LG6210E6225E service manual-201609

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<p>LG6210E&LG6225E Service Manual</p><p>880×1230 mm 16#</p><p>1st Edition in 2016. 9</p><p>18piece</p><p>2nd Print</p><p>SHANDONG LINGONG CONSTRUCTION</p><p>MACHINERY CO.，LTD</p><p>Address: Linyi Economic Development Zone</p><p>Tel: 86-0539-8785688</p><p>Fax: 86-0539-8785698</p><p>Postal code：276023</p><p>Website：www.sdlg.cn</p><p>Services Tel：8008607999 4006587999 0539-8785800</p><p>Services Fax：86-0539-8785671</p><p>http://www.sdlg.cn/</p><p>Service Manual──6210E&6225E Hydraulic Excavator</p><p>I</p><p>PREFACE .............................................................................................................................................................................. I</p><p>SECURITY ........................................................................................................................................................................... 1</p><p>Common precaution .................................................................................................................................................... 1</p><p>Security precautions .................................................................................................................................................................... 1</p><p>Safety Devices ............................................................................................................................................................................ 1</p><p>Clothing and Personal Protective Items ...................................................................................................................................... 1</p><p>Emergency matters preparation ................................................................................................................................................... 2</p><p>Fire Prevention for Oil and Fuel.................................................................................................................................................. 2</p><p>Properly dispose of scrap liquid .................................................................................................................................................. 2</p><p>Working in the dusty environmental ........................................................................................................................................... 3</p><p>Preparation .................................................................................................................................................................................. 3</p><p>Reasonably and safely use of tools .............................................................................................................................................. 4</p><p>Security locking system .............................................................................................................................................................. 4</p><p>.Use handrails or ladders ............................................................................................................................................................. 4</p><p>Precautions when operating ......................................................................................................................................... 5</p><p>Maintain the cooling system safety ............................................................................................................................................. 5</p><p>Avoid contacting with high-pressure liquid ................................................................................................................................ 6</p><p>Hoist goods ................................................................................................................................................................................. 6</p><p>Electric System ........................................................................................................................................................................... 7</p><p>Welding on the machine .............................................................................................................................................................. 8</p><p>Move and operate machinery safely .......................................................................................................................................... 10</p><p>Ⅰ.WHOLE MACHINE DESCRIPTION ........................................................................................................................ 11</p><p>1. SUMMARY .................................................................................................................................................................... 11</p><p>Components position ............................................................................................................................................................. 11</p><p>2. SPECIFICATION ............................................................................................................................................................. 12</p><p>Standard tightening torque ........................................................................................................................................................ 12</p><p>Tightening torque of split flange screws ................................................................................................................................... 13</p><p>Tightening torque of hydraulic plug with O ring ...................................................................................................................... 14</p><p>Tightening torque of rotating nut device with O ring ................................................................................................................ 14</p><p>Engine, specifications ............................................................................................................................................................... 15</p><p>Engine, specifications ............................................................................................................................................................... 16</p><p>Valve clearance, specifications ................................................................................................................................................. 16</p><p>Fuel pressure, specifications ..................................................................................................................................................... 16</p><p>Coolant, specifications .............................................................................................................................................................. 17</p><p>Engine speed control switch, specifications .............................................................................................................................. 17</p><p>Electrical system, specifications................................................................................................................................................ 17</p><p>Engine control, specifications ................................................................................................................................................... 18</p><p>Gauge control unit I-ECU, specifications ................................................................................................................................. 19</p><p>Connecting pins, specifications ................................................................................................................................................. 19</p><p>Engine control unit E-ECU (EMR2 ), specification .................................................................................................................. 20</p><p>Vehicle control unit V-ECU, specifications (I-ECU has been assembled.) ............................................................................... 21</p><p>Battery, specifications ............................................................................................................................................................... 24</p><p>AC generator,</p><p>262</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>VII</p><p>Rotating joints description ...................................................................................................................................................... 262</p><p>Rotary joints,assembly .......................................................................................................................................................... 263</p><p>Rotary joints, tools ................................................................................................................................................................ 264</p><p>Common tools .................................................................................................................................................................... 264</p><p>Special tools ....................................................................................................................................................................... 265</p><p>Rotary joint soft hose (valve - rotary joints), replacing ..................................................................................................... 266</p><p>Rotary joint hose (Rotary joints - motor), replacing .......................................................................................................... 267</p><p>Rotary joints, dismantling .................................................................................................................................................... 268</p><p>Rotary joints, assembly ......................................................................................................................................................... 271</p><p>Rotary joint,checking and troubleshooting ......................................................................................................................... 274</p><p>Inspection after assembly ........................................................................................................................................................ 276</p><p>Troubleshooting .................................................................................................................................................................... 277</p><p>3 UPPER ROTARY SYSTEM .............................................................................................................................................. 278</p><p>Rotary Gear Description ......................................................................................................................................................... 278</p><p>Ring gear lubricating pipe, replacing .................................................................................................................................. 279</p><p>Ⅶ FRAME AND TRACK EQUIPMENT ..................................................................................................................... 280</p><p>1 FRAME ......................................................................................................................................................................... 280</p><p>1.1 Overview ............................................................................................................................................................. 280</p><p>Upper structure, dissembbly .................................................................................................................................................... 280</p><p>Upper structure, installing ................................................................................................................................................... 280</p><p>1.2 Counter weight ................................................................................................................................................... 281</p><p>Additional weight and mining equipment ............................................................................................................................... 281</p><p>Counter weight, removing .................................................................................................................................................... 281</p><p>Balancing weight, installing Important! Move the control locking lever downwards to lock the system. ..................... 282</p><p>1.3 Frame, the lower part of body ............................................................................................................................ 