Manual──LG6210E Hydraulic Excavator Item Tightening Item Tightening torque: N torque: N m Valve blocks(Left) Flanage Valve blocks(Right) Plug 147 ±14.7 Cap of spool Screw Bucket arm locking valve — 49 ±4.9 Cleaner 49 ±4.9 Spool plate Screw 29.4 ±2.9… -
Page 434
Maintenance Manual──LG6210E Hydraulic Excavator 58.8 ±5.9 Moving straight valve Ring screw 98 ±9.8 Logic valve Rivet 98 ±9.8 14.7 ±2 Main parallel check Hole screw valve 196±19.6 49 ±4.9 Loading check valve Screw 58.8±5.9 98 ±9.8 Bucket confluence valve Screw 98 ±9.8… -
Page 435
Maintenance Manual──LG6210E Hydraulic Excavator measure for safety when dealing with it. Notice for disassembly • When removing the control ,do not be forced too much. Do not use the tool with sharp surface and high hardness. • Be careful when handling the parts, protect the fine surface with polishing. -
Page 436
Maintenance Manual──LG6210E Hydraulic Excavator assembly. Especially for the pressure staining parts: Seat: check valve seat. Throttle seal: contact surface of O-ring. Seal: main pressure relief, contact surface of boring of main pressure relief throttle. Spool • If there are injuries, rust and corrosion, •… -
Page 437
Maintenance Manual──LG6210E Hydraulic Excavator base. • If it is stuck, replace it • Check whether the nozzle is blocked. • If damaged, heated or discolored, replace • Check the spring. • It is difficult to to determine whether the valve is damaged with the naked eye, so be careful to check its operation status. -
Page 438
Maintenance Manual──LG6210E Hydraulic Excavator Fixture(Material :copper) Fig.43.Fixture A.Hexagonal fixture (2) B Screws (M5 × 60) Table 17 Fixture,use method Fixture 28.2 Main spool 15.9 Straight transition spool Main spool,removing (Order of assembly is oppose to the order of disassembly) When disassembling, mark the original… -
Page 439
Maintenance Manual──LG6210E Hydraulic Excavator Fig.44. Main spool 1 Remove the screw (1), and remove the cover (2). — Tools: 12 mm hex wrench — Tightening torque: 15 kgf · m Note! When assembling, make sure O-ring is installed before the assembly cover. -
Page 440
Maintenance Manual──LG6210E Hydraulic Excavator Fig.48 Removing the check valve Description of the main pressure relief valve Normal pressure (330 kgf / cm Py servo-hydraulic signal: OFF Supply of hydraulic oil from the pump flows to chamber (3 through th nozzle (2) of rotary tailstock A. -
Page 441
Maintenance Manual──LG6210E Hydraulic Excavator Servo-hydraulic pressure pushes the piston D, set pressure of the spring C increases, which can increase the set pressure. Fig.52 Increase the set pressure E:Servo-hydraulic signals: ON Main pressure relief valve, adjustment Limit the adjustment of pressure… -
Page 442
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic pressure Please refer to the P370, specifications of main control valve Fig.53 Hydraulic pump, pressure measurement throttle 1 quick coupler 2 hose (pressure gauge） 3.pressure gauge 4 Sealing cap Important! If the pressure relief valve is set incorrectly, hydraulic equipment will be damaged, the result will be very dangerous. -
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Maintenance Manual──LG6210E Hydraulic Excavator 46 kgf/cm 4 Firmly grip the adjusting screw (3), and then tighten the locking nut (4). Note! Tightening torque: 6 kgf · m 5 Re-adjust the low pressure set to the rated pressure. 6 re-confirm the high or low pressure settings. -
Page 444
Maintenance Manual──LG6210E Hydraulic Excavator If the pressure exceeds the set pressure of the spring C, servo-hydraulic tailstock B will open, so the oil will flow to channel of oil tank through the holes and channel of circuit. The pressure of hydraulic tank (2) will be reduced. -
Page 445
Maintenance Manual──LG6210E Hydraulic Excavator 2 Fixture sealing cap (4), loosen the locking nut (3). 3 Remove the sealing cap (4) and removed the well. 4 Remove the sleeve (6), pull out the piston (7), spring (8) and the nozzle (9). -
Page 446
Maintenance Manual──LG6210E Hydraulic Excavator Throttle pressure relief valve , measurement and adjustment Measurement conditions — Park the machine in the location B, refer to P45, maintenance position — Hydraulic oil temperature: 50 ± 5 ° C — Mode: «P» mode — Adjust the pump displacement — Main valve pressure: 44.1 MPa… -
Page 447
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic pressure Please refer to P32, the main control valve specifications. Basic pump provides oil to each actuator and test throttle. Table 19 Valve Plug Pump Actuator(Test throttle) Boom cylinder • bucket cylinder• right-lateral motor (at the… -
Page 448
Maintenance Manual──LG6210E Hydraulic Excavator Note! To correct the set pressure of throttle pressure relief valve, connect hose,conform to displacement adjustment procedures of pump. Note! When adjusting the rotary vacuum pressure , do not adjust the main pressure relief and displacement of pump. -
Page 449
Maintenance Manual──LG6210E Hydraulic Excavator Adjus Fig.64 Connect the pump to control valve t the View A Original servo hydraulic lines View B Servo-hydraulic lines for adjusting displacement throttl A main pump 9 Fastener (PF1 / 4) 2 servo-hydraulic pump 10 hose (oil flow control solenoid valve 45-A) -
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Maintenance Manual──LG6210E Hydraulic Excavator 3 Loosen the locking nut (2), twist the adjustment screw (1) twist clockwise as follows: With increasing pressure, twist it clockwise. Twist it counterclockwise to reduce pressure. 4. Firmly keep the adjusting screw (1) stable, and then tighten the locking nut (2). -
Page 451
Maintenance Manual──LG6210E Hydraulic Excavator 2 Remove the sealing cap (2), pull the spring (3) and servo-hydraulic tailstock with the turn (4). — Tools: 27 mm socket wrench — Tightening torque: 6 kgf · m Fig67 Remove spring servo-hydraulic lifting valve 3 Remove the servo-hydraulic seat (5), pull out the spring (6, 7),pistons (8) and the main rotary tailstock (9). -
Page 452
Maintenance Manual──LG6210E Hydraulic Excavator pipes of the fuel tank through the channel (4) and (5) . Fig.70 Phase 2 throttle release valve As the hydraulic oil flows through the rotary tailstock (D),before and after hole (3) of the piston (A) ,the pressure will drop. -
Page 453
Maintenance Manual──LG6210E Hydraulic Excavator Anti-cavitation operation Since d1> d2, hydraulic pressure is usually larger than the tank throttle, the tailstock (B) remains fixed at the base safety. Hydraulic throttle pressure decreases below the tank Fig. 74 Phase 2 throttle release valve… -
Page 454
Maintenance Manual──LG6210E Hydraulic Excavator High pressure adjustment 1.Remove the servo hydraulic hose connected to pressure relief valve, plug nozzle of hose. 2 Loosen the lock nut (2), twist the adjustment screw (1) clockwise until it is in the right place (X, Y and Z). -
Page 455
Maintenance Manual──LG6210E Hydraulic Excavator Note! The components installed on the machine is difficult to adjust the pressure, so do not remove the part of the Fig. 76 Phase 2 throttle release valve pressure adjustment. 1 Loosen the sleeve (1), completely remove the sleeve. -
Page 456
Maintenance Manual──LG6210E Hydraulic Excavator Spool operation Boom rise (Pv> Pc) (3Pi servo-hydraulic signal: OFF (off)) Chamber (1) connects with chamber (2)through nozzle (4), and the pressure Pc is obtained, rotary tailstock E will be opened. High-pressure oil supply pipe flows to cylinder piston side… -
Page 457
Maintenance Manual──LG6210E Hydraulic Excavator Boom down (Pc> Pv) (3Pi servo-hydraulic signals: ON) When using servo-hydraulic pressure (3Pi), the piston A moves upward, servo-hydraulic pressure (Pg2) flows to the chamber Y. Piston B and rotary tailstock C move towards the right side, so that channel (5) and (6) connects with each other. -
Page 458
Maintenance Manual──LG6210E Hydraulic Excavator Boom locking valve, disassembly (Order of assembly is oppose to order of disassembly) Disassembly, mark the parts to make assembly easier. Fig80 Boom locking valve The main check valve 1 Remove the screw (1) and remove cover assembly (2). -
Page 459
Maintenance Manual──LG6210E Hydraulic Excavator Cover assembly 4 Remove the sealing cap (8), pull out the spring (9) and check the tailstock with the switch (10). Tools: 8 mm hex wrench Tightening torque: 5 kgf · m… Fig.83 Cover assembly 5 Remove the sealing cap (11), pull out the piston (12). -
Page 460
Maintenance Manual──LG6210E Hydraulic Excavator This process can prevent the appearance of bubbles when the boom falls down. Boom back pressure check valve, removing (Order of assembly is oppose to order of disassembly) Disassembly, mark the parts to make assembly easier. -
Page 461
Maintenance Manual──LG6210E Hydraulic Excavator A position of spool is shown in the figure, the studio (1) and oil draining pipes (Dr2) are separated. Chamber (1) connects with Chamber (2) through nozzle (4) , the pressure in the chamber (1) is Pc. Because the area d1>… -
Page 462
Maintenance Manual──LG6210E Hydraulic Excavator Chamber (1) connects with Chamber (2) through nozzle (4) , the pressure in the chamber (1) is Pc, and with the tail base B will open. Hydraulic oil(Pv) in high pressure supply pipe supplies to the cylinder rod (3) side. -
Page 463
Maintenance Manual──LG6210E Hydraulic Excavator When appling servo hydraulic pressure (4pi), the spool A turns left, chamber (1) connects with oil drain pipes (Dr2) . Oil in the chamber(1) is emptied, the pressure in the chamber(2) is reduced. When applying pressure Pc (area d1 — an area d2), B will open, hydraulic oil from the cylinder rod side of the channel flow back to tank. -
Page 464
Maintenance Manual──LG6210E Hydraulic Excavator Fig.99 Removing spool Boom oil regeneration valve instructions Servo-hydraulic pressure (al3) will be pushed to the right side of the spool Stick (Stick shrink into), blocking the central bypass piping, pressurized oil flow from the pump to… -
Page 465
Maintenance Manual──LG6210E Hydraulic Excavator Piston pressure is high pressure(PB> PA) Oil returning flow of oil from the throttle BL3 to spool circuit notch, flow to limited pipeline (1) and (2), where oil pressure rose, move spools C to opena narrow channel leading to check valve . -
Page 466
Maintenance Manual──LG6210E Hydraulic Excavator Pressure of piston side is high pressure(P > P When the pressure of AL3 is greater than BL3, check valve A is closed. Hydraulic oil acts on the piston B, if it exceeds the spring force D, the piston B and spool C will move to the right side, channel (2) will be opened radically. -
Page 467
Maintenance Manual──LG6210E Hydraulic Excavator I Servo hydraulic oil R Reserved pipeline T Tank Channel J Bucket arm lock valve Fig.102 When the pressure of pistons side is too high Negative pressure relief valve,description Hydraulic oil in the central bypass pipeline flow to the pipe of oil tank through the hole C of rotary railbase A. -
Page 468
Maintenance Manual──LG6210E Hydraulic Excavator Disassembly, mark the parts to make assembly easier. 1.Remove the sealing cap (1), turn out with tailbase(2). Fig.105 Foot pressure relief valve 2 Remove the sealing cap (3), pull out the gasket (4) and spring (5). -
Page 469
Maintenance Manual──LG6210E Hydraulic Excavator — Tightening torque: 4 kgf · m Fig.108 Remove bucket arm flow regeneration and bucket arm confluence check valve 4 Remove the plug (10) from the piston (9), pull out the check valve (11). — Tools: 4 mm hex wrench — Tightening torque: 0.8 kgf ·… -
Page 470
Maintenance Manual──LG6210E Hydraulic Excavator Position A and B of the piston as is shown in figure and they are controlled by a spring force. When check valve C is open, the pressure Pa in the throttle (a) flows to chamber Z through the channel (1) and (2). -
Page 471
Maintenance Manual──LG6210E Hydraulic Excavator Fig.111 Logic valve,in the neutral position and the position of boom descending A Piston F From PL pump B.Piston G. Boom ascending servo-hydraulic oil C,Check valve H High pressure oil supply pipe used for the boom in the 3-spool side(Pb) D.Rotary tailbase… -
Page 472
Maintenance Manual──LG6210E Hydraulic Excavator — Tightening torque: 10 kgf · m Fig.113 Remove the spring 2 Remove the sleeve using horizontal holes (5), pull out the spring (6) and check valve (7). Fig.114 Remove check valve 3 Insert threaded screws (M5 × 0.8) of a rod into the end of sleeve (8), pull the sleeve out. -
Page 473
Maintenance Manual──LG6210E Hydraulic Excavator Bucket parallel confluence check valve, disassembly and assembly (Order of assembly is oppose to the order of disassembly) Disassembly, mark the parts to make assembly easier. 1 Remove the sealing cap (1), pull out the check valve (2) and spring (3). -
Page 474
Maintenance Manual──LG6210E Hydraulic Excavator 2 Grip a spool with clamps and vise, release the spool cap — Tools: 13 mm hex socket wrench — Tightening torque: 1.5 kgf · m Note! Tighten the nut prior to assembly. Fig.123 Remove the spool assembly 3 Remove the nut (2), pull out isolated pieces (3), spring (4) and the spring seat (5). -
Page 475
Maintenance Manual──LG6210E Hydraulic Excavator Fig.127 Load check valve A.(Single)Boom,rotation B. (Single)Bucket arm, straight, excavating, rotation 1 Remove the sealing cap (1), pull out the spring (2) and spool (3). — Tools: 41 mm hex socket wrench — Tightening torque: 10 kgf · m Fig.128 Remove the spool… -
Page 476
Maintenance Manual──LG6210E Hydraulic Excavator • Main tailstock nozzle is clogged. Port of servo-hydraulic circuit is Remove impurities. clogged. Servo-hydraulic pressure Moving straight valve is faulty. Travelling unit measurement. • Spool is stuck. and digging unit • Polish on the spool. -
Page 477
Maintenance Manual──LG6210E Hydraulic Excavator faulty. • Replace the spring. • There is duct between main the tailstock and the base. • Spring is broken or fatigue When extending Loading one-way valve is faulty. • Disassemble and clean. If damaged, the cylinder, it •… -
Page 478
Maintenance Manual──LG6210E Hydraulic Excavator • If finding something normal, must determine whether there is failure of these components: control valve, the main pump, servo-hydraulic pump or circuit components such as remote control valves, motors and the central channel and so on. -
Page 479
Maintenance Manual──LG6210E Hydraulic Excavator Table 22.Mode code K3V — 112 — DT — 1XJR — 9N2D — V K3V seires Dimension(Displacement:cm3/rev) S(Single pump) D(Doublepump) -
Page 480
Maintenance Manual──LG6210E Hydraulic Excavator Code of design number Observe the rotation of craneshaft from the end of shaft 9NOA Adjustor model Table 23 Throttle connection Throttle name Dimension SAE 6000 3/4″ A1,2 Oil output SAE 2500 2 1/2″ Absorb oil… -
Page 481
Maintenance Manual──LG6210E Hydraulic Excavator Fig.130 Main pump, (Partial map) 111 Transmission shaft 262 Cover 113 Transmission shaft 271 oil pump housing 114Spline coupling rack 312 valve valve block 123 Bearing 313 valve plates 124 Bearing 314 valve plates 127 Bearing isolation… -
Page 482
Maintenance Manual──LG6210E Hydraulic Excavator Fig.131 Pump, exploded view Operation principle of pump • The pump assembly consists of two pumps contacted by rack by the spline coupling (114). When transmission power transmits to the front transmission shaft (111), the two pumps is driven simultaneously… -
Page 483
Maintenance Manual──LG6210E Hydraulic Excavator hydraulic spring presses on the package pin by set plate and spherical bearing. Similarly, due to the action of spring, valve blocks of the hydraulic cylinder presses the valve plate (313). • Rotary swash plate assembly includes rotary swash plate (212),package pin (211),rotary swash plate support (251), tilt bearing (214), tilt pins (531), and the servo piston (532). -
Page 484
Maintenance Manual──LG6210E Hydraulic Excavator Maximum oil flow adjustment By releasing the nut (809) and tighten (or loosen) the adjustment screw (954) to adjust the oil flow. Only maximum oil flow can be adjusted without changing the other control features. Fig.134 Maximum oil flow adjustment… -
Page 485
Maintenance Manual──LG6210E Hydraulic Excavator Lubrication and draining the air Table25.Notice about lubrication and draining the air Item Notes Lubrication Fill the pump with special hydraulic oil through throttle P1, P2. • When continuing to repair or replace the pump, it is necessary to lubricate internal parts, bearings and sliding parts to prevent scratches, wear, stuck, etc. -
Page 486
Maintenance Manual──LG6210E Hydraulic Excavator careful avoid damage when processing these components Check the abnormal circumstance of oil pump. Pumps are usually equipped with a regulator, auxiliary valve or a pump, auxiliary throttle or an auxiliary pump, thus it is difficult to find the cause of the malfunction. Check the following main components, identified there are no unusual circumstances. -
Page 487
Maintenance Manual──LG6210E Hydraulic Excavator When a component exceeds the following standards, replace or adjust it. However, if a component is obviously and severely damaged, the replacement will not go wrong Table 26 Standard aging limit unit:mm Checking item Standard Correction… -
Page 488
Maintenance Manual──LG6210E Hydraulic Excavator Wear limit of cylinder, the valve plate and the swash plate Table 27.Repair standard Surface roughness of cylinder Surface roughness requirements Surface roughness of valve plate Correction and the swash plate. Standard surface roughness 0.4Z (Corrected value) -
Page 489
Maintenance Manual──LG6210E Hydraulic Excavator PF1 1/2 Pump tools Tool The necessary tools for removal / installation of K3V pump are shown in the following table. The size of the screw and plug depends on pump type. Table29.Tool Tool Dimens The necessary tools… -
Page 490
Maintenance Manual──LG6210E Hydraulic Excavator M24, PO-2 VP-1/4 Box end wrench VP-3/8 Jack open end M16, M16, wrench VP-1/2 VP-3/4 VP-1 VP-11/4 VP-11/2 Wrench Medium size. Screwdriver Flat head screwdriver, medium size, 2 sets. Hammer Plastic hammer. Pliers For clamp, TSR-160… -
Page 491
Maintenance Manual──LG6210E Hydraulic Excavator 2 Remove dirt, rust, etc on the surface of pumps with detergent . 3 Remove the oil throttle plug (467),drain hydraulic oil out of pump housing Note! For the tandem pump, remove the plug from the front /rear pump. -
Page 492
Maintenance Manual──LG6210E Hydraulic Excavator to not damaging the sealing when removing. 9 Remove the screws (408) Fig.140 Remove the seal cover 10 Gently tap the side of pump housing, and rotate the flange of swash plate (251), so that separate the swash plate support from the pump housing (271). -
Page 493
Maintenance Manual──LG6210E Hydraulic Excavator Note! Remove the tilt pins, and use a clamp to prevent the pin head from being damaged. Because the tilt servo Fig.144 Remove the valve plate piston pin and the installation parts are coated with Loctite liquid, pay attention to not damaging the servo piston. -
Page 494
Maintenance Manual──LG6210E Hydraulic Excavator strength). 2 Put the pump housing on the inclined surface of regulator. Install the tilt bearing on the tilt pin (531)and install swash plate (212) to the swash plate support (251) Note! Move swash plate with both hands to confirm its ability to slide smoothly. -
Page 495
Maintenance Manual──LG6210E Hydraulic Excavator 5 Install the piston cylinder body [cylinder (141), piston attachment assembly (151,152), set plate (153), spherical bushing (156) and cylinder spring(157)]. Then, insert the cylinder assembly into pump housing. Note! Align the splines of spherical bearing (156) and the cylinder stopper (141). -
Page 496
Maintenance Manual──LG6210E Hydraulic Excavator Note! After assembly, fill the hydraulic oil to prevent rust. When installing the machine, add hydraulic oil and drain from the air in the hydraulic circuit. Pump, installing Starting notice • Fill pump housing with the hydraulic oil . -
Page 497
Maintenance Manual──LG6210E Hydraulic Excavator Table30. Sign Specification Tightening torque Specification M18 × 60L 31 ~ 33 (Loctite)277 M18 × 55L M20(10.9,JIS) 40 ~ 48 M16 × 20L 31 ~ 33 1.5 ~ 1.9 M10 × 50L 6.5 ± 0.7 Pump,troubleshooting Table31. -
Page 498
Maintenance Manual──LG6210E Hydraulic Excavator Inserted package Check whether the hydraulic oil is • Auxiliary pump is damaged. partially damaged. cloudy. • Oil absorbing pipe absorbs Fuel tank has cracks. Replace the piston and track the air. Pump installed plate. •… -
Page 499
Maintenance Manual──LG6210E Hydraulic Excavator P: positive-pressure oil flow control M: Manual control of oil flow E: E oil flow control C: negative pressure oil flow control (maximum oil flow shut-off control) N: positive-pressure oil flow control (control of oil flow off additional) Regulator design series number Table 35.Throttle connection… -
Page 500
Maintenance Manual──LG6210E Hydraulic Excavator 412 screws 625 outside springs 654 rebound spring 413 screws 626 inner springs 655 adjustable spring 436 Screw 627 Ring 656 cap 438 Screw 628 Screw 708 ~ 763 O-ring 496 plug 629 cover 801 nuts… -
Page 501
Maintenance Manual──LG6210E Hydraulic Excavator Fig155. Regulator (exploded view) Operation principle of regulator In-line type axial piston pump consists of the following controllers. Horsepower control When the oil pressure of the pumps P1 and P2 increase, the oil flow rate is automatically reduced, so that the input torque is adjusted to certain value. -
Page 502
Maintenance Manual──LG6210E Hydraulic Excavator Fig.156 controller structure X large terminal part 625 outside spring Y Small terminal part 626 Inner spring 531 tilt pin 646 servo-hydraulic spring 548 Feedback pin 651 bushing 611Feedback lever 652 spool 612 lever-1 654 rebound springs… -
Page 503
Maintenance Manual──LG6210E Hydraulic Excavator The regulator has the above three control functions, but the different control functions can also act at the same time, the low oil flow will be mechanically operated priority. Oil output rate of pump can be controlled by changing the servo-hydraulic pressure Pi. -
Page 504
Maintenance Manual──LG6210E Hydraulic Excavator When the servo piston moves to the right, the point «D» also moves to the right. Spool is installed with oil return spring (654), which is under tension at all times, this pin (897) is pressed in the hole «C» of pole 2. -
Page 505
Maintenance Manual──LG6210E Hydraulic Excavator Because the regulator is the type of the entire cumulative horsepower, control the angle of the two pumps (oil drain) to show the same values according to the following formula: Tin = P1 x Q/2p + P2 x Q/2p = (P1 + P2) x Q/2p Horsepower control function is the same asoil flow control Fig.158 Full-power control… -
Page 506
Maintenance Manual──LG6210E Hydraulic Excavator Results, the throttle (CI) opens the channel connected to the tank, and spool moves to right, until the most pressure of piston is released, resulting in the increase of oil flow rate. The movement of the servo piston is transferred to spool by the action of feedback mechanism, until the port between the spool and the sleeve is turned off. -
Page 507
Maintenance Manual──LG6210E Hydraulic Excavator check. Refer to disassembly and assembly. Overload of engine Determine the location of faults, in former pump or rear pumps. Method：exert the load to each pump. Two pumps are found with faults, carry out the inspections of (1) and (2).Only one pump fails, check to begin from (3),… -
Page 508
Maintenance Manual──LG6210E Hydraulic Excavator The performance of adjustment screw 628,924,925 has been significantly changed, so only let professional technicians perform the operation. Adjust the input horsepower Because the regulator is full cumulative horsepower type, when changing the horsepower settings, the adjustment screw before and after pump needs to be adjusted. -
Page 509
Maintenance Manual──LG6210E Hydraulic Excavator Pump control curve Fig.163 Pump control curve Oil flow output Pd Oil pressure Servo-hydraulic pressure Tin Input torque Note! Actual sent oil flow = engine rpm/1800 × Q (readings at bending) Load of sync 2 pump (1800 rpm) -
Page 510
Maintenance Manual──LG6210E Hydraulic Excavator Regulator disassembly Note •Before removing the adjuster, thoroughly clean the pump. • Mark the symmetry on the regulator and the pump. • Choose a clean workplace. • Be careful not to mix with the different components of front and rear regulators. -
Page 511
Maintenance Manual──LG6210E Hydraulic Excavator Tightening torque Table38 Tightening torque Instruction Dimension Tightening B(mm) Tool torquekgf·m Screw (material: SCM Hex wrench 435) 1000 1600 2400 3400 4400 PT plug Hex wrench PT1/16 (Material: S45C) PT1/8 Note! Use Loctite # 577 PT1/4… -
Page 512
Maintenance Manual──LG6210E Hydraulic Excavator 3 Remove the screws (412,413), and remove the regulator. Note! Be careful not to lose the O-ring. Fig.164 Remove the adjustor 4 Remove the screws (438), and remove the cover (C) (629). — Cover (C) is installed with the adjustment screw (C), (C1) (628,925), adjustment ring (C) (627), lock nut (630), nut (801) and the adjustment screw (924). -
Page 513
Maintenance Manual──LG6210E Hydraulic Excavator 7 Remove clamp (814), and remove the outer spring seat (653), rebound springs (654) and sleeve (651). — Sleeve (651) is installed with clamp (836). Note! Remove clamp (814), the rebound spring (654) will pop up. Be careful not to lose it. -
Page 514
Maintenance Manual──LG6210E Hydraulic Excavator Note! Record direction of feedback rod. Fig.171 Remove the pin shaft and oil returning lever 11 Remove rod (1) (612). Note! Do not pull the pin (875). 12 Pull out the servo-hydraulic spool (643) and spool (652). -
Page 515
Maintenance Manual──LG6210E Hydraulic Excavator • According to marks, aligned regulators with the oil pump housing. 1. Put compensation rod (623) into the compensation hole of housing (601). 2 Put forced pin of rod(1) (612) into the casing of compensation rod, then install the rod (1) to the pin in the housing. -
Page 516
Maintenance Manual──LG6210E Hydraulic Excavator confirm it is without too much gap, and will not be entangled. Fig.173 Assemble plug of support shaft 9Install reobound spring (654) and the spring seat (653) into the hole of spool with clamp (814). Note! Note that the original direction of the spring base. -
Page 517
Maintenance Manual──LG6210E Hydraulic Excavator Then install the screws (438). Hydraulic pump, replacing Fig.177 Assemble the cover WARNING! Hydraulic oil with high temperature and high pressure can cause serious injury. WARNING! Put the excavating unit to the ground, and turn off the engine (ignition switch is ON position). -
Page 518
Maintenance Manual──LG6210E Hydraulic Excavator 5 Remove the screw (1) and cover (2). Fig.180 6 Remove the screw (1,3,5,7,9,11) and cover (2,4,6,8,10, 12). Fig.181 7 Loosen coupling fastening nut (1) of the muffler and remove the nut (3). Move the pipe (2) to the left about 3 cm. -
Page 519
Maintenance Manual──LG6210E Hydraulic Excavator 11 Disconnect the hose (1,2,5,6). Remove the screws (3) and disconnect outlet hose (4) with O-ring. Fig.184 12.Disconnect the wiring harness of proportional valve (3). Disconnect the servo-hydraulic hose (1,2,4). Remove assembly screws (5) of the absorbing tube. -
Page 520
Maintenance Manual──LG6210E Hydraulic Excavator Fig.187 16 Remove the screw (1) and flange (2). 17 Install the flange to a new hydraulic pump. Note! Removed O-ring and seal ring must be replaced with Fig.188 new one. 18. Move the servo-hydraulic pump to the new hydraulic pump. -
Page 521
Maintenance Manual──LG6210E Hydraulic Excavator 3 Install the seal (1) and O-ring (3) to cover (2). 4 Install the front cover to oil pump housing, and install the screws. Note! Coat the sealing lip with a little grease. Install the seal, be careful not to damage the seal. -
Page 522
Maintenance Manual──LG6210E Hydraulic Excavator mp, structure 353 driver gear 466 plug 354 driven gear 700 ring 355 filter 710 O-ring 361 Front shell 725 O-ring 433 Screw 732 O-ring 434 locking nut 850 snap ring 435 shell… -
Page 523
Maintenance Manual──LG6210E Hydraulic Excavator ed view) Table39.Tightening torque Dimension kgf·cm M14 x 1.5 29.4 433,434 16.7 PF1/4 15.7 Note •It is not recommended to repair the pump. • When installing a new pump, replace the O-ring (710). • Before connecting to the pump, check whether there are impurities throttle and hose. -
Page 524
Maintenance Manual──LG6210E Hydraulic Excavator Servo-hydraulic pressure control • Engine speed: high idle • Oil temperature when measuring: 50 ~ 60 ° C Measuring Remove the plug, install pressure gauge 100 kgf/cm2 on the oil pump Note! Pump housing is made of aluminum alloy. If tightening over, the thread may be damaged. -
Page 525
Maintenance Manual──LG6210E Hydraulic Excavator 1 Put machine in a level surface, lower the bucket to the ground, stop the engine. Fig.197 Cut off the connection,hose Operate all the operation levers (attachments and walking) to their end, to release the remaining pressure. -
Page 526
Maintenance Manual──LG6210E Hydraulic Excavator Code Electronic proportional pressure reducing valve KDRDE Standard naming Casing type Serial number Maximum pressure setting auxiliary (40 kgf/cm2 ) Solenoid valve Specifications C = 18.5Ω * 0.7A Circuit connection Solenoid valve controls auxiliary pressure (the pressure of throttle A), and make the auxiliary pressure proportional with the current through the coil of solenoid valve. -
Page 527
Maintenance Manual──LG6210E Hydraulic Excavator Solenoid valve is no electrode. Input current Do not impose current higher than 0.7A on the electromagnetic coil. Adjustment screw Setting before shipment of original plants. When adjusting the screw twist throttle A clockwise to enhance pressure. -
Page 528
Maintenance Manual──LG6210E Hydraulic Excavator proportional solenoid M22 × 1 450 ± 50 valve Spool Sleeve M14 × 1 300 ± 30 Spring Valve housing Port 6±1 (# 24) O-ring O-ring O-ring Screw Plug PF 1/4 Plug NPTF 1/16 O-ring O-ring solenoid valve M22 ×… -
Page 529
Maintenance Manual──LG6210E Hydraulic Excavator • Start the engine and measure the current value. Fig.201 Connection, proportional solenoid valve 1. Black components with red (BR) 2. White 3. Tester 4. Red 5. Black Measurement and adjustment of proportional solenoid valve Measurement conditions •… -
Page 530
Maintenance Manual──LG6210E Hydraulic Excavator Fig.202 Pressure checking 1. Adjustment screw(1) 2. Adjustment screw(2) 3.Pressure checking throttle Proportional solenoid valve (power shift), replacing Note! Disconnected hose, pipe and fittings must be plugged. Oil drained from a hose, pipe and fittings should be collected in the container. -
Page 531
Maintenance Manual──LG6210E Hydraulic Excavator 10 Start the engine. Check for leaks, repair it if necessary Current/pressure, specification Current/pressure, specification Switch Mode Engine speed rpm Valve output Valve auxiliary Close the rotary —Noloading/loading current(mA) pressure-Nolo solenoid （±40rpm） switch —Noloading/loading ading kgf/cm2 valve （±20rpm）… -
Page 532
Maintenance Manual──LG6210E Hydraulic Excavator Piston or spool is stuck. Pressure Incorrect high-frequency vibration Readjust. stable. adjusted. l High-frequency vibration is too low. l Altitude of high-frequency vibration is too high. Response is slow. Basic servo hydraulic pressure is too low. -
Page 533
Maintenance Manual──LG6210E Hydraulic Excavator Remote control valve (Operation lever), instruction Servo-valve hydraulic valve PV48K is pressure relief valve type of remote control valves, 4 pressure reducing valve control auxiliary pressure within the valve housing. The auxiliary pressure is adjusted by adjusting the tilt angle of the handle. -
Page 534
Maintenance Manual──LG6210E Hydraulic Excavator main valve spool. This function is executed by the the spring provided at the end of spool, and impose output pressure at the other end of the hydraulic servo-valve. To accomplish this function, the servo hydraulic valves include the following components: •… -
Page 535
Maintenance Manual──LG6210E Hydraulic Excavator Exterior view (right operation lever) 1.1#lever 11.Green line A.Neutral position marked with white paint 2.2#lever 12.Red line B single operating angle B (19°) 3 .3#lever 13.Yellow line Bb single operating angle B (25°) 4.4#lever 14 Black line… -