283</p><p>Underframe / chassis, indication .......................................................................................................................................... 283</p><p>2 TRAVELLING DEVICES(WHEELS; TRACK; TIRES; HUB) ............................................................................................ 283</p><p>Select the track pieces ........................................................................................................................................................... 283</p><p>The method selecting track pieces ....................................................................................................................................... 283</p><p>2.1.Front idle control, including the front fork ...................................................................................................... 285</p><p>Guiding wheel, specification ................................................................................................................................................. 285</p><p>Guiding wheel, measuring .................................................................................................................................................... 286</p><p>Measuring thread surface and flange wear ......................................................................................................................... 287</p><p>Guiding wheel,dissembly or assembly tools ........................................................................................................................ 288</p><p>Guiding wheel, dissembling .................................................................................................................................................. 288</p><p>Guide wheel assembly ........................................................................................................................................................... 290</p><p>Front guide wheel, replacement ........................................................................................................................................... 291</p><p>2.2 Sprocket teeth ..................................................................................................................................................... 292</p><p>Sprocket, wear measurement ............................................................................................................................................... 292</p><p>Measure the profile of sprocket tooth .................................................................................................................................. 293</p><p>Measure sprocket tooth width .............................................................................................................................................. 293</p><p>Sprocket, replacement .......................................................................................................................................................... 294</p><p>2.3 Steel Track ......................................................................................................................................................... 294</p><p>Track, adjust the track tension ............................................................................................................................................ 294</p><p>Track chain,specification ...................................................................................................................................................... 296</p><p>Track chain ............................................................................................................................................................................</p><p>296</p><p>Track chain, wear limitation ................................................................................................................................................ 296</p><p>Track chain，wear measurement ........................................................................................................................................ 298</p><p>Measure the wear of track connection pitch ....................................................................................................................... 298</p><p>Measure wear of the outside diameter of bushing .............................................................................................................. 298</p><p>Wear measurement of connection height ............................................................................................................................ 299</p><p>Measure the wear of the height track plate ......................................................................................................................... 300</p><p>Track chain, removing .......................................................................................................................................................... 301</p><p>Track chain, installing .......................................................................................................................................................... 303</p><p>Main pin ,assembly ............................................................................................................................................................... 303</p><p>Track chain assembly, removing ......................................................................................................................................... 304</p><p>Track chain assembly, assembling ....................................................................................................................................... 306</p><p>Track chain assembly, removing ......................................................................................................................................... 308</p><p>2.4 Supporting sprocket; sliding rail ................................................................................................................... 309</p><p>Description of the top roller ................................................................................................................................................. 309</p><p>Supporting sprocket; measuring .......................................................................................................................................... 309</p><p>Measure the wear of outside diameter of supporting sprocket thread. ............................................................................ 310</p><p>Measure the wear of flange width of supporting sprocket. ................................................................................................ 311</p><p>Top rollers,dissembly and assembly tools ........................................................................................................................... 311</p><p>Top roller, dismantling ......................................................................................................................................................... 312</p><p>Supporting wheel, assembly ................................................................................................................................................. 312</p><p>Top roller, replacing one ...................................................................................................................................................... 314</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>VIII</p><p>Installation............................................................................................................................................................................... 314</p><p>2.5 Bottom roller ...................................................................................................................................................... 315</p><p>Bearing wheel specification .................................................................................................................................................. 315</p><p>Bearing wheel,wear limitation.............................................................................................................................................. 316</p><p>Measure the wear of outside diameter of roller thread. ..................................................................................................... 317</p><p>Measure the wear of flange width of roller ......................................................................................................................... 317</p><p>Bearing wheel, installing ....................................................................................................................................................... 318</p><p>Bearing wheel, dissembly and assembly tools ..................................................................................................................... 319</p><p>Roller, dismantling ................................................................................................................................................................ 319</p><p>Bearing wheel, assembly ....................................................................................................................................................... 321</p><p>Track plate, replacing one .................................................................................................................................................... 323</p><p>2.7 Spring kit; tensioning device ............................................................................................................................. 324</p><p>Spring group description ...................................................................................................................................................... 324</p><p>Spring group, dismantling .................................................................................................................................................... 325</p><p>Spring group, dissembly ....................................................................................................................................................... 326</p><p>Track tension spring(Tensioner) assembly, replacing........................................................................................................ 328</p><p>Ⅷ CAB AND INTERIOR TRIMMING ....................................................................................................................... 329</p><p>1. CAB ...................................................................................................................................................................... 329</p><p>Cab specifications (Refer to overview) ................................................................................................................................ 329</p><p>Cab, removing ....................................................................................................................................................................... 329</p><p>Cab, installing ........................................................................................................................................................................ 329</p><p>Fiber plastic device, description ........................................................................................................................................... 330</p><p>Fiber plastic device, removing .............................................................................................................................................. 330</p><p>Fiber plastic device, installing .............................................................................................................................................. 331</p><p>2 OPERATOR SEAT ........................................................................................................................................................</p><p>332</p><p>The operator seat specifications (Refer to Overview) ........................................................................................................ 332</p><p>Operator seat instructions .................................................................................................................................................... 332</p><p>Operator seat, tightening torque .......................................................................................................................................... 333</p><p>Seat, replacing ....................................................................................................................................................................... 333</p><p>3 AIR CONDITIONING UNITS .......................................................................................................................................... 