Page 536
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 205 Remote valve stem (cross section diagram) 101 Housing 211Plug 302 Plate 454 Rubber hose 111Metal plates 212 Lever 312 adjusting nut 455 switch 121 gasket (seal) 213 seal 315 lock nut 456 wire 122 O-ring… -
Page 537
Maintenance Manual──LG6210E Hydraulic Excavator The housing has the hydraulic oil input port –throttle (P) and the hydraulic oil output -throttle (T). In addition, the auxiliary pressure goes through the throttle1, 2, 3 and 4. Each control valve is equipped with an electronic switch, and switch (455) is built-in at the top of handle. -
Page 538
Maintenance Manual──LG6210E Hydraulic Excavator Remaining stable(9) — When the lever is released from any position, this lever will return to the «Keep stable” position. Rotary device, stick, bucket or boom are stopped. Move the operation lever diagonally , the two functions can work at the same time. -
Page 539
Maintenance Manual──LG6210E Hydraulic Excavator Handle in the neutral position The elasticity of sring (241) determines output pressure of servo-hydraulic valves will not be imposed to the spool (201). Therefore, the spool is pushed to the position of throttle 3 by spring (221). Then, because the output is only connected to the tank throttle (T), the pressure of output throttle should be equal to the pressure of tank. -
Page 540
Maintenance Manual──LG6210E Hydraulic Excavator contacts with the bottom of the lever, the output pressure are connected to the output pressure throttle (P). Fig.209 Handle in the operating position Fig.210 Diagram of operating pressure Maintenance standard of remote valve(operation lever) Table46 Maintenance standard… -
Page 541
Maintenance Manual──LG6210E Hydraulic Excavator cSt oil replaced. Spool Sliding surface is worn more than 10µm in Leakage comparison with non-worn surface, this part estimated should be replaced. equal leakage. Lever A Wear more than 1mm When the top is worn more than 1mm (0.004.),this part should be replaced… -
Page 542
Maintenance Manual──LG6210E Hydraulic Excavator Screw2 with 18 ~ 22 Flat type 4~5mm Bushing screwdriver Special tool Joint 480 ±30 Torque 100 ~ 1000 kgf·cm wrench Others: • Rust preventive • Cleaner • High-temperature grease(Recommended to use spray type) • Liquid Loctite # 241 (special type # 261) • Sandpaper (# 1000, # 2000) •… -
Page 543
Maintenance Manual──LG6210E Hydraulic Excavator 3 Lift the terminal of bellows (501) from the housing (101). Important! Be careful not to damage the bellows. Fig.212 Lift the bellow pipes 4 Loosen the lock nut (315) and the adjusting nut (312). Tighten each nut with a wrench. -
Page 544
Maintenance Manual──LG6210E Hydraulic Excavator Fig.215 Remove the disc 7 Twist the joints clockwise to release it,wiht the clamp (special tools). Note! (Photo) shows how to fix clamp. Important! Note that when loosening the joint, the metal plate (151), plug (211) and putters (212) may be flying due to compression of the rebound spring (221). -
Page 545
Maintenance Manual──LG6210E Hydraulic Excavator Important! Use this plug the external edge of the well to remove it, and be careful not to damage the part due to the load. When removing, this plug will rebound as the spring (211). Pay attention to this. -
Page 546
Maintenance Manual──LG6210E Hydraulic Excavator Fig.223 Remove the bushing 14 To remove the pressure reducing valve, press the auxiliary pressure spring (241) and remove the spring (241) through the large hole of the spool (201). Important! Be careful not to damage the surface of spool. -
Page 547
Maintenance Manual──LG6210E Hydraulic Excavator 18 Remove the ring (213) from the plug (211) with a small screwdriver. Fig.228 Remove the sealing 19 Remove the bellows pipe(501), method is to pull the well from the top. Fig.229 Remove the bellow pipes 20 Remove the handle (402) cover. -
Page 548
Maintenance Manual──LG6210E Hydraulic Excavator and location on the handle. Fig.232 Remove the switch 23 Cleaning of parts: — Clean the remote control valve assembly with detergent to remove the accumulative thick dust. Important! Let the parts soak in detergent to soften the dirt. -
Page 549
Maintenance Manual──LG6210E Hydraulic Excavator • O-ring and prop ring will be replaced with a new one. • When fixing O-ring fixed, be careful not to damage it. • When assembling, coat the part with grease to keep it in place. -
Page 550
Maintenance Manual──LG6210E Hydraulic Excavator Note! Adjust the position of throttle plates, and make the spring pin (126) can enter the shell holes. Replace he gasket (121) with new ones. Fig.235 Remove the throttle plate Fig.236 Replace the new washer 4 Tighten screws (125) to the specified tightening torque. -
Page 551
Maintenance Manual──LG6210E Hydraulic Excavator spring (241) and install the spring (241) through the big holes of spool (201). Fig.239 Assemble the pressure reducing valve 7 Install the rebound spring (221) into the shell. Install the valve sub-assembly into the shell(101). -
Page 552
Maintenance Manual──LG6210E Hydraulic Excavator 10 Install the lever (212) on the plug (211). Important! Coat the surface of lever with oil. Fig.243Assemble O-ring Fig.244 Coat the lever with oil 1.Lever 3Plug 2.Lever 4.Use oil 11.Install sub-component assembly to the plug housing (101). -
Page 553
Maintenance Manual──LG6210E Hydraulic Excavator 13 Install metal plate (151). — E-tool part number: 8940—00200 Fig.247Assemble the metal plates 14 Tighten the connector (301) onto the housing with a clamp according to the specified torque. Fig.248 Tighten the connector 15 Assemble the disc (302) to the connector(301). -
Page 554
Maintenance Manual──LG6210E Hydraulic Excavator 17 Put the switch its base in the original position, tighten the screws. Fig.251 Assemble the switch 18 Place the handle cover, tighten the screws (431) with cap. Fig.252 Assemble the handle cover 19 Install the bellow pipe well at the bottom of the handle (402). -
Page 555
Maintenance Manual──LG6210E Hydraulic Excavator Fig.254 Assemble the handle and connector 21.Determine the direction of the handle, tighten the lock nut (315) to the specified torque. Fig.255 Assemble the lock nut 22.Coat the rotary part of conector, the plate and contact part of lever with grease. -
Page 556
Maintenance Manual──LG6210E Hydraulic Excavator However, failure is not always just caused by a faulty part, but because of the relationship between parts and other components. Therefore, it may be necessary to repair other parts that not listed in this table. -
Page 557
Maintenance Manual──LG6210E Hydraulic Excavator Type Hydraulic Stroke Operation force kgf·cm Safety Type Supply pipeline of servo-hydraulic is lock closed by safety lever and the solenoid valve. Remote control valve (pedal),instruction Remote control valve RCVD8C is the type of pressure reducing valve. Angle of controller is adjusted with the pedal or lever, and it is associated with the auxiliary the pressure to form output oil pressure proportional to the tilt. -
Page 558
Maintenance Manual──LG6210E Hydraulic Excavator Throttle output1:2 single type-1 series Throttle output2:4 single type-2series Throttle output3:4 single type-2 series Rotary digit Rotary number A, B, C— correction Basic functions Spool (301) connection guides the hydraulic oil from the throttle (P) from the hydraulic pump to the output throttle (2) or pipe of tank throttle (T).Auxiliary pressure setting… -
Page 559
Maintenance Manual──LG6210E Hydraulic Excavator Fig.258 Remote control valve (pedal), structure 101 housing 221retaining ring 337 spring 151 plug 223 bushing 412 bushing 201 cover 224 Pistons 413camshaft 202 plug 225 ball 420 cam 203 oil seal cap 271 screws 423set screws… -
Page 560
Maintenance Manual──LG6210E Hydraulic Excavator g.259 Remote control valve (pedal) Table51 Tightening torque ,unit:mm Dimension Tightening torque NPTF 1/16 70 ± 10 M 12 800 ± 100 70 ±10 M 10 340±35 Operation Remote control valve (pedal) is based on the hydraulic circuit diagrams and cross sections to illustrate, the graph is a typical application example of remote control valve. -
Page 561
Maintenance Manual──LG6210E Hydraulic Excavator Fig260. Remote control valve (pedal) diagram 1 remote control valves 4 control valves 2 servo-hydraulic motor 5 hydraulic pump 3 main pump 6 hydraulic column Neutral position Spool (301), spring seat (311) and gasket (215) is pushed into the front by rebound spring (335), and set in the position shown in cross section. -
Page 562
Maintenance Manual──LG6210E Hydraulic Excavator section. Operating position According to the following sections, pedal cam rotates clockwise, lever in the side of throttle 1 is pushed down. Oil in the damping piston is drained from oil draining nozzle, and was then suppressed by the generated pressure. -
Page 563
Maintenance Manual──LG6210E Hydraulic Excavator Therefore, the operator is pressed from the neutral position to fully operating position, or from operating position to the neutral position. Fig.262 Operate the pedal to the opposite direction Turn the rod back from → to···>, the left piston will be used. -
Page 564
Maintenance Manual──LG6210E Hydraulic Excavator Fig.263.Auiliary pressure and operating force Table52 Maintenance standard Item Standard Specification… -
Page 565
Maintenance Manual──LG6210E Hydraulic Excavator Conditions: Leakage Handle is in the neutral position: more than 1000 Basic pressure: ml per minute, kgf/cm When operating: more than 2000 ml per minute — Viscosity :23 cSt Spool When the wear between sliding surface and non-worn surface is exteeding 10mm, this part should be replaced. -
Page 566
Maintenance Manual──LG6210E Hydraulic Excavator • Before assembly, take measure for corrosion, so check whether the surface hs scratches, dents, or wear. Any damaged part should be replaced. Tool and tightening torque Table63.Tool and tightening torque Tool Specification,(m Component Component Screw Tightenin… -
Page 567
Maintenance Manual──LG6210E Hydraulic Excavator Fig.265 Fixture 2 (For the assembly of locking ring) Disassembly 1 Clean the servo hydraulic valves with detergent. — Use no hole plug to close all the throttles. 2 Fix hydraulic servo valve with vise of brass band. -
Page 568
Maintenance Manual──LG6210E Hydraulic Excavator Fig.268 Align the ends of cam 5 Remove the cam (420) as complete assembly with additional screw (471) and lock nut (472). — Record the relative position of its shell. Fig.269 Remove the cam 6 Remove the screw (271). Loosen each screw at the same time, keep the cover level. -
Page 569
Maintenance Manual──LG6210E Hydraulic Excavator 9 Remove the oil seal cap (203) and NHU package (210) from the plug. Record the relative positions between the plug and shell. Important! Note that the stopper may pop up because of elasticity of rebound spring. -
Page 570
Maintenance Manual──LG6210E Hydraulic Excavator 13 Pull out check balls with a magnet (225). Note! Note that the loss of check ball. Fig.277 Remove and removing the ball 14 Pull out the lock ring out from the shell (221)with the clamp pliers. -
Page 571
Maintenance Manual──LG6210E Hydraulic Excavator Fig.280 Remove the valve assembly and rebound spring 17 Put the cover (201) on a horizontal plate, and align the bushing with special tools. Tap with a hammer to pull out the bushing. Fig.281 Remove the bushing 18.Fix the cam assembly with the vise. -
Page 572
Maintenance Manual──LG6210E Hydraulic Excavator Sometimes, however,some washers are not installed before delivery. Fig.284 Remove the spool 21 Remove the grease seal cap (203) from the plug (202). — Note that don’t damage the surface of lever. Fig.285 Remove the grease seal 22 Remove NHU package (210) from the plug with a flat head screwdriver. -
Page 573
Maintenance Manual──LG6210E Hydraulic Excavator the humidity of the air. 25 Process all the parts with rust preventive: Important! If thes pars does not be promptly treated after washing, these parts will rust, and they will not function perfectly after re-assembly… -
Page 574
Maintenance Manual──LG6210E Hydraulic Excavator Fig.289 Assemble the washer 3 Assemble washer 1 (215), and prevent the sharp edge of the spool head being stuck. Important! Spring seat should not be pressed more than 4 mm. Fig.290 Assemble the limit washer A. -
Page 575
Maintenance Manual──LG6210E Hydraulic Excavator Fig.293 Assemble the washer 7 Install the bushing (223) on the spring seat (311) of the housing assembly. — Assemble it back to the original position. Fig.294 Assemble the bushing 8 Install the locked loop (221) into the hole of shell with a snap ring pliers carefully. -
Page 576
Maintenance Manual──LG6210E Hydraulic Excavator Fig.297 Assemble the check ball 11 Assemble the spring seat (218) inside the bushing. — Assemble it back to the original position. Fig.298 Press the spring seat 12 Assemble the damping spring (336) into the shell. -
Page 577
Maintenance Manual──LG6210E Hydraulic Excavator 15 Install O-ring(212) on the plug (202). Fig.302 Install O-ring 16. Install NHU package (210) scraper (211) and O-ring (212) into the plug (202). — Pay attention to the assembly direction of sealing and scraper. — Coat the seal and scraper with a thin coat of grease before assembly. -
Page 578
Maintenance Manual──LG6210E Hydraulic Excavator Fig.306 Assemble the lever 19 Install the lever above steps 13,14,15,16 into shell. Fig.307Assemble the sub-assembly of lever 20 Install the bushing (412) to cover (201) with special tool, and tap it gently to press it tightenedly. -
Page 579
Maintenance Manual──LG6210E Hydraulic Excavator Fig.310 Tighten the screw to the specified torque 23 Install the set screw (471) and lock nut (472) in the cam (420) temporarily. Fig.311.Assemble set screw (471) and lock 24 Install the cam (420) on the lid. -
Page 580
Maintenance Manual──LG6210E Hydraulic Excavator Fig.314 Use Loctite 27 Tighten the screw (423) to the rated torque. Fig.315 Tighten the screw 28 Adjust the height of set screw (471) to make the upper surface of cam and the below surface of cover parallel.After the gap of lever is «0», tighten the lock nut… -
Page 581
Maintenance Manual──LG6210E Hydraulic Excavator 31.If bellow pipe is inserted incorrectly or twisted, anti-rust protection will be greatly reduced. Fig.319 Assemble the bellow pipe Remote control valve (pedal) Troubleshooting To find fault is not always smooth. Some of the general phenomenon that should be considered are listed in the table below. -
Page 582
Maintenance Manual──LG6210E Hydraulic Excavator • Repeat the operation several • The working chamber of piston has air. times in order to exhaust the air. clamping. • Sliding parts is stuck. • Repair or replace stuck parts. • Damping springs (336,337) have •… -
Page 583
Maintenance Manual──LG6210E Hydraulic Excavator Pin of boom cylinder End pin of bucket arm cylinder linkage Pin of bucket arm cylinder Coupling pin of boom-bucket arm End pin of bucket arm cylinder linkage Pin of bucket cylinder Coupling pin of linkage-bucket arm… -
Page 584
Maintenance Manual──LG6210E Hydraulic Excavator attachment should be maintained every 10 hours, or carry out daily maintenance. Note! Lubrication period will be affected to external working conditions. When there is abnormal sound, lubricate the pin and bushing with grease as soon as possible. -
Page 585
Maintenance Manual──LG6210E Hydraulic Excavator Note! Coat the screw(13)of sealing cover(5) with » card 1360K» fixative (or similar production). Cylinder includes cylinder cylinder column (1), the piston (10) which does reciprocating motion, piston linkage (3) following the piston and the cover (5) that plays the role of guiding. -
Page 586
Maintenance Manual──LG6210E Hydraulic Excavator Fig.325 Washer action of linkage A Chamber T hydraulic tank C Washer ring 5 Cover D Air breaking 7 pad ring Washer of piston side As the same with the construction of the washer of linkage… -
Page 587
Maintenance Manual──LG6210E Hydraulic Excavator Fig.326 Washer action of the piston side 9 Pad plunger A air break T Hydraulic tank Cylinder, disassembly and assembly Notes • When re-installing a fuel tank, it is important to empty the fuel tank of gas. -