334</p><p>3.1 Overview ........................................................................................................................................................... 334</p><p>Air-conditioning unit, specifications (Refer to Overview) ................................................................................................. 334</p><p>Air-conditioning unit, instruction ........................................................................................................................................ 334</p><p>Air Conditioning Components ............................................................................................................................................. 337</p><p>Air conditioning switch ......................................................................................................................................................... 341</p><p>Automatic air conditioning switch ..................................................................................................................................... 341</p><p>Air conditioning switch function ....................................................................................................................................... 342</p><p>Control system, indication .................................................................................................................................................... 345</p><p>Temperature setting ........................................................................................................................................................... 346</p><p>Initial heating mode ........................................................................................................................................................... 346</p><p>Air mixture throttle control ................................................................................................................................................ 346</p><p>Blower fan speed control ................................................................................................................................................... 346</p><p>Model throttle control ........................................................................................................................................................ 346</p><p>Gas inlet control ................................................................................................................................................................. 347</p><p>Memory and Replay........................................................................................................................................................... 347</p><p>Protection of compressor ................................................................................................................................................... 347</p><p>Self-diagnostics and instruction of system status ............................................................................................................... 348</p><p>Emergency mode ............................................................................................................................................................... 349</p><p>Expansion valve ..................................................................................................................................................................... 349</p><p>Expansion valve ,description ............................................................................................................................................. 349</p><p>Expansion valve, operation ................................................................................................................................................ 349</p><p>Evaporator ............................................................................................................................................................................. 350</p><p>Evaporator,instruction ........................................................................................................................................................ 350</p><p>Compressor ............................................................................................................................................................................ 351</p><p>Compressor,instruction ...................................................................................................................................................... 351</p><p>Condenser .............................................................................................................................................................................. 352</p><p>Condenser,instruction ........................................................................................................................................................ 352</p><p>Dry Filter ............................................................................................................................................................................... 353</p><p>Dry cleaner, instructions .................................................................................................................................................... 353</p><p>Drier ................................................................................................................................................................................... 353</p><p>Pressure Switch .................................................................................................................................................................. 353</p><p>Safety valve ....................................................................................................................................................................... 354</p><p>Drier, replacing ..................................................................................................................................................................... 354</p><p>Refrigerant hose .................................................................................................................................................................... 354</p><p>Blower motor ......................................................................................................................................................................... 355</p><p>Ceramic resistor .................................................................................................................................................................... 356</p><p>3-point relay ........................................................................................................................................................................... 356</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>IX</p><p>Actuator, foot / face driver ................................................................................................................................................... 357</p><p>Actuator, air mixing valve driver ........................................................................................................................................ 358</p><p>Water temperature sensor</p><p>.................................................................................................................................................... 359</p><p>Pipe temperature sensor ....................................................................................................................................................... 360</p><p>Temperature sensor inside the vehicle ................................................................................................................................ 361</p><p>Air conditioning units, maintenance .................................................................................................................................... 361</p><p>Periodic inspection ................................................................................................................................................................ 361</p><p>Inspection items ..................................................................................................................................................................... 362</p><p>Ambient temperature sensor ................................................................................................................................................ 364</p><p>Air conditioning unit, refrigerant inspecting and filling .................................................................................................... 365</p><p>Special tools ........................................................................................................................................................................... 365</p><p>Connection method of quick joints .................................................................................................................................... 365</p><p>Disconnection method of quick joints .................................................................................................................................. 365</p><p>Pressure check procedure ..................................................................................................................................................... 365</p><p>Use the test values of meter to troubleshoot ........................................................................................................................ 366</p><p>Abnormal readings of pressure gauge, reason .................................................................................................................... 366</p><p>Steps of refrigerant filling..................................................................................................................................................... 369</p><p>Refrigerant draining ............................................................................................................................................................. 370</p><p>Draining ................................................................................................................................................................................. 370</p><p>Refrigerant filling .................................................................................................................................................................. 370</p><p>Ⅸ.HYDRAULIC SYSTEM, HYDRAULIC WORK, AND OTHER EQUIPMENT ................................................. 373</p><p>Summary ................................................................................................................................................................................ 373</p><p>Instruction, summary ........................................................................................................................................................... 373</p><p>Hydraulic oil, indication ....................................................................................................................................................... 374</p><p>Hydraulic systems, hydraulic components in the maintenance of repair plant ............................................................... 374</p><p>Hydraulic oil, storage and processing .................................................................................................................................. 375</p><p>Hydraulic system, the cleanliness when dealing with the hydraulic components ............................................................ 375</p><p>Hydraulic components, storage and transportation ........................................................................................................... 376</p><p>1．HYDRAULIC OIL AND PIPELINE (WORKING HYDRAULIC, SERVO-HYDRAULIC) ........................................................... 376</p><p>1.1 Overview ............................................................................................................................................................. 376</p><p>Hydraulic system, working notes ......................................................................................................................................... 376</p><p>Hydraulic system, indication ................................................................................................................................................ 377</p><p>Hydraulic schematic diagram .............................................................................................................................................. 377</p><p>Hydraulic components, description ..................................................................................................................................... 