Page 588
Maintenance Manual──LG6210E Hydraulic Excavator • Lateral load (bending) of cylinder or over-vibration can damage dry bearings of fuel tank, seals of brush plate and linkage chrome plate, resulting in oil leakage and the impurities may go into it. • High-pressure hose may take dirt and contaminated water into the sealing lip of brush plate, leading to the impurities into the fuel tank. -
Page 589
Maintenance Manual──LG6210E Hydraulic Excavator Pressed into the dust jacket for. Rust preventive Sandpaper Measurement gauge Sliding caliper Micrometer Hydraulic Table V — shaped valve block Special tool Sealing of anti-dust brush plate Table59. Sealing of anti-dust brush plate,unit:mm Cylinder Component No. -
Page 590
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm 8920 — 01110 83 10 Bucket 8920 — 00260 69 10 Fig.328 Guide of seal cover, specification Dry bearing cylinder(Sealing washer) Table61. Guide of seal cover,unit:mm f A f B Cylinder Component No. Boom 8920 — 00290 70.5 15… -
Page 591
Maintenance Manual──LG6210E Hydraulic Excavator Fig.329 Dry bearing cylinder, specification Bushing clamp cylinder Table62.Bushing fixture cylinder,unit:mm Cylinder Component No. Boom 8920 — 01150 47.5 Bucket arm 8920 — 01150 47.5 Bucket 8920 — 01150 47.5… -
Page 592
Maintenance Manual──LG6210E Hydraulic Excavator Fig.330 Bushing fixture cylinder, specification Preparation before disassembly Spacious workplace To remove the cylinder, cylinder head and the piston rod must be fully extended. Therefore, the most important prerequisite is that the workplace must have enough space for such operations. -
Page 593
Maintenance Manual──LG6210E Hydraulic Excavator leakage of oil. For this reason, avoid grinding and welding operations in the workplace, in order to keep the venue clean. Crane and Crane Cranes and crane must be capable of lifting cylinder in the assembly state. They must also be able to be move straight under load to insert or pull out the piston rod. -
Page 594
Maintenance Manual──LG6210E Hydraulic Excavator Note! Presented cylinder is heated type, but, during the demolition and maintenance of cylinder components, you should check the structure of the cylinders. Draining oil Put the wedge on the table to support the cylinder, clamp it with fixtures to prevent its rotation. -
Page 595
Maintenance Manual──LG6210E Hydraulic Excavator Fig.333 Piston rod,removing 1 Cylinder 2 Hanging wire 3 Piston rod 3 Remove the piston assembly from the cylinder rod. 1 Remove the set screw and clamp ball from the piston nut. 2 Remove the piston nut, then remove the piston assembly, cushion plunger and cylinder head assembly. -
Page 596
Maintenance Manual──LG6210E Hydraulic Excavator Note! If the gasket is not damaged, do not remove it. If the assembly should be removed , replace it with a new gasket. Inspection after the demolition Firstly clean it, then check whether there are wear, cracks and other problems on the components with naked eye all parts. -
Page 597
Maintenance Manual──LG6210E Hydraulic Excavator Seal cover of Bushing Internal surface ,wear Replace cylinder Internal surface ,wear If the wound is deep into the subsurface, it is needed to be replaced. Repair methods Check all seals and components, to see whether there is excessive damage or wear. -
Page 598
Maintenance Manual──LG6210E Hydraulic Excavator the dial gauge reading ×1 V-blocks Replace Important! If the bending is within the above limit,cylinder will not operate smoothly due to the bending. During the functional test after the assembly, you should pay special attention to this point. If the cylinder is making an unusual sound or can not operate smoothly, you should replace the Fig.338 Removing sharp corners… -
Page 599
Maintenance Manual──LG6210E Hydraulic Excavator 3 Install the seal to pay attention to its direction. Fig.341 Degraded seal assembly 1 Damp ring 2 Prop ring 3.Linkage package 4 Install the connecting rod package to pay attention to its direction. Fig.342 Assembling connecting rod package… -
Page 600
Maintenance Manual──LG6210E Hydraulic Excavator Fig.344 Seal of dust brush plate ,assembly 1 clamp 2 Seal of dust brush plate 7 Install retaining ring (1) into the sealing cover. Note! Use the brass, aluminum or plastic clamp, be careful on the sharp corner of the clamp. If possible, insert the package with hands but not clamp. -
Page 601
Maintenance Manual──LG6210E Hydraulic Excavator 9．Coat the position A of the piston with hydraulic fluid. Fig.349 Coat with hydraulic 10．Install the pad ring into the central pipes of piston. (Piston package kit includes a pad ring). Fig.350 Assemble pad ring 11. Assemble piston package on the pad ring.. -
Page 602
Maintenance Manual──LG6210E Hydraulic Excavator Fig.352 Piston ,assembly 1 O-ring 4 gasket ring 2 ring wear 5 piston package Piston rod and bushing, replacement 3.Anti- impurities seal Important! If it is necessary to replace the bushing, use the same method in the figure of to remove the bushing, replace it with the new one. -
Page 603
Maintenance Manual──LG6210E Hydraulic Excavator Fig.356 Cylinder, assembly A Grease gun with a muzzle 2 Column Piston rod assembly and seal cover 19 piston rod installed in the table, careful not to damage the chrome rod sliding surface. 20 pieces of lead with a sealing cap to the piston rod will be installed on the closures. -
Page 604
Maintenance Manual──LG6210E Hydraulic Excavator Note! Tighten the set screw to the specified torque. • Tighten: 1.0±0.2 kgf · m Fig.360 Tightening the piston 1 Seal cover 3 lock nut 5 piston 7 set screw 2 lock washers 4 pad ring 6 clamp ring Cylinder piston rod and cylinder 27 Insert the piston rod assembly into cylinder. -
Page 605
Maintenance Manual──LG6210E Hydraulic Excavator Cylinder with cushion valve 28 Assemble plunger assembly and lock pin in the terminal of piston rod. — Make the hole of lock pin up and install the lock pin. Fig.363 cushion plunger assembly 1 plunger pad 4 piston… -
Page 606
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 365 Gap limit Inspection after assembly No-load function test Put the cylinder horizontally without loading. Important! Do not increase the hydraulic oil pressure to the maximum pressure of the machine. Note! Grease on the O-ring seals and cover may overflow. -
Page 607
Maintenance Manual──LG6210E Hydraulic Excavator Leakage through the • Drilling has impurities. • Remove impurities. package sliding surface of the • Internal surface, • Replace packages. piston rod. (Form the external surface and oil ring on the piston package edge pieces rod and drop out). -
Page 608
Maintenance Manual──LG6210E Hydraulic Excavator Sliding surface of seal kit in order to avoid sliding ring.contains duplication because impurities. different parts of life care. • replacement of the slip Other abnormalities of ring. sliding ring. 5.2 Boom with a linkage (See Overview… -
Page 609
Maintenance Manual──LG6210E Hydraulic Excavator metal plate screws screw screws pring washer spring washer general gasket Dustproof sealing bushing Table66.Gap and washer(mm) Item Necessary washer Position Washer Quantit Washer Quantity No.(1.0t) No.(0.5t) Gap1 +0.25 +0.9 1173-0369 Gap2 +1.0 +2.5 1173 — 01630… -
Page 610
Maintenance Manual──LG6210E Hydraulic Excavator Rear bushing of boom 80 ×2 Bucket arm cylinder pipe Boom cylinder linkage 160 × 2 Boom cylinder pipe 15× 2 Note! Oil hose / air bearing are included. Boom, removing 1. Retract the boom cylinder, and lower the boom to the ground. -
Page 611
Maintenance Manual──LG6210E Hydraulic Excavator control lever when the key is still in the ignition switch —«ON position to release the remaining pressure. 6.Put the boom cylinder on the valve block (A), disconnect the hose (32). Then, plug the port of hose and cylinder throttle. -
Page 612
Maintenance Manual──LG6210E Hydraulic Excavator stall the boom Boom cylinder Boom cylinder, specification (Refer to Overview) Description of boom cylinder Refer to instructions of cylinders. Fig.375 Boom lifting cylinder (single washer) 1 column 8 retaining ring 15 seals wiper 22 O-ring… -
Page 613
Maintenance Manual──LG6210E Hydraulic Excavator 3 After starting the engine, align the hole of boom cylinder rod and pin on a straight line. . 4 If they are aligned, push the pin (31) from the opposite side of boom with the hammer. Install lock hoop (31) and screws (28). -
Page 614
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 377 Wear limit Table.68.Tightening torque,unit: kgf·m （lbf·ft） Piston Locking Screw Set screw nut,tightenin nut,tightening g closewise counterclosewi M 64 M 60 M 16 1.0 ± 0.2 35 ±5 15±3 26.7 ±2.7 Note!Before tightening,use（Three Bond）1360K or Lottile #242 on the linkage an thread. -
Page 615
Maintenance Manual──LG6210E Hydraulic Excavator Table70. Wear limit:mm Item Standar Allowed error Standard d value limit Hole Gap between linkage and bushing(1) 80 — 0.030 -0.195~ — 0.090~ 0.57 0.060 0.271 Gap between linkage pin and ~ 0.076 -0.168~-0.0 0.180~0.3 bushing(2) Gap between rear pin and — 0.030… -
Page 616
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 379 Bucket small structure 1.Pin with lock cover 7 Dustproof seal 13Screws 2.Pin with hole 8 Washer 14.Nut 3. Pin with base 9. Washer 15.Spring washer 4. Metal plates 10.Washer 16.Bushing 5. Dustproof seal 11.Washer 6.Dustproof seal… -
Page 617
Maintenance Manual──LG6210E Hydraulic Excavator Gap2 +0.5 +2.5 1173 — 01210 1173 — 01330 Gap3 +0.5 +2.5 1173 — 01210 1173 — 01330 Note!Gap1:Max0.5mm Note!Other:Max1.0mm Table72 Initial lubricating table Gun nozzle Initial grease volume Position Boom bearing(left) Bucket arm cylinder pipe… -
Page 618
Maintenance Manual──LG6210E Hydraulic Excavator 2 Align the boom with the pin hole of bucket arm. Insert pin (20), install the lock plate (19). 3 Stretch the bucket arm cylinder (18), and align it with pin hole of linkage in a straight line. -
Page 619
Maintenance Manual──LG6210E Hydraulic Excavator volume Bucket arm cylinder pipe 12 ×2 Connection linkage+ Yoke 12× 2 Connection linkage+ Bucket Note! Oil hose / air bearing are included. Linkage, removing 1 Lower terminal of bucket arm to the ground. 2 Make sure that bucket arm cylinder is fully retracted, remove locking screw of the pin (7). -
Page 620
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm cylinder Bucket arm cylinder, Specifications (Refer to Overview) Bucket arm cylinder, Description See instructions of cylinder Fig.386 Bucket arm cylinder (with two washers) 1 column 7 retaining ring 13.screw 19 prop ring 25 impurity-proof seal… -
Page 621
Maintenance Manual──LG6210E Hydraulic Excavator 6 Remove the bucket arm cylinder. 7 When disconnecting the hose (22), close the port of the hose with the sealing cap, and then plug the cylinder throttle (24), and tie the hose on the pipelines firmly. -
Page 622
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm cylinder disassembly and assembly Note See cylinder disassembly and assembly, Page General Tools See cylinder disassembly and assembly, Page Special tools See cylinder disassembly and assembly, Page Tightening torque Fig. 391 Tightening torque Table 75 Tightening torque, unit: kgf · m… -
Page 623
Maintenance Manual──LG6210E Hydraulic Excavator Leakage volume of hydraulic oil Table76. Leakage of hydraulic oil Leakage volume of inner hydraulic oil 6.0cc every 10 minutes Wear limit Fig. 392 Wear limit Table77. Wear limit:mm Item Standar Allowed error Standard d value… -
Page 624
Maintenance Manual──LG6210E Hydraulic Excavator See cylinder disassembly and assembly Inspection after assembly See cylinder disassembly and assembly Bucket arm Cylinder Troubleshooting See cylinder troubleshooting, page Bucket cylinder Bucket removing 1 Put the excavating device down to make the bucket on ground fully. -
Page 625
Maintenance Manual──LG6210E Hydraulic Excavator Bucket, installating 1 Place the bucket on a flat solid ground. 2 Insert seal ring (6). Align the hole of bucket pin and bucket arm in line. 3 Insert the pin (5), tighten the screw of cap. -
Page 626
Maintenance Manual──LG6210E Hydraulic Excavator Note! After removing all gaskets ,the required gap has not yet been reached, and replace the old bushing with a new one (B). Important! Bucket clearance standard (D) 0.5~2.0 mm (0.02 ~ 0.08 in) Important! Use a synthetic agents or anti-jam grease to lubricate the outside diameter of bushing (B). -
Page 627
Maintenance Manual──LG6210E Hydraulic Excavator Bucket cylinder, removing WARNING! When the engine is running, hydraulic pipelines are under high pressure. Turn off the engine, release the residue pressure by operating the operation lever. 1 Tie the linkage on the cylinder with a cable. -
Page 628
Maintenance Manual──LG6210E Hydraulic Excavator Tightening torque Fig.399 Tightening torque Table 78 Tightening torque, unit: kgf · m Piston nut,tightening Locking nut,tightening Screw Set screw closewise counterclosewise M 64 M 60 M 16 1.0 ± 0.2 35 ±5 15±3 26.7 ±2.7 Coat the screw (13 )of seal cover(5) with «… -
Page 629
Maintenance Manual──LG6210E Hydraulic Excavator Table80.Wear limit:mm Item Standard Allowed error Standard value limit Hole Gap between linkage and -0.036~0.09 -0.195~0.06 0.090~ 0.58 bushing(1) 0.271 Gap between linkage pin -0.030~0.09 -0.257~0.17 0.206 and bushing(2) ~0.347 Gap between rear pin and -0.030~-0.07 -0.168~-0.07… -
Page 630
Maintenance Manual──LG6210E Hydraulic Excavator 6. Optional equipment (Hydraulic work; servo-hydraulic) 6.1 Hydraulic equipment is installed on the machine for additional equipments. 6.1.1Other hydraulic system Hammer and scissors (select X1),Description Hammer and hydraulic shear equipments includes a single pedal, hydraulic shear and crush hammer selector valve, oil flow control valves, solenoid valves, shuttle valve and hoses and other devices. -
Page 631
Maintenance Manual──LG6210E Hydraulic Excavator Fig.402 Hammer and scissors (select X1),pipe paving(2) Table81 Throttle connection Component Throttle Component Throttle Instructio Main control Shruttle device(59) valve(2)(ViewA,B) Servo hydraulic selector valve(33’) Shruttle device(59) Servo hydraulic Main control valve(2) selector valve(ViewA) Valve block of accumulator(9) -
Page 632
Maintenance Manual──LG6210E Hydraulic Excavator Shruttle device(60) Hydraulic tank(21) Valve block Solenoid valve(41,43) (31)-Detailed view C Rod(14) Solenoid valve(41,43) X1 penal (42) Rod(14) Logic valve Hydraulic tank(21) (46)-Detailed view E Shruttle device(60) X1 penal Shruttle device(60) (42)-Detailed view F Shruttle device(60) -
Page 633
Maintenance Manual──LG6210E Hydraulic Excavator X1 penal (42) Solenoid Valve block (31) valve(11)-Detailed Main control valve(2) viewN Central channel(17) Valve block of accumulator(9) Valve block of accumulator(9) Hydraulic tank(21) Solenoid valve(11) Valve block of Main control valve(2) accumulator(9) Solenoid valve(11) -Detailed viewO… -
Page 634
Maintenance Manual──LG6210E Hydraulic Excavator Proportional solenoid valve, instructions Proportional solenoid valve (X1 double switch) Fig.403 Solenoid valve (X1 double switch) A valve 8 solenoid coil 2 spools – B 9 screws 3 springs — C 10 O-ring 4 plug 11 O-ring… -
Page 635
Maintenance Manual──LG6210E Hydraulic Excavator Description of the solenoid valve X1, 3-section solenoid valve Fig.404 X1, 3-section solenoid valve… -
Page 636
Maintenance Manual──LG6210E Hydraulic Excavator X12 pipeline of pump Fig. 405 Hammer and shears (1) 2 pump oil flow pipe, laying A servo-hydraulic selector valve (40) C shuttle device (59) B 2 pump oil flow solenoid valve (43) D hydraulic tank… -
Page 637
Maintenance Manual──LG6210E Hydraulic Excavator Shruttle device(59) Hydraulic tank(21) Servo hydraulic selector valve(33’) Solenoid valve(12) Main control valve(2) Hydraulic tank(21) Proportional solenoid valve Fig.406 Hammer and hydraulic shear proportional solenoid valve Table84. Proportional solenoid valve,specification Instruction Unit Specification Max. Working pressure… -
Page 638