378</p><p>1.2 Fuel tank; pipeline; hydraulic oil cooling; filter; ventilation device ............................................................... 380</p><p>1.2.1 The fuel tank ................................................................................................................................................................. 380</p><p>Hydraulic tank ,description .................................................................................................................................................. 380</p><p>Hydraulic oil filter bypass valve........................................................................................................................................... 381</p><p>SCBA ...................................................................................................................................................................................... 381</p><p>Hydraulic tank, vacuum technology, and connection and disconnection of oil pump ..................................................... 382</p><p>Hydraulic oil level gauge, replacing ..................................................................................................................................... 383</p><p>Respirator, replacing ............................................................................................................................................................ 384</p><p>1.2.2 pipeline; fixtures; connection block; locator .............................................................................................................. 384</p><p>Shuttle valve blocks, description .......................................................................................................................................... 384</p><p>Servo-hydraulic selector valve, instructions ....................................................................................................................... 385</p><p>Check valve ............................................................................................................................................................................ 386</p><p>Servo-hydraulic pipeline ....................................................................................................................................................... 387</p><p>Remote control valve (operation lever) pipeline ................................................................................................................ 387</p><p>Remote control valve (pedal) pipeline ...............................................................................................................................</p><p>389</p><p>Solenoid valve pipeline ...................................................................................................................................................... 390</p><p>Hydraulic oil pump pipeline ................................................................................................................................................. 392</p><p>Main valve pipeline ............................................................................................................................................................... 395</p><p>Hydraulic main pipeline ....................................................................................................................................................... 397</p><p>Descending pipeline ............................................................................................................................................................... 398</p><p>Oil returning pipeline and pump pipeline ........................................................................................................................... 399</p><p>1.2.3 Hydraulic oil cooling system ........................................................................................................................................ 400</p><p>Hydraulic oil cooling system,instruction ............................................................................................................................. 400</p><p>1.3 Servo-hydraulic system ...................................................................................................................................... 400</p><p>1.3.1 Pressure accumulator.................................................................................................................................................... 400</p><p>Description of the pressure accumulator............................................................................................................................. 400</p><p>Valve block of accumulator ............................................................................................................................................... 401</p><p>Accumulator, replacing ........................................................................................................................................................ 402</p><p>1.3.2 Solenoid valve, on / off function .................................................................................................................................. 403</p><p>The electromagnetic valve,description ................................................................................................................................ 403</p><p>Solenoid valve, disassembly and assembly .......................................................................................................................... 406</p><p>Tools and Torque ............................................................................................................................................................... 406</p><p>Dissembling ....................................................................................................................................................................... 407</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>X</p><p>Assembly ........................................................................................................................................................................... 407</p><p>Solenoid valve, replacing ...................................................................................................................................................... 408</p><p>Solenoid valve troubleshooting ............................................................................................................................................ 409</p><p>2 MAIN CONTROL VALVE (DIRECTIONAL VALVE; CONTROL VALVE) ......................................................................... 409</p><p>Hydraulic circuit, valve ........................................................................................................................................................ 409</p><p>Description of the main control valve .................................................................................................................................. 411</p><p>Main control valve, partial view ........................................................................................................................................ 414</p><p>General notes ......................................................................................................................................................................... 417</p><p>Notice for disassembly ....................................................................................................................................................... 417</p><p>Notice for disassembly ....................................................................................................................................................... 418</p><p>Notice for assembly ........................................................................................................................................................... 418</p><p>General Tools ........................................................................................................................................................................ 420</p><p>Fixture(Material :copper) ................................................................................................................................................... 421</p><p>Main spool,removing ......................................................................................................................................................... 421</p><p>Description of the main pressure relief valve ...................................................................................................................... 423</p><p>Normal pressure (330 kgf / cm2) ........................................................................................................................................ 423</p><p>Pressurized (350 kgf/cm2) .................................................................................................................................................. 423</p><p>Main pressure relief valve, adjustment ............................................................................................................................... 424</p><p>Limit the adjustment of pressure ........................................................................................................................................ 424</p><p>Measuring .......................................................................................................................................................................... 424</p><p>High-pressure adjustment (boost pressure) ........................................................................................................................ 425</p><p>Low pressure adjustment (standard pressure) .................................................................................................................... 425</p><p>Throttle pressure relief valve, description .......................................................................................................................... 426</p><p>Overload operation ............................................................................................................................................................ 426</p><p>Anti-cavitation operation ................................................................................................................................................... 427</p><p>Main pressure relief valve,removing ................................................................................................................................... 427</p><p>Main pressure relief valve,replacing.................................................................................................................................... 428</p><p>Throttle pressure relief</p><p>valve , measurement and adjustment .......................................................................................... 428</p><p>Measurement conditions .................................................................................................................................................... 428</p><p>Measuring .......................................................................................................................................................................... 429</p><p>Hydraulic pressure ............................................................................................................................................................. 429</p><p>Basic pump provides oil to each actuator and test throttle. ................................................................................................ 429</p><p>Track motor, pressure measurement throttle ...................................................................................................................... 430</p><p>Displacement control of pump ........................................................................................................................................... 430</p><p>Adjust the throttle pressure reducing valve ........................................................................................................................ 431</p><p>Rotary motor throttle pressure relief valve, adjusting ........................................................................................................ 432</p><p>Throttle pressure relief valve, disassembly ........................................................................................................................ 432</p><p>Phase 2 throttle pressure relief valve, description .............................................................................................................. 433</p><p>Overload operation (for selection) ..................................................................................................................................... 433</p><p>Anti-cavitation operation ................................................................................................................................................. 435</p><p>Stage 2 section adjustable gate valve ................................................................................................................................... 435</p><p>High pressure adjustment ................................................................................................................................................... 436</p><p>Low-pressure adjustment ................................................................................................................................................... 436</p><p>Stage 2 throttle pressure relief valve, disassembly ............................................................................................................. 436</p><p>Boom locking valve,instructions .......................................................................................................................................... 437</p><p>Spool in neutral position .................................................................................................................................................... 437</p><p>Spool operation .................................................................................................................................................................. 438</p><p>Boom oil regeneration valve,instruction .............................................................................................................................. 441</p><p>Boom back pressure check valve, removing ...................................................................................................................... 442</p><p>Bucket arm lock valve,instructions ...................................................................................................................................... 442</p><p>Spool in neutral position .................................................................................................................................................... 442</p><p>Operation of spool ............................................................................................................................................................. 443</p><p>Auxiliary lock valve, removing............................................................................................................................................. 445</p><p>Boom oil regeneration valve instructions ............................................................................................................................ 446</p><p>Negative pressure relief valve,description ........................................................................................................................... 449</p><p>Negative pressure relief valve, disassembly ........................................................................................................................ 449</p><p>Bucket arm flow regeneration and bucket arm confluence check valve, removing ......................................................... 450</p><p>Description of logic valve ...................................................................................................................................................... 451</p><p>In the neutral position and the position of boom descending ............................................................................................. 451</p><p>Boom up ............................................................................................................................................................................ 452</p><p>Logic valve disassembly and assembly ................................................................................................................................ 453</p><p>Bucket arm parallel confluence valve ,disassembly and assembly .................................................................................... 454</p><p>Bucket arm parallel confluence check valve, disassembly and assembly ......................................................................... 454</p><p>Central bypass valve, removing ........................................................................................................................................... 454</p><p>Straight transition valve, removing ..................................................................................................................................... 455</p><p>Load check valve - single valve, removing .......................................................................................................................... 455</p><p>Load check valve - double valve, removing ......................................................................................................................... 456</p><p>Troubleshooting of the main control valve.......................................................................................................................... 456</p><p>Troubleshooting of the pressure reducing valve ................................................................................................................. 459</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>XI</p><p>3 MAIN PUMP AND THE SERVO PUMP (HYDRAULIC WORK; SERVO-HYDRAULIC) ....................................................... 460</p><p>3.1 Oil pump, hydraulic work .................................................................................................................................. 460</p><p>Pump instructions ................................................................................................................................................................. 460</p><p>Pump, partial view ............................................................................................................................................................. 462</p><p>Pump, exploded view .........................................................................................................................................................</p><p>463</p><p>Operation principle of pump .............................................................................................................................................. 463</p><p>Maximum oil flow adjustment ........................................................................................................................................... 465</p><p>Minimum oil flow adjustment............................................................................................................................................ 465</p><p>Pumps, maintenance standards............................................................................................................................................ 465</p><p>Precaution for use .............................................................................................................................................................. 465</p><p>Lubrication and draining the air ......................................................................................................................................... 466</p><p>Start.................................................................................................................................................................................... 466</p><p>General Considerations ...................................................................................................................................................... 466</p><p>Check the abnormal circumstance of oil pump. ................................................................................................................. 466</p><p>Check the hydraulic oil filter and draining the hydraulic oil .............................................................................................. 467</p><p>Check the abnormal sound or vibration ............................................................................................................................. 467</p><p>Measure the pressure in different measurement points. ..................................................................................................... 467</p><p>Standard of maintenance and replacement of parts ............................................................................................................ 467</p><p>Wear limit of cylinder, the valve plate and the swash plate ............................................................................................... 469</p><p>Tightening torque ............................................................................................................................................................... 469</p><p>Pump tools ............................................................................................................................................................................. 470</p><p>Tool.................................................................................................................................................................................... 470</p><p>Pump,removing ..................................................................................................................................................................... 471</p><p>Pump assembly ...................................................................................................................................................................... 474</p><p>Preparation ......................................................................................................................................................................... 474</p><p>Pump, installing ..................................................................................................................................................................... 476</p><p>Starting notice .................................................................................................................................................................... 476</p><p>Installation Notes ............................................................................................................................................................... 477</p><p>Pump,troubleshooting ........................................................................................................................................................... 477</p><p>Regulation, specification ....................................................................................................................................................... 479</p><p>Regulator, exploded view .................................................................................................................................................. 481</p><p>Operation principle of regulator ......................................................................................................................................... 481</p><p>Power Shift Control ........................................................................................................................................................... 482</p><p>Negative oil flow control ................................................................................................................................................... 483</p><p>Reducing function of oil flow ............................................................................................................................................ 483</p><p>Increasing function of oil flow ........................................................................................................................................... 484</p><p>Regulator, full-power control ............................................................................................................................................. 485</p><p>Oil flow re-set function ...................................................................................................................................................... 485</p><p>Regulator, low-angle (low oil flow) command priority function ....................................................................................... 486</p><p>Regulator, power shift control ........................................................................................................................................... 486</p><p>Regulator maintenance ......................................................................................................................................................... 