Maintenance Manual──LG6210E Hydraulic Excavator Hammer and hydraulic shear selecting solenoid valve Fig. 407 Hammer and hydraulic shears (1) solenoid valves A valve 9 DC solenoid valve 2 spool 10 solenoid coil 3 locator-A 11 O-ring 4 locator-B 12 O-ring 5 gasket… -
Page 639
Maintenance Manual──LG6210E Hydraulic Excavator Max. Working pressure kgf/cm Operating flow L/min 50 kgf/cm cc/min And 20 cSt Oil temperature ºC -20 ~ 9 Viscosity range 5 ~ 500 Power source D28G Normal voltage Normal current DC 28 V and 20ºC .it is 1.0 Hammer and shears with 2 pump oil flow pipe (2) Fig.408 Hammer and hydraulic shears solenoid valve (2) -
Page 640
Maintenance Manual──LG6210E Hydraulic Excavator Table 86 Specifications, the solenoid valve (2) Instruction Unit Specification Max. Working pressure kgf/cm Operating flow L/min Max. pressure loss kgf/cm Allowed back pressure of T Throttle kgf/cm kgf/cm —20 cSt cc/min Oil temperature ºC -20 ~ 90… -
Page 641
Maintenance Manual──LG6210E Hydraulic Excavator X1 logic valve Figure 410 X1 logic valve 1 valve body 10 plug 2 Tailstock 11 spools 3 tailstock 12 springs 4 spring 13 O-ring 5 O-ring 14 cover 6 O-ring 15 screws 7 prop ring 16 plug… -
Page 642
Maintenance Manual──LG6210E Hydraulic Excavator PF 1 33 ± 2 PF 3/8 Check valve Fig.411 Check valve, position 1.Use for shearing, crushing, hydraulic shear ,tilt and hammer 2.No use. 6.2 Machinery Equipment / Additional Equipment Additional base, mechanical and hydraulic quick-mount… -
Page 643
Maintenance Manual──LG6210E Hydraulic Excavator load increases, and the operator’s vision is also greatly improved. The quick installation accessories are equipped with double actuated cylinder. Quick locking wedge (4) is mounted on the piston rod. Servo pressure acts on the piston side of the lock cylinder, and lock the bucket on the rear hook(5). -
Page 644
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 413 Quick Installation,pin 1. pin with locking cover 3 nut 2 screws 4. 2 mm gap ( nut and locking parts) Table90.Gap and washer Position Gap(mm) Necessary washer of max.gap Washer No.(1t) Washer No.(0.5t) Gap1… -
Page 645
Maintenance Manual──LG6210E Hydraulic Excavator Fig. 414 Quick installation, pipeline on the boom and bucket rod 1 rubber clip 2 Quick installation valve 3 Hose assembly (connected to the quick installation cylinder A) 4 Hose assembly (connected to the quick installation cylinder B) -
Page 646
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 647
Maintenance Manual──LG6210E Hydraulic Excavator Fig.416 Quick installation, the pipeline of the basic machine 1 to the main control valve ‘Y’ 5 to the valve block (1)’ P6 ‘ 2 to the return pipe ‘t1′ 6 Quick installation valves’ PS’ 3 to solenoid valve (2) ‘P1’… -
Page 648
Maintenance Manual──LG6210E Hydraulic Excavator Check the position of locking wedge, and the position of tool accessories on the board. Then calculate the adjustment of gasket; If the locking wedge inserts into the hook too long ，put thick gaskets. Fig.418 Tool Accessories, Adjustment… -
Page 649
Maintenance Manual──LG6210E Hydraulic Excavator 7 Troubleshooting (Working hydraulic, servo hydraulic) Troubleshooting diagnostics procedures If the small fault does not rule out and continue to operate,it may cause serious problems to spend more costs and a lot of time to repair. Therefore, don’t neglect the small fault, and don’t only rely on self-intuition and… -
Page 650
Maintenance Manual──LG6210E Hydraulic Excavator Learning machine equipment technical manual. Understand the system components, how to work and its structure, function, and the specification of the system. — Use the troubleshooting tables and hydraulic charts to solve the problem! Fig.420 Study the system. -
Page 651
Maintenance Manual──LG6210E Hydraulic Excavator If you can not determine the reason of failures, shut down the motor, and further understand the details of the failure to the operator. — After the repair, operate the machine personally, confirm that the failure has been removed. -
Page 652
Maintenance Manual──LG6210E Hydraulic Excavator Remove dustproof plugs under the motor flywheel, check whether the rubber pieces or parts are still there. Coupling element is damaged, remove and replace. Rack /spline of coupling component is worn or screws are loose. Replace coupling assembly and tighten the… -
Page 653
Maintenance Manual──LG6210E Hydraulic Excavator Whether replacement internal of hydraulic oil is timely implemented? Drop some oil on the hot plate, check whether there are bubbles. Water is mixed with oil. Hydraulic oil is mixed with other brands? Is only one brand of hydraulic oil. -
Page 654
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic oil level is correct? Hydraulic oil cooler is blocked? Whether there are objects blocking the air circulation? Clean hydraulic oil cleaner. Ensure air circulation pipe is not blocked. Hydraulic oil cooling fan speed is within the specified value? Check and close release pressure, re-adjust or replace relief valve. -
Page 655
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic oil level is correct? Hydraulic oil viscosity is too high? Replace hydraulic oil with the appropriate viscosity. Pumping mesh is blocked? Clean pumping mesh. Check whether there are air intruding the pump pipeline? Check whether there are air intruding the pumping pipeline? Re-adjust the set pressure. -
Page 656
Maintenance Manual──LG6210E Hydraulic Excavator Table 95 Hydraulic oil with impurities Hydraulic oil is used more than the required replacement time? Replace hydraulic oil and filters. If conditional, clean the hydraulic system. The oil filter is replaced at the right time? Replace hydraulic oil and filters. -
Page 657
Maintenance Manual──LG6210E Hydraulic Excavator Servo-hydraulic pressure is applied to the servo chamber of master valve? Repair or replace master valve. Filter of control valve connector is clogged? Clean the connector filter. If the servo-hydraulic pipes of remote control valve is changed with the pipes of a operating circuit, whether the system has movement Repair or replace the remote control valve. -
Page 658
Maintenance Manual──LG6210E Hydraulic Excavator Check whether the remote control valve is operating properly. Repair or replace master valve. Repair the cylinder seal of mining equipment. Repair or replace remote control valve. Table 98 The movements of digging devices is too slow… -
Page 659
Maintenance Manual──LG6210E Hydraulic Excavator Whether its speed is slow only combined with other movements ? Normal Speed is within the specified value? The confluence of oil flow is normal when boom raises and stick extends? Digging speed is within the specified value? -
Page 660
Maintenance Manual──LG6210E Hydraulic Excavator Table 99 When operating the operation lever , the cylinder doesn’t work. 1Check whether the left side of control box is lowered (unlocked position). Check whether the safety limit switch is working well. Check whether servo hydraulic pressure of the servo solenoid valve throttle Pi is at the required pressure. -
Page 661
Maintenance Manual──LG6210E Hydraulic Excavator 2.When operating stem of remote control valve, the sound of motor have changed? Hydraulic oil level is too low? Add hydraulic oil. Check whether the main pumping Repair the main pumping throttle. throttle has air. Pumping mesh is blocked? Clean the mesh. -
Page 662
Maintenance Manual──LG6210E Hydraulic Excavator Whether all the actuators can not provide tap power? There is abnormal sound in pump? Hydraulic oil level is too Fill hydraulic oil fully. low? Are the pumping oil pipeline Repair pumping oil open? pipeline. Pump is abnormal or pumping mesh is blocked . -
Page 663
Maintenance Manual──LG6210E Hydraulic Excavator Power transmission example Table102 Rotation is not smooth Rotation only is not well? Only one direction of rotation is not working well? Left and right servo hydraulic hose change Check the spool of with each other failure phenomena is control valve . -
Page 664
Maintenance Manual──LG6210E Hydraulic Excavator Lubrication of swing ring and pinion gear is normal? Lubrication of bearings is normal? Rotary release valve is with unusual sound? Disassemble and repair or replace. Check whether the rotary piston is stuck or bearing is worn out? Rotary motor is faulty. -
Page 665
Maintenance Manual──LG6210E Hydraulic Excavator Except for the rotation, all other functions are normal? Pressure of remote control valve throttle 2 and 4 are normal? Input of the rotary motor has obtained normal pressure? Rotary park brake release valve throttle Pg can obtain normal… -
Page 666
Maintenance Manual──LG6210E Hydraulic Excavator Steering can not be done on the slope. Rotation speed is too slow. Is there turning power in a direction? Steering right to accelerate and steering left to brake is not right, steering left to accelerate and steering right to brake is not rightis not correct. -
Page 667
Maintenance Manual──LG6210E Hydraulic Excavator Are all work equipments too slow? Check whether the oil supply of Repair or replace the main main pump is normal? pump. Whether it is smooth within the Repair replace traveling central channel? motor . Replace seal of steering knuckle . -
Page 668
Maintenance Manual──LG6210E Hydraulic Excavator One side of the steering force is too weak. No acceleration, but braking force is normal. The limit of pressure mainrelief valve limits are the same? Whether there arehigh / low gear on the right and left sides ? Please refer to the running motor . -
Page 669
Maintenance Manual──LG6210E Hydraulic Excavator After turning off the motor, this phenomenon is still there? Output pressure of remote control valve is not adjusted correctly. Repair or replace the remote control valve. Replace the throttle valve with the throttle valve of a normal actuator , the problem goes away? Replace throttle release valve. -
Page 670
Maintenance Manual──LG6210E Hydraulic Excavator The interpretation of the hydraulic schematic Symbol Sign Interpretation Pipeline Servo pipeline/guide pipeline Pipeline connection Cross pipeline no connection Inserted connector Quick connection(Such as ,pressure test connector) Limit device Limit device, tiny viscous control Adjustable limit device… -
Page 671
Maintenance Manual──LG6210E Hydraulic Excavator Mechanical with spring,spring in neutral position, rebound spring Electromagnetic control(One coil) Hydraulic control Hydraulic control,2 pressure grades Control by hydraulic pressure reducing Gas control Control by gas pressure reducing Power source Gas engine Electrical motor Pump… -
Page 672
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic motor, fixed displacement and single direction Hydraulic motor, fixed displacement and double- direction Cylinder Single acted cylinder,return stroke by the spring Double cylinder, single piston rod(The side of piston is named as “Positive”, and the side of piston rod is named as “Positive”… -
Page 673
Maintenance Manual──LG6210E Hydraulic Excavator Close valve/invention device Application Schematic symbols shows pipeline connections, process line and functions of system components,but that doesn’t note the design of the components. Fig.425 Valve sign Note! In the hydraulic diagram, the symbol of valve is always drawn at the middle position of the valve. -
Page 674
Maintenance Manual──LG6210E Hydraulic Excavator The position that the piston moves outward Through the piston rod, sliding devices are affected, so that the positive side of cylinder is connected to the import, at the same time the negative side is connected to the tank. -
Page 675
Maintenance Manual──LG6210E Hydraulic Excavator Pump Deny control signal throttle Deny control signal throttle-P2 Pump Rapid pairing of gauge throttle Rapid pairing of gauge throttle Signal throttle of power shift valve Rapid pairing of gauge throttle Basic pressure throttle of power… -
Page 676
Maintenance Manual──LG6210E Hydraulic Excavator Swing throttle(Right) Selecting throttle Selecting throttle Swing servo hydraulic throttle(Turn left) Swing servo hydraulic throttle(Turn right) Option(X1)shruttle valve block Option(X1)shruttle valve block Boom descending —servo hydraulic throttle Signal throttle of boom lock valve Boom servo hydraulic throttle… -
Page 677
Maintenance Manual──LG6210E Hydraulic Excavator Bucket arm —oil regeneration valve throttle Switch Pressurized servo hydraulic throttle-Main Auto slow down pressure source(Travelling) Switch Auto slow down pressure source(Excavating unit) Pressure source of moving straightly Bucket arm confluence throttle Option 2 phrase-signal throttle of… -
Page 678
Maintenance Manual──LG6210E Hydraulic Excavator Check valve(3k) Check valve(4k) Input throttle of swing motor(Turn right) -AL1 Input throttle of swing motor(Turn left) Replacement throttle of swing motor Release signal throttle of swing brake valve Release pressure source of swing brake valve… -
Page 679
Maintenance Manual──LG6210E Hydraulic Excavator block of Input throttle of accumulator accumula Basic pressure throttle of safety solenoid valve Pressure source of moving straightly and auto slow-down signal Release pressure source of swing brake valve Pressure source of proportional valve Option 2 phrase-signal throttle of… -
Page 680
Maintenance Manual──LG6210E Hydraulic Excavator Pressure source of emergency control valve Boom confluence cuts off the auxiliary pressure of solenoid valve input throttle Bucket armconfluence cuts off the auxiliary pressure of solenoid valve input throttle Oil draining port Re mote Servo hydraulic throttle of swing… -
Page 681
Maintenance Manual──LG6210E Hydraulic Excavator Oil return throttle of hydraulic tank Re mote Left traveling throttle(Forward) control Left traveling throttle(Backward) valve(Pe Right traveling throttle(Forward) nal) Right traveling throttle(Backward) Pressure source of remote control valve Oil return throttle of hydraulic tank Shruttle… -
Page 682
Maintenance Manual──LG6210E Hydraulic Excavator (bucket descending) Auxiliary pressure source of bucket descending Auxiliary pressure source of bucket hitting solenoid valve Auxiliary pressure input throttle(boom) Auxiliary pressure source of bucket Pressure source of boom confluence Signal throttle of bucket arm semi-parallel valve Central Left track throttle（Forward）… -
Page 683
Maintenance Manual──LG6210E Hydraulic Excavator Fuel tank-oil return Fuel tank-oil return Fuel tank-oil return Oil draining filter Oil return filter element Bypass valve BDCA Draining Oil draining of pump filter Oil draining of motor Oil leakage Fuel tank-oil return Valve Pressure input of auto… -
Page 684
Maintenance Manual──LG6210E Hydraulic Excavator control valve(Left) Basic pressure source of remote control valve(hammer and hydraulic shear throttle) Fuel tank-oil return Fuel tank-oil return(hammer and hydraulic shear throttle) Fuel tank-oil return (thumb bucket) Fuel tank-oil return (Remote control valve-right operation lever) -
Page 685
Maintenance Manual──LG6210E Hydraulic Excavator Signal throttle of boom confluence disconnected Signal throttle of bucket lock valve releasing Hydraulic diagram, neutral Servo-hydraulic circuit (Safety lock lever is in the unlocked position) Servo-hydraulic pressure circuit Oil drained by drive gear pump goes into the following… -
Page 686
Maintenance Manual──LG6210E Hydraulic Excavator In the negative pressure control circuit of pump P1, oil from the control valve throttle FI goes into the throttle Pi1 (FI) of the pump. In the negative pressure control circuit of pump P2, oil from the control valve throttle FI goes into the throttle Pi2 (Fr) of the pump. -
Page 687
Maintenance Manual──LG6210E Hydraulic Excavator 17 central channel 66 moving straight conversion valve 18 hydraulic oil cooler 67 Central bypass valve 19 check valve (3 k) 68 foot pressure reducing valve 20 check valve (4.5k) 69 throttle pressure reducing valve 21 hydraulic tank… -
Page 688
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 689
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, bucket arm retracted confluence • When the control handle (13) is operate to «Bucker arm withdrawing», the auxiliary hydraulic servo oil flow from the remote control valve flows to the throttles (AI1, AI2, A3 ,2-a)on the shruttle valve blocks (16) . -