486</p><p>Failure and corrective methods .......................................................................................................................................... 486</p><p>Overload of engine............................................................................................................................................................. 486</p><p>Unable to obtain the maximum oil flow............................................................................................................................. 487</p><p>Regulator, checking and adjustment .................................................................................................................................. 487</p><p>Adjust the input horsepower .............................................................................................................................................. 488</p><p>Pump control curve ............................................................................................................................................................... 489</p><p>Regulator disassembly .......................................................................................................................................................... 490</p><p>Regulator disassembly .......................................................................................................................................................... 491</p><p>Regulator assembly ............................................................................................................................................................... 494</p><p>Hydraulic pump, replacing...................................................................................................................................................</p><p>496</p><p>Hydraulic pump (removed), replace the shaft seals ........................................................................................................... 500</p><p>Pump regulator, replacing .................................................................................................................................................... 500</p><p>3.2 Servo-hydraulic system ...................................................................................................................................... 501</p><p>3.2.1 Pump ............................................................................................................................................................................. 501</p><p>Description of the servo pump ............................................................................................................................................. 501</p><p>Servo-hydraulic pressure control ......................................................................................................................................... 503</p><p>Measuring .......................................................................................................................................................................... 503</p><p>Adjustment ......................................................................................................................................................................... 503</p><p>Servo pump, replacing .......................................................................................................................................................... 504</p><p>3.2.2 Proportional solenoid valve ......................................................................................................................................... 505</p><p>Proportional solenoid valve instructions ............................................................................................................................. 505</p><p>Model code (KDRDE 5 K - 20 / 40 C L) ........................................................................................................................... 505</p><p>Operational records ............................................................................................................................................................ 506</p><p>Tightening torque ............................................................................................................................................................... 507</p><p>Inspection techniques ......................................................................................................................................................... 508</p><p>Measurement and adjustment of proportional solenoid valve .......................................................................................... 508</p><p>Measurement conditions .................................................................................................................................................... 508</p><p>Adjustment ......................................................................................................................................................................... 508</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>XII</p><p>Proportional solenoid valve (power shift), replacing .......................................................................................................... 509</p><p>Current/pressure, specification ............................................................................................................................................ 510</p><p>Troubleshooting .................................................................................................................................................................... 510</p><p>4. REMOTE CONTROL VALVE(CONTROL PRESSURE VALVE) ....................................................................................... 511</p><p>4.1 Remote control valve(Operation lever) ............................................................................................................. 511</p><p>Remote control valve(Operation lever),specification ......................................................................................................... 511</p><p>Remote control valve (Operation lever), instruction .......................................................................................................... 512</p><p>Maintenance standard of remote valve(operation lever) ................................................................................................... 519</p><p>Remote control valve（operation lever）,removing .......................................................................................................... 520</p><p>Remote control valve (operation lever), assembly .............................................................................................................. 527</p><p>Remote control valve (joystick),troubleshooting ................................................................................................................ 534</p><p>4.2 Remote control valve (pedal) ............................................................................................................................. 535</p><p>Remote control valve (pedal),specification .......................................................................................................................... 535</p><p>Remote control valve (pedal),instruction ............................................................................................................................ 535</p><p>Remote control valve (pedal), removing .............................................................................................................................. 543</p><p>Remote control valve (pedal) assembly ............................................................................................................................... 551</p><p>Remote control valve (pedal) Troubleshooting ................................................................................................................... 559</p><p>5. EXCAVATING DEVICE ................................................................................................................................................. 560</p><p>5.1 Summary ............................................................................................................................................................ 560</p><p>Maintenance of excavating equipment ................................................................................................................................ 560</p><p>Cylinder, specification ........................................................................................................................................................... 561</p><p>Cylinder, disassembly and assembly ....................................................................................................................................... 564</p><p>Cylinder, troubleshooting ........................................................................................................................................................ 583</p><p>5.2 Boom with a linkage .......................................................................................................................................... 585</p><p>Boom, specifications .............................................................................................................................................................. 585</p><p>Boom, removing...................................................................................................................................................................... 586</p><p>Boom , installing ................................................................................................................................................................ 587</p><p>Boom cylinder ........................................................................................................................................................................</p><p>588</p><p>Boom cylinder, specification ................................................................................................................................................. 588</p><p>Description of boom cylinder .................................................................................................................................................. 588</p><p>Boom cylinder, removing ........................................................................................................................................................ 589</p><p>Boom cylinder, installing ........................................................................................................................................................ 589</p><p>Boom cylinder, disassembly and assembly ............................................................................................................................. 590</p><p>Maintenance capacity limit ..................................................................................................................................................... 591</p><p>5.3 Bucket arm with a linkage ................................................................................................................................. 592</p><p>Bucket arm specification ......................................................................................................................................................... 592</p><p>Bucket arm, instruction ........................................................................................................................................................... 592</p><p>Bucket arm, removing ............................................................................................................................................................. 593</p><p>Linkage, instructions ............................................................................................................................................................... 594</p><p>Linkage, removing .................................................................................................................................................................. 595</p><p>Linkage, installing ................................................................................................................................................................... 595</p><p>Bucket arm cylinder, Specifications ........................................................................................................................................ 596</p><p>Bucket arm cylinder, Description ............................................................................................................................................ 596</p><p>Bucket arm cylinder, removing ............................................................................................................................................... 