Page 690
Maintenance Manual──LG6210E Hydraulic Excavator • When oil supply is sufficient, oil regeneration valve (70) is pushed right and the oil return circuit is not limited. • When the engine is running at low speed, or oil flow is not enough due to the combination of action. In this case, oil regeneration valve (70) is pushed to the left, the oil return circuit is limited. -
Page 691
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 692
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, bucket arm extends • When the control handle (13) is operate to «Bucker arm withdrawing», the auxiliary hydraulic servo oil flows from the remote control valve flows to the throttles (AO1, AM)on the shruttle valve blocks (16) . -
Page 693
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 694
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, bucket arm withdraw / boom up The operations that the bucket arm retracts and the boom rises work at the same time. (Priority and precision control) • When the control handle (13) is operate to «Bucker arm withdrawing», the auxiliary hydraulic servo oil flows from… -
Page 695
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 696
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit,swing (turn left) • When the control handle (13) is operate to » turn left «, the auxiliary hydraulic servo oil flows from the remote control valve flows to the throttles (SL1, SW)on the shruttle valve blocks (16) . -
Page 697
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 698
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, rotating priority (turn right / bucket retracting) • When the control handle (13) is operate to»turn right» and «Bucket retracting», the auxiliary hydraulic servo oil flows from the remote control valve flows to the throttles (SR1, SW, AI1, AI2, AM)on the shruttle valve blocks (16) . -
Page 699
Maintenance Manual──LG6210E Hydraulic Excavator Color of pipeline index High-pressure oil Blue Low-voltage, servo-hydraulic basic pressure oil Brown Servo-hydraulic auxiliary oil Green Oil draining circuit, pump absorbs the hydraulic… -
Page 700
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 701
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, moving straight (low shift / automatic shift) • When two walking pedal (15) are operating to «FORWARD » position, the auxiliary servo hydraulic oil flow from the remote control valve is sent as the following line:… -
Page 702
Maintenance Manual──LG6210E Hydraulic Excavator inner main control valve with internal is used to control moving straight valve. • Travel motor is used to brake, to prevent air bubbles, automatic transformation of low / high-speed, and to prevent overspeeding. • In walking, the main booster is done automatically by the controller. -
Page 703
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 704
Maintenance Manual──LG6210E Hydraulic Excavator Hydraulic circuit, moving straight/Bucket arm (automatic shift,bucket arm withdraws) • When left/right walking pedals (15) are operating to «FORWARD » position, the auxiliary servo hydraulic oil flows to the throttle (2-br3) and (2-br4) of the remote control valve. -
Page 705
Maintenance Manual──LG6210E Hydraulic Excavator… -
Page 706
Maintenance Manual──LG6210E Hydraulic Excavator Ⅹ Electronic and information system(Guide) Electronic system; warning system; information system; gauges and instrument 1 Overview 1.1 Overal information, electrical 1.1.1 Overview of Electrical System Electrical system, instruction «Maintenance Manual» describes the electrical system and the design and structure of all its components. This section also includes the function description, troubleshooting, and maintenance methods. -
Page 707
Maintenance Manual──LG6210E Hydraulic Excavator Special repair of electrical system maintenance, overview WARNING! Without the guarantee of out company, it is prohibited to make any changes to the electrical system. Changes will affect the machine’s functions, and even lead to serious personal injury and damage of machine. -
Page 708
Maintenance Manual──LG6210E Hydraulic Excavator hydrogen-oxygen gases. Short circuit, open flames or sparks near the battery can cause a strong explosion. Please always disconnect the charging power before releasing the charging clamp. Maintain good ventilation, especially in a closed space for charging battery. -
Page 709
Maintenance Manual──LG6210E Hydraulic Excavator Specified instruction of electrical system maintenance, electrical components, alternators and charging regulator • Before carrying out the test for any alternator or regulator, we must check whether the battery and wire is with good insulation, loose and rust. Check the belt of alternator. -
Page 710
Maintenance Manual──LG6210E Hydraulic Excavator can only be repaired by trained personnel. Or replacer can replace the entire wire harness. Note! Electronic equipment is very sensitive, vulnerable to be damaged by the static electricity of electromagnetic fields, or from the tool or the body. Therefore, when carrying out the operation about the electronic components, you must observe the following instructions. -
Page 711
Maintenance Manual──LG6210E Hydraulic Excavator • When drilling on machine or any similar actions, any electrical components within the region must be very precise positioned. Important! It is prohibited to drill holes or other operations on the tructure in the cab! The reason is that ROPS protection will be lost in the operation of the cab structure. -
Page 712
Maintenance Manual──LG6210E Hydraulic Excavator — Connect the first cable (A) to the battery positive (1) of the starting machine. — Connect the other end of cable (A) to the battery positive (2) of the auxiliary starting machine(2). — Connect the other starting cable (B) to battery negative of the auxiliary starting machine (3). -
Page 713
Maintenance Manual──LG6210E Hydraulic Excavator All communication between the control components in the system occurs through a data bus. Major vehicle components are all equipped with their own control components, control components are connected to the bus for mutual communication. In short, it can be described as follows: When the operator… -
Page 714
Maintenance Manual──LG6210E Hydraulic Excavator If a fault occurs, a signal is sent out by bus, you can read the information on the instrument display unit or the operator’s gauge . The figure shows how the control components and repair outlet is connected to the bus. -
Page 715
Maintenance Manual──LG6210E Hydraulic Excavator Engine speed and the actual operating mode (P,H,G,F, I mode) will be displayed on the display window. • Battery voltage, operating hours of hydraulic hammer (option) and the fault code will be displayed in the display window, which can be changed in some cases. -
Page 716
Maintenance Manual──LG6210E Hydraulic Excavator Vehicle control components are the control nodes of system. It includes all the features associated with the vehicle. All key decisions are made in the vehicle control components. It can control, adjust and monitor hydraulic devices. -
Page 717
Maintenance Manual──LG6210E Hydraulic Excavator VB41 SE9140 Running guiding pressure switch Digit VB43 SW9110 Max. Power selecting switch Digit VB44 SW2703 Auto idle switch Digit VB51 SE9107 Overloading warning pressure switch Digit VB64 SW2705 Overloading warning stopping Digit pressure switch Starting key(ACC) -
Page 718
Maintenance Manual──LG6210E Hydraulic Excavator set to one value,which is corresponding to the model of engine speed control switch. When the starting switch is OFF: — Signal of starting switch is sent to V-ECU. — Important data is stored in ECU. -
Page 719
Maintenance Manual──LG6210E Hydraulic Excavator -Engine speed electric Engine speed control -Step9 Engine speed -Input current of power shift switch,sw2701 control switch proportional valve for Hmode -Engine speed -Engine speed forH mode -Step6/7/8 Engine speed -Input current of power shift control switch… -
Page 720
Maintenance Manual──LG6210E Hydraulic Excavator H mode. By using 95% of the rated output horsepower of engine, increase operating capacity and operating speed. This model is for the heavy workload with the lifting force and mining force. G mode (Normal workload operation) •… -
Page 721
Maintenance Manual──LG6210E Hydraulic Excavator I mode (idle operation) • I mode includes the following two steps range: Two steps minimizes the output of the pump power. Step 1 set low idle when starting the engine. Step 2 is automatic idle, if the automatic idle speed selector switch SW2703 is ON, it can be choosen. -
Page 722
Maintenance Manual──LG6210E Hydraulic Excavator — Engine speed control switch — Input current of — Automatic idle selector switch, mode F3/F2/F1 / powe shift SW2703 G3/G2/G1/H/P(10) proportional valve — Additional pilot pressure switch, — Auto-idle selector switch is on. is corresponding… -
Page 723
Maintenance Manual──LG6210E Hydraulic Excavator control switch,SW9107 control switch,actuating position solenoid valve is -Control lever switch -Control lever switch on for 9s. boost/hammer.SW9108 boost/hammer is pressed. Automatic running speed control Automatic speed mode Choose the operating speed mode according to the type of soil conditions. -
Page 724
Maintenance Manual──LG6210E Hydraulic Excavator Running speed selecting -Running speed selecting Running speed switch, switch is in high position selecting solenoid SW4202 — Running-oriented pressure valve is off. -Running-oriented pressure switch is on. switch, SE4306 — Engine speed control — Engine speed control switch,… -
Page 725
Maintenance Manual──LG6210E Hydraulic Excavator Battery is used to start the engine, to provide the electric current for system components or store the current exchanged from the alternator. When electrical system is under maintenance, the battery should be in good condition. If necessary, use a battery charger to charge the battery. -
Page 726
Maintenance Manual──LG6210E Hydraulic Excavator Batteries, storage Battery will gradually lose power through self-discharge, which is changed according to storage temperature and charging level. If a fully charged battery is stored in a cool place, the loss of amounts of electricity is very tiny in only three months, and put it at room temperature. -
Page 727
Maintenance Manual──LG6210E Hydraulic Excavator Charge, indication When the starting motor is activated and the engine is started: • Alternator generates electricity to activate the entire electrical system, the extra current charges the battery. • Current flows to safety starting relay to cut off the… -
Page 728
Maintenance Manual──LG6210E Hydraulic Excavator ) of starting switch→Terminal of ACC → • Terminal (B — V-ECU ) of starting switch → BR terminal → Coil of • Terminal (B battery the relay →Grounding wires When the battery relay is working: •… -
Page 729
Maintenance Manual──LG6210E Hydraulic Excavator 4.2 Starting motor including coil Starting engine, indication Starter (MO3301) is provided with power directly from the battery. Relay (RE3101) is controlled by a vehicle electronic control unit (V-ECU), then the ignition switch (SW3301) will turn to the open position. -
Page 730
Maintenance Manual──LG6210E Hydraulic Excavator Figure 19 Battery Relay Safety starting relay, instructions If the engine is running ,try to restart the engine, or after engine is activated,the starting switch is in START position, the relay will be cut off current leading to the starting motor to protect it. -
Page 731
Maintenance Manual──LG6210E Hydraulic Excavator temperatures, and reduce the dust generated under cold start conditions. 5 Other electronic equipments 5.1 Sound warning from the speaker; assembly Electric horn, specifications • Press the two horn switches on the operation lever to operate the speaker horn. -
Page 732
Maintenance Manual──LG6210E Hydraulic Excavator • If the upper wiper switch is on, the motor will move the wiper arm / blade from the parked position (on the left side of the window) to the windows, and sweep blades for 60 °. -
Page 733
Maintenance Manual──LG6210E Hydraulic Excavator 1 AVS 0.85 W/GN 2 AVS 0.85 W/BL 3 AVS 0.85 BL/Y 4 AVS 0.85 BN/W 5 AVS 0.85 SB 6 AVS 0.85 Y/BL 7 AVS 0.85 GN 8 AVS 0.85 R 11 AVS 0.85 GN/Y 12 AVS 0.85 R/GN… -
Page 734
Maintenance Manual──LG6210E Hydraulic Excavator 5.3 Switch; connector Battery disconnects switch (optional), Description • When welding, repairing the circuit, the electrical system is disconnected from the battery to protect the electronic components, park the machine when the battery is disconnected from the electrical system as a safety precaution. -
Page 735
Maintenance Manual──LG6210E Hydraulic Excavator 5 Connect connector of wiring harness to E-ECU, and tighten the clamp. 6 Close the left side door and check the operating conditions of the machine. I-ECU, replace ECU Note! Before removing I-ECU, make sure the main switch is turned off. -
Page 736
Maintenance Manual──LG6210E Hydraulic Excavator 7 Connect two wiring harness with the V-ECU. 8 Install the plastic shell above the cab air-conditioning fan. 9 to restore the driver’s seat position before starting work. 6. Instrument; sensor; warning and information system 6.1 Transmitter, monitoring system… -
Page 737
Maintenance Manual──LG6210E Hydraulic Excavator Note! If the terminal of transmitter is bent in the assembly, indicate the exact amount of fuel value by moving the floated mark Table10. Specification of wire Signal AVS 0.8B AVS 0.85 YL Transmitter Empty Coolant temperature sensor, description Coolant also is provided to integrated oil cooler of the engine. -
Page 738
Maintenance Manual──LG6210E Hydraulic Excavator Control lock lever switch, indication When the safety lock lever is in the upper position, the hydraulic system, turning and walking units can work. When the safety lock lever is in the lower position, all the functions of servo-hydraulic valve controlled by operation lever and pedals are cut off. -
Page 739
Maintenance Manual──LG6210E Hydraulic Excavator LC9201 Quick Installation IM3803 fuel level gauge LC2901 overloading warning LC3803 central warning light LC9107 power boost LC2201 engine oil pressure warning LC9112 boom floating operation LC2601 engine coolant temperature warning light LC9110 operation of hydraulic hammer… -
Page 740
Maintenance Manual──LG6210E Hydraulic Excavator Failure message Some errors occur during the operation, there will be a failure message displayed on the front display. At the same time the buzzer will ring, if the failure is very serioust, central warning light will be also lit. Press the key to shut off the buzzer, you can press the key twice to delete 7.Radio,CD player, voltage divider… -
Page 741
Maintenance Manual──LG6210E Hydraulic Excavator Conection Fig.60 Table13.Pin connection Items Instruction Items Instruction Power(12V) Rear lamp(+) Grounding,rear lamp Right speaker(+) Right speaker(-) Power signal of controoler Left speaker(-) Grounding,controller Left speaker(+) Antenna Spare(+) Grounding 7.2 Voltage divider DC-DC Transformer, indication • 24V of battery reduced by transformers supplies for operating voltage of cassette tape player. -
Page 742
Maintenance Manual──LG6210E Hydraulic Excavator Inspection methods • Put the tester on the measurement position of the voltage, and measure the voltage between the jump output and grounding terminals. Power supply,instruction + Supply Function Suply by the battery relay Suply by the battery directly Suply by the battery directly “-”Supply… -
Page 743
Maintenance Manual──LG6210E Hydraulic Excavator Parts list, heating coil Mark Name Circuit HE2501 Preheator Circuit SCH03 HE3801 Cigretter lighter Circuit SCH14 Parts list,lamp Mark Name Circuit LA3501 Indoor working lamp Circuit SCH14 LA3512 Left side of upper frame working Circuit SCH07… -
Page 744
Maintenance Manual──LG6210E Hydraulic Excavator LC9157 Shear selecting lamp Circuit SCH15 Parts list, solenoid valve Mark Name Circuit MA4212 Starting engine solenoid valve Circuit SCH08 MA8701 Circuit SCH10 X1 （hydraulic hammer ）solenoid valve MA9104 Circuit SCH15 (Optional) MA9105 Boom conflux/cutoff solenoid valve… -
Page 745
Maintenance Manual──LG6210E Hydraulic Excavator MO8707 Circuit SCH10 Mixed actuator Parts list, relay Mark Name Circuit RE2501 Preheating relay Circuit SCH01 Circuit SCH03 RE3101 Battery relay Circuit SCH01 RE3301 Starting relay Circuit SCH01 Circuit SCH03 RE3501 Circuit SCH07 Working lamp relay… -
Page 746
Maintenance Manual──LG6210E Hydraulic Excavator SE3603 Circuit SCH13 Boottom limit switch(Optional) SE4306 Travelling pressure sensor Circuit SCH12 SE8701 Circuit SCH10 Air refrigerant pressure monitor SE8702 Circuit SCH10 Refrigerant temperature sensor SE8705 Circuit SCH10 Environmental temperature sensor SE8706 Circuit SCH10 Room temperature sensor… -
Page 747
Maintenance Manual──LG6210E Hydraulic Excavator Circuit SCH08 SW9158 Circuit SCH17 Boom translation switch pump(Optional) SW9160 Circuit SCH16 Rapid assembly buzzer STOP/CONFIRM (Optional) SW9405 Circuit SCH16 X3 left switch SW9406 Circuit SCH16 X3 right switch Parts list, fuse Slow-melt fuse Fuse Capacity… -
Page 748
Maintenance Manual──LG6210E Hydraulic Excavator FU22 Compressor Circuit SCH10 FU23 Radio Circuit SCH12 FU24 12V power base Circuit SCH12 FU25 Transformer Circuit SCH02 Circuit SCH08 FU27 Solenoid valve Circuit SCH08 Circuit SCH28 FU28 Rapid assembly Circuit SCH15 Circuit SCH16 Circuit SCH17… -
Page 749
Maintenance Manual──LG6210E Hydraulic Excavator Circuit SCH01 Power feedback, AC generator, battery Circuit SCH01 SCH02 ECU power supply and communications Circuit SCH02 SCH03 Starting and engine speed control Circuit SCH03 SCH04 Warning sensor Circuit SCH04 SCH07 Working light Circuit SCH07 SCH08 Machine control… -
Page 750
Maintenance Manual──LG6210E Hydraulic Excavator SCH01 Fig.62 Circuit of SCH01 Mark Name Mark Name BA3101 Battery1 BA3102 Battery2 FC01 Slow-melt fuse FC02 Slow-melt fuse FC03 Slow-melt fuse FC04 Slow-melt fuse AL3201 Generator RE3101 Battery relay SW330 Starting switch RE3301 Starting relay… -
Page 751
Maintenance Manual──LG6210E Hydraulic Excavator Fig.63 Element position… -
Page 752
Maintenance Manual──LG6210E Hydraulic Excavator SCH02 Fig.64 Circuit of SCH02 Mark Name Mark Name IECU Gauge controller VECU Vehicle EMR2 Engine controller PO3904 Diagnosis base SEROIA Diagnosis base… -
Page 753
Maintenance Manual──LG6210E Hydraulic Excavator Fig.65 Element position… -
Page 754
Maintenance Manual──LG6210E Hydraulic Excavator SCH03 Fig.66 Circuit of SCH03 Mark Name Mark Name SW330 Starting switch SW270 Engine speed control switch SW270 Auto idle switch RE2501 Preheator relay RE3301 Starting relay SW911 Operator lockin lever switch… -
Page 755
Maintenance Manual──LG6210E Hydraulic Excavator HE2501 Air preheator MO330 Starting engine SE2701 Engine speed sensor(crane) SE2703 Engine speed sensor(Camshaft) MA9108 Operation locking solenoid valve VECU Vehicle controller EMR2 Engine controller Fig.6 Element position… -
Page 756
Maintenance Manual──LG6210E Hydraulic Excavator SCH06 Fig.68 Circuit of SCH06 Mark Name Mark Name LM3811 Coolant temperature gauge IM3803 Fuel level gauge LM3812 Hour meter HE2501 Preheating component LC3803 Central warning indicator lamp LC3201 Battery charging indicator lamp LC2201 Fuel low pressure indicator lamp… -
Page 757
Maintenance Manual──LG6210E Hydraulic Excavator LC2502 Preheating indicator lamp LC2601 High engine temperature indicator lamp LC2602 Coolant low level indicator lamp SE2303 Coolant level sensor SE2603 Coolant level sensor SE2606 Coolant temperature sensor SE2203 Engine fuel pressure sensor SE2508 Boost pressure sensor… -
Page 758
Maintenance Manual──LG6210E Hydraulic Excavator SCH07 Fig.70 Circuit of SCH07 Mark Name Mark Name SW350 Standard working lamp switch SW350 Auxillary working lamp switch… -
Page 759
Maintenance Manual──LG6210E Hydraulic Excavator LA3512 Left side of upper frame working LA3513 Right side of upper frame working lamp lamp LA3527 Left side of boom working lamp LA3528 Right side of boom working lamp LA3521 Left front part of cab working lamp… -
Page 760
Maintenance Manual──LG6210E Hydraulic Excavator SCH07 Fig.70 Circuit of SCH07 Mark Name Mark Name SW350 Standard working lamp switch SW350 Extra working lamp switch9(Optional) LA3512 Left side of upper frame working LA3513 Right side of upper frame working lamp lamp LA3527… -
Page 761
Maintenance Manual──LG6210E Hydraulic Excavator Fig.71 Element positions… -
Page 762
Maintenance Manual──LG6210E Hydraulic Excavator SCH08 Fig.72 Circuit of SCH08 Mark Name Mark Name SE9111 Guiding pressure sensor SW9110 Electric max model SW420 Travelling speed switch SW9103 Auto/manual pump control switch SW270 Auto idle switch SW9118 Operation lever switch MA4212 Starting engine solenoid valve… -
Page 763
Maintenance Manual──LG6210E Hydraulic Excavator R9101 Manual resistor1 Fig.73 Element positions… -
Page 764
Maintenance Manual──LG6210E Hydraulic Excavator SCH10 Fig.74 Circuit of SCH10 Mark Name Mark Name CU8701 Air controller MO8701 Cooling fan motor MO870 Inlet actuator MO8704 Face actuator MO870 Right foot actuator MO8706 Left foot actuator MO870 Mixed actuator SE8701 Air refrigerant pressure monitor… -
Page 765
Maintenance Manual──LG6210E Hydraulic Excavator RE8703 First speed relay RE8704 Second speed relay RE8705 Third speeed relay RE8706 Fourth speed relay MA8701 Compressor relay R8701 Resistor RE8702 Compressor relay Fig.75 Element positions… -
Page 766
Maintenance Manual──LG6210E Hydraulic Excavator SCH12 Fig.74 Circuit of SCH12 Mark Name Mark Name SO3901 Voltage transformer CR3901 Radio ANT3901 Antenna SW3901 Silence switch SA3901 Left speaker SA3902 Rigt speaker PO3901 12V power base SE4306 Travelling pressure sensor RE3611 Horn relay… -
Page 767
Maintenance Manual──LG6210E Hydraulic Excavator Fig.77 Element positions… -
Page 768
Maintenance Manual──LG6210E Hydraulic Excavator SCH13 Fig.80 Circuit of SCH13 Mark Name Mark Name SW360 Upper wiper switch SW360 Bottom wiper switch(Optional) SW360 Cleaner switch CU3601 Wiper controller SE3602 Upper limit switch SE3603 Boottom limit switch(Optional) MO360 Cleanser pump MO360 Upper wiper motor… -
Page 769
Maintenance Manual──LG6210E Hydraulic Excavator MO360 Bottom wiper motor Fig.79 Element position… -
Page 770
Maintenance Manual──LG6210E Hydraulic Excavator SCH14 Fig.80 Circuit of SCH14 Mark Name Mark Name SW360 Turning signal lamp switch LA3601 Turning signal lamp SW350 Indoor lamp switch LA3501 Indoor lamp HE3801 Cigarette Lighter… -
Page 771
Maintenance Manual──LG6210E Hydraulic Excavator Fig.81 Element position… -
Page 772
Maintenance Manual──LG6210E Hydraulic Excavator SCH15 Fig.82 Circuit of SCH15 Mark Name Mark Name LC9153 Turbocharger selecting lamp LC9156 Hydraulic hammer selecting lamp LC9157 Shear selecting lamp SW910 Shear/ hydraulic hammer selecting switch SW910 Strengthening/hydraulic hammer MA9107 Booster valve switch MA9117 X1… -
Page 773
Maintenance Manual──LG6210E Hydraulic Excavator Fig.83 Element position SCH16… -
Page 774
Maintenance Manual──LG6210E Hydraulic Excavator Fig.84 Circuit of SCH16 Mark Name Mark Name SE9405 X3 left switch SW940 X3 right switch SW910 Rapid assembly switch 1(Optional) SW910 Rapid assembly switch 2(Optional) SW916 Rapid assembly buzzer RE9104 Rapid assembly 1 relay(Optional) STOP/CONFIRM… -
Page 775
Maintenance Manual──LG6210E Hydraulic Excavator Fig.85 Element position… -
Page 776
Maintenance Manual──LG6210E Hydraulic Excavator SCH17 Fig.87 Circuit of SCH17 Mark Name Mark Name SE9140 Boom floating position SW915 Boom translation switch switch(Optional) pump(Optional) MA9120 Boom floating position solenoid valve VECU Vehicle control switch… -
Page 777
Maintenance Manual──LG6210E Hydraulic Excavator Fig.87 Element position SCH18 Fig.88 Circuit of SCH18 Mark Name Mark Name SW2304 Fuel filling pump switch(Optional) MO230 Fuel filling pump(Optional) -
Page 778
Maintenance Manual──LG6210E Hydraulic Excavator Fig.89 Element position 2.Fuse;relay;circuit cut-off 2.1 Fuse Fuse,instruction Energy Application/circuit Energy Application/circuit I-ECU Starting switch Working lamp(Ceiling) Cab lamp Working lamp(Boom) Diagnose connector Wiper and sprayer Diagnose connector Cigarette lighter Fuel filling pump Horn conditioning… -
Page 779
Maintenance Manual──LG6210E Hydraulic Excavator compressor Air conditioning Radio with CD player Extra working Power inlet lamp(Rear,counter weight) Extra working lamp(Cab) X1 oil flow control valve Rotation warning lamp Safety solenoid valve Hydraulic hammer,booster,hydraulic shear V-ECU Rapid assembly,solenoid valve of rotator… -
Page 780
Maintenance Manual──LG6210E Hydraulic Excavator Replacement process of fuse 1. Loosen the screws(9) fixes the fuse housing on the supporting frame. 2. Open the cover( 2) with clamp. 3. Open the side cover with screwdriver. 4. Remove the bolt(4) from the connector (5) to remove the fuse(1) 5. -
Page 781
Maintenance Manual──LG6210E Hydraulic Excavator Fig.93 Relay box Relay box 1 SO3901 Voltage vonvertor Relay box 2 CU3601 Wiper controller RE3101 Battery Relay Resistance box, indication When the auto / manual switch is in the MANUAL mode, the resistance of resistance box to reduce the current, corresponding to 85% of the rated engine output of the solenoid valve. -
Page 782
Maintenance Manual──LG6210E Hydraulic Excavator V-ECU power VA15, VA16, voltage is low. Fuse Solenoid & relay VA09, voltage is low. Fuse PWM VA11, voltage is low. Fuel level sensor VB67, signal > 4.5V or signal < 0.5V, open or short…
Гусеничный экскаватор SDLG E 6210F хоть
и изготавливается в Поднебесной, но, по сути,
собирается по лицензии и под контролем
шведской компании Volvo. Причем смена
гражданства никоим образом не отразилась
на надежности и функциональности техники
Экскаватор SDLG E 6210F с собственной массой около 21 тонны со штатным кубометровым ковшом и двигателем мощностью 167 л.с. достаточно универсален. Машины этого среднего класса востребованы на рынке и могут быть задействованы на разработке различных грунтов, даже рыхлых, где, например, тридцати тонная техника может уже вязнуть. Такие экскаваторы хорошо себя зарекомендовали при работе в карьерах, прокладке трубопроводов, строительстве дорог и зданий. Да и планировка площадки благодаря точной настройке гидравлики им по силам. Даже экскаватор на площадке у дилера уже прошел тестовую эксплуатации и скоро отправится к своему владельцу. Еще важно отличие этих машин от более тяжелых собратьев – экономичность в плане топлива и технического обслуживания.
Техника под маркой SDLG производится компанией Shandong Lingong Construction Machinery Co., Ltd (Шаньдун Линьгун Констракшн Машинери Ко. Лтд.), штаб-квартира которой находится в китайском городе Линьи в провинции Шаньдун. Завод специализируется на производстве фронтальных погрузчиков и экскаваторов. После создания в 2006 году совместного предприятия с Volvo китайская компания начала выпускать экскаваторы по лицензии и технологиям шведской фирмы. Тем самым фактически китайцы предлагают проверенные европейские технологии, но по более доступным ценам.
Экскаватор SDLG E 6210F отличается классической конструкцией, свойственной такого рода технике. Рядный 6-цилиндровый турбодизель DEUTZ BF6M2012 установлен сзади полноповоротной платформы поперек продольной оси машины. Этот мотор DEUTZ серии 2012 развивает мощность в 167 л.с. и широко применяется на строительной технике и в промышленных установках. Из особенностей стоит отметить жидкостную систему охлаждения, непосредственный впрыск топлива, литую чугунную головку блока цилиндров, биметаллические подшипники распредвала, и интегрированную в картер систему полного баланса массы с двумя валами. В целом это традиционный проверенный временем мотор, больше консервативный, чем инновационный. Сбоку башни через люк радиаторного отсека открывается доступ к радиаторам двигателя, оборудованными защитными сетками. Последние легко можно демонтировать и почистить при необходимости. Здесь же под радиаторами находятся аккумуляторы. Такое их расположение, по мнению производителя, обеспечивает им лучший температурный режим работы.
Трансмиссия у экскаватора полностью гидростатическая. Тандемный аксиально-поршневой гидронасос Kawasaki, присоединенный к двигателю, передает весь поток мощности. Его секции вырабатывают два гидропотока, которые направляются или на гидромоторы ходовой части, или на рабочее оборудование. Также возможен совмещенный режим, то есть когда один поток отвечает за передвижение машины, а другой обеспечивает рабочие операции и поворот платформы, которая вращается гидромоторм с планетарным редуктором. Гидролинии к механизмам хода проходят через центральный коллектор, поэтому поворотную платформу можно вращать в любую сторону без ограничения оборотов. Дополнительный пилотный насос необходим для контуров управления (джойстики, и другие органы управления в кабине). Также управляющее давление может кратковременно направляться в рабочие контуры при предельных нагрузках, например, для увеличения вырывного усилия при разработке твердого грунта. За это отвечает автоматическая электронная система.
Современная кабина соответствует всем требованиям безопасности и комфорта. Удобное эргономичное кресло с подголовником, боковой и поясничной поддержкой обладает массой регулировок и настроек под конкретного оператора даже с учетом его массы. В базовой версии уже есть система микроклимата и обогрева, воздуховоды которой расположены снизу и сверху салона. Также имеется магнитола, электророзетки и ящички для инвентаря. Большие стекла обеспечивают хорошую обзорность, причем лобовое можно убрать под потолок для вентиляции или чтобы выглянуть из кабины. Рычаги, отвечающие за перемещение экскаватора, жестко соединены с педалями, которые пригодятся, если руки водителя лежат на джойстиках. Все основные клавиши управления расположены под правой рукой оператора, а на передний жидкокристаллический дисплей выводится необходимая информация о рабочих режимах систем, оборотах двигателя и уровнях жидкостей. Все надписи, правда, или на английском, или на китайском. Грамотная настройка гидравлики и достаточная мощность позволяет с помощью джойстиков точно и плавно управлять рабочим оборудованием. Отрадно отметить, что здесь применена не полностью электронная, а электронно-гидравлическая схема с подведенными рукавами высокого давления и золотниками в джойстиках. То есть при отказе электроники в аварийном режиме оператор сможет завершить текущие операции.
Для обеспечения рабочих операций используются четыре гидроцилиндра: два подъемных для стрелы, один отвечает за движение рукояти и еще один опрокидывает или поднимает ковш. Металлоконструкции собраны на шарнирах с втулками из легированной стали. Нижняя часть рукояти усилена литыми элементами. В базовой версии экскаватор поставляется с ковшом, но на рукояти есть штатное место для прокладки дополнительной гидролинии, обеспечивающей работу опционального допоборудования. Конструкция гусеничного шасси и поворотной платформы аналогична таковой у моделей других ведущих мировых фирм. Ходовая тележка с Х-образной рамой, опорно-поворотный механизм на гигантском роликовом подшипнике. Привод гусениц с двухскоростными аксиально-поршневыми гидромоторами, планетарными редукторами со встроенными дисковыми тормозами.
Вся гусеничная техника малоподвижна, и, как правило, привозится тралом на объект и остается там до полного окончания работ. Поэтому еженедельное техническое обслуживание возлагается непосредственно на самого оператора. Благо для этого в модели E 6210F предусмотрена удобная система смазки узлов и агрегатов через пресс-масленки. Для памятки на двери кабины есть схема, на которой указаны места обслуживания и график проведения работ. Периодичность ТО составляет 250 моточасов, а проблем с его проведением у владельцев этого экскаватора не возникнет – дилерская сеть компании «Русбизнесавто» довольно широкая, и есть возможность обслуживания на территории клиента с помощью выездныех сервисных бригад. Но как показывает практика, техника SDLG достаточно надежна и долговечна, что позволяет ее успешно эксплуатировать в интенсивном режиме даже в условиях Заполярья.