596</p><p>Bucket arm cylinder, installing ............................................................................................................................................... 597</p><p>Bucket arm cylinder disassembly and assembly ..................................................................................................................... 598</p><p>Tightening torque .................................................................................................................................................................. 598</p><p>Bucket arm Cylinder Troubleshooting .................................................................................................................................... 600</p><p>Bucket removing ................................................................................................................................................................ 600</p><p>Bucket, installating .................................................................................................................................................................. 601</p><p>Bucket clearance adjusting ...................................................................................................................................................... 601</p><p>Bucket cylinder, specification ................................................................................................................................................. 602</p><p>Bucket cylinder, removing ...................................................................................................................................................... 603</p><p>Bucket cylinder disassembly and assembly............................................................................................................................. 603</p><p>Bucket Cylinder Troubleshooting ........................................................................................................................................... 605</p><p>6. OPTIONAL EQUIPMENT (HYDRAULIC WORK; SERVO-HYDRAULIC) .............................................................................. 606</p><p>6.1 Hydraulic equipment is installed on the machine for additional equipments. ................................................ 606</p><p>6.1.1Other hydraulic system ................................................................................................................................................. 606</p><p>Hammer and scissors (select X1),Description ......................................................................................................................... 606</p><p>Proportional solenoid valve, instructions ............................................................................................................................ 610</p><p>Proportional solenoid valve (X1 double switch) ................................................................................................................ 610</p><p>Hammer oil return filter ....................................................................................................................................................... 610</p><p>Description of the solenoid valve .......................................................................................................................................... 611</p><p>X1, 3-section solenoid valve .............................................................................................................................................. 611</p><p>X12 pipeline of pump ............................................................................................................................................................ 612</p><p>Proportional solenoid valve .................................................................................................................................................. 613</p><p>Hammer and hydraulic shear selecting solenoid valve (1) ................................................................................................. 614</p><p>Hammer and shears with 2 pump oil flow pipe (2) ............................................................................................................. 615</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>XIII</p><p>Hammer and hydraulic shear shuttle valve -A type ........................................................................................................... 616</p><p>X1 logic valve ......................................................................................................................................................................... 617</p><p>Check valve ............................................................................................................................................................................ 618</p><p>6.2 Machinery Equipment / Additional Equipment ................................................................................................ 618</p><p>Hydraulic Quick Installation, instruction ........................................................................................................................... 618</p><p>Hydraulic quick installation, adjusting ...............................................................................................................................</p><p>623</p><p>7 TROUBLESHOOTING (WORKING HYDRAULIC, SERVO HYDRAULIC) ........................................................................ 625</p><p>Troubleshooting diagnostics procedures ............................................................................................................................. 625</p><p>Examples of hydraulic system failure .................................................................................................................................. 627</p><p>Power transmission example ................................................................................................................................................ 639</p><p>8 HYDRAULIC DIAGRAM ............................................................................................................................................... 646</p><p>The interpretation of the hydraulic schematic .................................................................................................................... 646</p><p>Symbol ............................................................................................................................................................................... 646</p><p>Application ........................................................................................................................................................................ 649</p><p>Valve symbols ................................................................................................................................................................... 649</p><p>Interpretation of the valve symbol ..................................................................................................................................... 649</p><p>Hydraulic circuit,throttle ......................................................................................................................................................... 650</p><p>Hydraulic diagram, neutral ...................................................................................................................................................... 660</p><p>Servo-hydraulic circuit (Safety lock lever is in the unlocked position).............................................................................. 660</p><p>Hydraulic circuit, standard ...................................................................................................................................................... 661</p><p>Hydraulic circuit, bucket arm retracted confluence ................................................................................................................. 664</p><p>Hydraulic circuit, bucket arm extends ..................................................................................................................................... 667</p><p>Hydraulic circuit, bucket arm withdraw / boom up ................................................................................................................. 669</p><p>The operations that the bucket arm retracts and the boom rises work at the same time. ......................................................... 669</p><p>Hydraulic circuit,swing (turn left) ........................................................................................................................................... 671</p><p>Hydraulic circuit, rotating priority (turn right / bucket retracting) .......................................................................................... 673</p><p>Hydraulic circuit, moving straight (low shift / automatic shift) ......................................................................................... 676</p><p>Hydraulic circuit, moving straight/Bucket arm (automatic shift,bucket arm withdraws).............................................. 679</p><p>Ⅹ.ELECTRONIC AND INFORMATION SYSTEM(GUIDE) ................................................................................... 681</p><p>1 OVERVIEW .................................................................................................................................................................. 681</p><p>1.1 Overal information, electrical system ................................................................................................................. 681</p><p>1.1.1 Overview of Electrical System ....................................................................................................................................... 681</p><p>Electrical system, instruction .................................................................................................................................................. 681</p><p>Special repair of electrical system maintenance, overview ..................................................................................................... 681</p><p>Electrical system, work descriptions, electronic components, batteries .................................................................................. 682</p><p>Specified instruction of electrical system maintenance, electrical components, alternators and charging regulator ............... 683</p><p>Specified instruction of electrical system maintenance, electrical components ...................................................................... 684</p><p>Specified instruction of electrical system maintenance while working on the machine .......................................................... 685</p><p>Auxiliary starting .................................................................................................................................................................... 685</p><p>Start with the starting cables ................................................................................................................................................... 686</p><p>1.1.2 Overview of electronic systems ..................................................................................................................................... 687</p><p>Electronic control system, indication ...................................................................................................................................... 687</p><p>Using data bus communication ............................................................................................................................................... 688</p><p>CAN/J1939 control bus ........................................................................................................................................................... 688</p><p>Instrument Control Unit I-ECU, Function instruction ............................................................................................................. 689</p><p>Vehicle control components V-ECU, Function instruction ..................................................................................................... 690</p><p>Input signal.............................................................................................................................................................................. 691</p><p>Output signal ........................................................................................................................................................................... 691</p><p>Software functions, engine-related .......................................................................................................................................... 