Общие размеры
| Габаритные размеры (длина), мм. | 9700 |
| Габаритные размеры (ширина), мм. | 2800 |
| Колея, мм. | 2200 |
| Длина гусеницы, мм. | 4170 |
| Ширина гусеницы, мм. | 600 |
| Минимальный клиренс, мм. | 460 |
| Ширина по верхней части, мм. | 2700 |
| Высота по кабине, мм. | 2940 |
| Радиус порота по противовесу, мм. | 2860 |
| Высота по двигательному отсеку, мм. | 2345 |
| Клиренс до противовеса, мм. | 1032 |
| Длина опорной поверхности, мм. | 3370 |
| Высота по сложенной стреле, мм. | 2920 |
Общие параметры
| Эксплуатационная масса, кг. | 20700 |
| Максимальная сила копания, кН | ≥147,1 |
| Объем ковша, мᶟ | 0,85-1,2 |
| Скорость вращения башни, об./мин. | 11 |
| Скорость передвижения (высокая / низкая), км/ч | 5,5/3,2 |
| Удельное давление на грунт, кПа | 45 |
| Максимальная глубина копания, мм. | 6730 |
| Максимальный радиус копания, мм. | 9940 |
| Максимальная высота копания, мм. | 9450 |
| Максимальная высота выгрузки, мм. | 6650 |
| Минимальный радиус поворота, мм. | 3650 |
Двигатель
| Производитель | DEUTZ |
| Модель двигателя | BF6M2012C |
| Номинальная мощность, л.с. | 163 |
| Номинальная мощность, кВ | 120 |
| Номинальные обороты, об./мин. | 2000 |
| Объем двигателя, л. | 6 |
| Диаметр цилиндра, мм. | 101 |
| Ход поршня, мм. | 126 |
| Максимальный крутящий момент, Нм | 671 |
| Экологический стандарт | Tier 3 |
| Удельный расход топлива, г/кВт*ч | ≤214 |
Ходовая часть
| Количество ведущих катков | 2 |
| Количество опорных катков | 7 |
| Тип тормоза | Дисковый мокрый |
| Поворотная часть | Однорядный шарикоподшипник гидропривода с внутренними зубцами |
| Тормоз поворотной части | Дисковый мокрый |
Гидравлическая система
| Тип | Сдвоенный насос с постоянной мощностью и системой регулировки потока |
| Тип управления | Пилотный пропорциональный клапан управления |
| Максимальный гидропоток, л./м. | 2х200+20 |
| Рабочее давление, мПа | 330/350 |
| Модель основного насоса | Kawasaki K3V112DT |
| Цилиндр стрелы, мм. | 125x80x1235 |
| Цилиндр рукояти, мм. | 135x95x1540 |
| Цилиндр ковша, мм. | 120x80x1065 |
Заправочные емкости
| Топливный бак, л. | 350 |
| Гидравлическая система, л. | 295 |
| Двигатель, л. | 19 |
| Редуктор поворота, л. | 8 |
| Редуктор движения, л. | 2×5,8 |
| Эксплуатационная масса, кг. | 20700 |
| Максимальная сила копания, кН | ≥147,1 |
| Объем ковша, мᶟ | 0,85-1,2 |
| Скорость вращения башни, об./мин. | 11 |
| Скорость передвижения (высокая / низкая), км/ч | 5,5/3,2 |
| Удельное давление на грунт, кПа | 45 |
| Максимальная глубина копания, мм. | 6730 |
| Максимальный радиус копания, мм. | 9940 |
| Максимальная высота копания, мм. | 9450 |
| Максимальная высота выгрузки, мм. | 6650 |
| Минимальный радиус поворота, мм. | 3650 |
Все характеристики
О товаре
Технические характеристики Экскаватор гусеничный LGCE (SDLG) E6210F
| Производитель |
Linyi Lingong Heavy Industry Machinery Co., Ltd |
|---|---|
| Эксплуатационная масса, кг. | 21250 |
| Объем ковша, м³ | 1,0 |
| Максимальная глубина копания, мм | 6730 |
| Производитель | Dalian DEUTZ |
| Номинальная мощность, л.с./кВ | 167 / 123 |
| Модель основного насоса | Kawasaki K3V112DT |
| Модель основного клапана | Toshiba UX28 |
| Максимальный гидропоток, л./м. | 2×207+18 |
| Ширина гусеницы, мм. | 600 |
| Габаритная ширина, мм. | 2800 |
| Радиус порота по противовесу, мм. | 2880 |
| Двигатель производитель модель | DALIAN DEUTZ BF6M2012 |
| Высота по двигательному отсеку, мм. | 2345 |
| Клиренс до противовеса, мм. | 1032 |
| Длина опорной поверхности, мм. | 3370 |
| Длина гусеницы, мм. | 4170 |
| Колея, мм. | 2200 |
| Минимальный клиренс, мм. | 460 |
| Габаритная длинна, мм. | 9720 |
| Высота по сложенной стреле, мм. | 2940 |
| Диаметр цилиндра / ход поршня, мм. | 101 / 126 |
| Скорость вращения башни, об./мин. | 12,1 |
| Скорость передвижения (высокая / низкая), км/ч | 5,7 / 3,5 |
| Удельное давление на грунт, кПа | 45,3 |
| Максимальный крутящий момент, Нм | 695 |
| Максимальный радиус копания, мм. | 9940 |
| Максимальная глубина копания, мм. | 6730 |
| Максимальная высота копания, мм. | 9450 |
| Максимальная высота выгрузки, мм. | 6650 |
| Номинальные обороты, об./мин. | 1800 |
| Объем двигателя, л. | 6,057 |
| Максимальный крутящий момент, Нм | 695 |
| Диаметр цилиндра / ход поршня, мм. | 6×101/126 |
| Максимальный крутящий момент, Нм | 695 |
| Экологический стандарт | GB 20891-2014 China Ⅲ emission |
| Количество ведущих катков | 2 |
| Тип транспортного средства | Экскаватор гусеничный |
| Количество опорных катков | 7 |
| Модель | SDLG E6210F |
| Тип тормоза | Многодисковый мокрого типа |
| Вид кузова | Экскаватор гусеничный |
| Тормоз поворотной части | Многодисковый мокрого типа |
| Тип кузова | Экскаватор гусеничный |
| Рабочее давление, мПа | 32,3/34,3 |
| Модель двигателя | BF6M2012-17T3R/5 |
| Рабочий вес, кг | 21250 |
| Цилиндр стрелы, мм. | 125x80x1235 |
| Цилиндр рукояти, мм. | 135x95x1540 |
| Длина рукояти, мм | 2900 |
| Цилиндр ковша, мм. | 120x80x1065 |
| Длина стрелы, мм | 5700 |
| Топливный бак, л. | 350 |
| Гидравлическая система, л. | 295 |
| Максимальная сила копания, кН | 147,1 |
| Двигатель, л. | 23,5 |
| Тип | Аксиально-поршневой гидронасос |
| Редуктор поворота, л. | 8,6 |
| Тип управления | Пилотный пропорциональный клапан управления |
| Редуктор движения, л. | 2×5,8 |
| Мощность, л.с. при об. в мин. | 167/1800 |
| Общая длина, мм | 9720 |
| Общая ширина, мм | 2800 |
| Общая высота, мм | 2940 |
| Ширина по верхней части, мм. | 2700 |
| Высота по кабине, мм. | 2940 |
ДОСТАВКА ЛЮБЫМ СПОСОБОМ
Русбизнесавто предоставляет услуги по перевозке и перегону техники по территории
России. Мы сотрудничаем только с проверенными транспортными компаниями, прошедшими проверку на
благонадежность и обладающими многолетним опытом по перевозке стандартных и негабаритных
грузов любыми видами транспорта.
Русбизнесавто предоставляет услуги по перевозке и перегону техники по территории
России.
Мы сотрудничаем только с проверенными транспортными компаниями, прошедшими проверку на
благонадежность и обладающими многолетним опытом по перевозке стандартных и негабаритных
грузов любыми видами транспорта.
Экскаваторы SDLG серии F поставляются в Россию с 2018 г., до этого в нашей стране были доступны машины серии E. В новой линейке есть несколько вариантов силовых агрегатов: например, на SDLG 6210F стоит Dalian Deutz c насос-форсунками (производство — Китай), а на 6300F — Deutz с полноценным Common Rail (Германия). Все дизели сертифицированы по стандарту Tier 3.
Источник фото: exkavator.ruГерой тест-драйва — гусеничный экскаватор SDLG 6210F
Увидеть 6210F в деле журналист Экскаватор Ру смог в Самаре, где в конце апреля прошел конкурс Excavator Challenge SDLG. В тот день экскаватором управляли как сотрудники дилерской компании (в рамках демо-шоу), так и машинисты подрядных организаций (именно на данной модели операторы показывали свое мастерство, соревнуясь друг с другом). На вопрос, по каким критериям выбиралась техника для мероприятия, представитель дистрибьюторской компании «Русбизнесавто» Станислав Булгаков ответил так: «Сегодня мы делаем акцент на эту машину, потому что она подходит для использования как на городских стройках, так и на небольших карьерах. У модели оптимальная развесовка, размеры и объем ковша для различных задач».
Источник фото: exkavator.ruУчастники Excavator Challenge SDLG
Комплектация: усиленная рукоять, японская гидравлика и климат-контроль
Помимо двигателя, новая серия экскаваторов SDLG отличается усиленной конструкцией нижней и верхней рамы, а также рабочего оборудования. И сразу отметим, что производитель дает трехлетний срок для того, чтобы покупатель удостоверился в надежности машины: именно столько (3 года или 3 000 моточасов) длится гарантия на технику SDLG.
Источник фото: exkavator.ruОсматриваем элементы, с помощью которых была усилена рама
Усиленную рукоять производители зачастую предусматривают только для машин, которые были спроектированы для работ со скальными породами. 6210F оснащается ею уже в стандартной комплектации. Если же говорить о деталях, то надежность конструкции достигается за счет изготовления основания из литой стали, а также установки дополнительных ребер жесткости. «При работе с грубыми материалами, если ковш запрокинуть на себя, никаких повреждений рукояти не возникнет», — прокомментировал Станислав Булгаков.
Источник фото: exkavator.ruОснование стрелы и рукояти выполнено из литой стали
Отдельно стоит сказать и о рабочих характеристиках модели. Максимальная глубина компания составляет внушительные для экскаваторов данного класса 6,73 м, радиус — 9,94 м. Объем стандартного ковша — 1 куб.м.
Источник фото: exkavator.ruКовш также является усиленным
Модель поставляется вместе с джойстиковым управлением, бортовым компьютером, системой самодиагностики двигателя (выполняется по семи параметрам) и климат-контролем. Переднее стекло возможно снять: в кабине предусмотрено место для его хранения.
Источник фото: exkavator.ruКабина является одной из самых просторных в данном классе экскаваторов
Источник фото: exkavator.ruИзучаем элементы управления
Источник фото: exkavator.ruКресло на пневмоподвеске. Переднее остекление снимается
Источник фото: exkavator.ruДополнительное место для хранения вещей
Помимо двигателя (изготавливается в Китае по немецкой лицензии) и гидравлики (например, установлен мотор хода Kawasaki, главный распределительный клапан Toshiba), все остальные элементы изготавливаются на заводе SDLG. В китайском городе Линьи под контролем специалистов Volvo (концерн владеет брендом SDLG) выпускаются верхняя и нижняя рамы, стрела, кабина, сам корпус, все внешние гидроцилиндры и др.
Источник фото: exkavator.ruПомимо двигателя и гидравлики все остальные элементы изготавливаются на заводе SDLG
На что способен SDLG 6210F? Экскаватор в действии
После изучения общей конструкции экскаватора SDLG, наблюдаем за выполнением машиной отдельных операций. В частности, специалист «Русбизнесавто» наглядно продемонстрировал работу гидромотора хода Kawasaki, который обеспечивает плавность выполнения команд.
Источник фото: exkavator.ruОператор доказывает надежность конструкции экскаватора
Источник фото: exkavator.ruМаксимальная высота копания составляет 9,45 м
Источник фото: exkavator.ruЯпонская гидравлика обеспечивает точность выполнения работ
Скорость поворота платформы (во многом благодаря использованию японских компонентов) составляет 12 оборотов в минуту. Гидромотор поворота платформы имеет увеличенный диаметр.
Далее обращаем внимание на моменты, которые связаны с техническим обслуживанием. Машина поворачивается к гостям мероприятия правым бортом — именно с этой стороны расположены топливные и масляные фильтры.
Источник фото: exkavator.ruУдобный доступ с уровня земли. Все фильтры сгруппированы в одном отсеке
Теперь левый борт: здесь находятся воздушный фильтр, блок предохранителей и радиатор охлаждения.
Источник фото: exkavator.ruИзучаем компоненты, которые расположены с левого борта
В целом производитель постарался сделать все, чтобы упростить выполнение стандартных операций: обслуживание доступно с уровня земли, у вас не возникнет необходимости в использовании стремянок. Предусмотрены самосмазываемые втулки шарнира стрелы и дополнительный фильтр очистки гидравлической жидкости.
Источник фото: exkavator.ruПродолжаем изучать SDLG 6210F изнутри
Еще один важный показатель работы экскаватора — расход топлива. Как рассказал Станислав Булгаков, опытная эксплуатация в одном из карьеров показала, что SDLG 6210 потребляет на 15% меньше топлива в сравнении со стандартными ТНДВ.
Источник фото: exkavator.ruШирина трака составляет 600 мм
Для эксплуатации в северных условиях экскаваторы дорабатывают непосредственно в России. В частности, дилер устанавливает в кабину систему обогрева, подогреватель двигателя, предлагает замену масел на арктические. В целом же большинство техники на данный момент продано в Центральной части России (Москва, Центральное Черноземье, южные регионы).
О технике из уст операторов и механиков
В этот день поработать на новом экскаваторе представилась возможность 29 операторам (именно сколько человек принимали участие в конкурсе профессионального мастерства). Мы побеседовали победителем из компании «Автодоринжиниринг» сразу после вручения призов. На вопрос о том, порекомендует ли данную модель своему руководству, Р. Курбанов ответил положительно.
Источник фото: exkavator.ruВыполнение одного из заданий в рамках конкурса профмастерства
Еще один из присутствующих на мероприятии специалистов особо отметил ремонтопригодность экскаватора: «Его преимущество в том, что необходимые компоненты можно быстро достать и обслужить. Аккумуляторы расположены возле радиатора, все шланги и прочие рабочие агрегаты находятся снаружи. К тому же машина легкая в эксплуатации. Ее можно даже сравнить с CAT по плавности хода (они вполне сопоставимы по данному показателю)».
Источник фото: exkavator.ruУчастники мероприятия осматривают технику
Также свое мнение о продемонстрированной технике высказал главный механик ОАО «Автодоринжениринг» (напомним, что представитель именно этой компании победил в Excavator Challenge SDLG). Одна из целей, которую ставил перед собой Сергей Павлюков при посещении данного мероприятия, — присмотреться к экскаваторам китайского бренда. На данный момент в парке компании присутствует 18 единиц SDLG, большинство из которых — погрузчики. Но теперь (заинтересовавшись, в том числе, ценой), они рассматривают покупку и других типов техники.
Источник фото: exkavator.ruГлавный механик ОАО «Автодоринжениринг» Сергей Павлюков
«Мы в основном занимается дорожным строительством, но используем машины и в карьере, — рассказал С. Павлюков. — Некоторые погрузчики SDLG отработали уже порядка 20 000 моточасов (или примерно пять лет). В день они трудятся от 10 до 20 моточасов (если работа круглосуточная). Парк техники в компании очень разнообразен, есть практически все. Сейчас используем экскаваторы Caterpillar. У SDLG покупаем именно погрузчики: они хорошо зарекомендовали себя в работе, и переходить на другие марки мы смысла не видим. Обслуживание в основном выполняем сами, изредка обращаемся к дилерам. Пока же техника была на гарантии, и ее обслуживала компания «Русбизнесавто», специалисты реагировали на наши запросы быстро: если сегодня позвонили, то буквально на следующий день они приезжали. В России есть практически все запчасти. И машинистам техника нравится».
В целом главный механик ОАО «Автодоринжениринг» отметил, что недочетов в машинах SDLG он не видит, и единственное пожелание, которое он может дать производителю, — это продолжать развивать линейку продукции. «Соблюдайте регламент ТО. Если все делать вовремя, техника будет работать без нареканий», — добавил специалист.