692</p><p>Safety starting and stopping,engine ......................................................................................................................................... 692</p><p>When the functions of V-ECU fails ...................................................................................................................................... 692</p><p>Mode selection and engine speed-sensitive power control ...................................................................................................... 692</p><p>P mode (full workload of operation) ....................................................................................................................................... 694</p><p>H mode(Heavy workload-operation)</p><p>specifications ..................................................................................................................................................... 24</p><p>Starting motor, specifications .................................................................................................................................................... 24</p><p>Battery relay, specifications ...................................................................................................................................................... 25</p><p>Security starting relay, specifications ........................................................................................................................................ 25</p><p>Preheating, specifications .......................................................................................................................................................... 25</p><p>Battery relay, specifications ...................................................................................................................................................... 25</p><p>Traveling warning, specifications ............................................................................................................................................. 26</p><p>Upper wiper motor, specifications ............................................................................................................................................ 26</p><p>Cutting switch of battery, specifications ................................................................................................................................... 26</p><p>Starting switch, specifications ................................................................................................................................................... 26</p><p>Security lever switch, specifications ......................................................................................................................................... 27</p><p>Manual/auto switch, specifications ........................................................................................................................................... 27</p><p>Fuse specifications .................................................................................................................................................................... 28</p><p>Slow melt fuse, specification ................................................................................................................................................... 28</p><p>Relay box, specifications ......................................................................................................................................................... 29</p><p>Resistance box, specification .................................................................................................................................................. 29</p><p>Radio with cassette or CD player specifications ................................................................................................................... 30</p><p>CD and MP3 player with recorder ....................................................................................................................................... 30</p><p>DC-DC converter specification .............................................................................................................................................. 30</p><p>Track gearbox specification ................................................................................................................................................... 30</p><p>Rotary gearbox specifications ................................................................................................................................................ 30</p><p>Travel motor, specifications .............................................................................................................................................. 31</p><p>Rotary unit specifications ....................................................................................................................................................... 32</p><p>Frame and the track unit, specifications ............................................................................................................................... 32</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>II</p><p>Rotary gear ring，specifications ........................................................................................................................................... 33</p><p>Regulator, specifications ......................................................................................................................................................... 34</p><p>Cab specifications .................................................................................................................................................................... 34</p><p>Operator seat specifications ................................................................................................................................................... 35</p><p>Recommended hydraulic oil specifications ........................................................................................................................... 35</p><p>Hydraulic oil, specifications ................................................................................................................................................... 36</p><p>Hydraulic pressure，specifications ....................................................................................................................................... 36</p><p>Hydraulic tank, specifications ................................................................................................................................................ 36</p><p>Air conditioning unit，specifications .................................................................................................................................... 36</p><p>Proportional solenoid calve specifications ............................................................................................................................. 38</p><p>Main control valve specifications ........................................................................................................................................... 38</p><p>Pump, specifications ................................................................................................................................................................ 40</p><p>Servo pump specifications ...................................................................................................................................................... 41</p><p>Accumulator specifications..................................................................................................................................................... 41</p><p>Servo-hydraulic selector valve, specifications ....................................................................................................................... 41</p><p>Solenoid valve, specifications ................................................................................................................................................. 42</p><p>Remote control valve （lever）specifications ...................................................................................................................... 43</p><p>Remote control valve （pedal）specifications ..................................................................................................................... 43</p><p>Walking pedal specifications .................................................................................................................................................. 43</p><p>Straight pedal specification .................................................................................................................................................. 43</p><p>Hydraulic oil cooling system, specifications ..........................................................................................................................</p><p>....................................................................................................................................... 694</p><p>G mode (Normal workload operation) .................................................................................................................................... 694</p><p>F mode (fine work operations) ................................................................................................................................................ 694</p><p>I mode (idle operation) ............................................................................................................................................................ 695</p><p>Auto single-touch power boost ............................................................................................................................................... 696</p><p>Automatic running speed control ............................................................................................................................................ 697</p><p>Software functions of electrical system of (equipped with I-ECU) ......................................................................................... 698</p><p>2 BATTERY ..................................................................................................................................................................... 699</p><p>Batteries, instructions .............................................................................................................................................................. 699</p><p>Battery, charging ..................................................................................................................................................................... 699</p><p>Batteries, storage ..................................................................................................................................................................... 700</p><p>Batteries, replaing ................................................................................................................................................................... 700</p><p>3 ALTERNATOR; CHARGING TRANSFORMER ................................................................................................................... 701</p><p>Alternator, indication .............................................................................................................................................................. 701</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>XIV</p><p>Charge, indication ................................................................................................................................................................... 701</p><p>4.STARTING SYSTEM ...................................................................................................................................................... 701</p><p>4.1Overview ............................................................................................................................................................................ 701</p><p>Starting operations .................................................................................................................................................................. 701</p><p>4.2 Starting motor including coil .............................................................................................................................. 703</p><p>Starting engine , indication...................................................................................................................................................... 703</p><p>Battery relay instructions ........................................................................................................................................................ 703</p><p>Safety starting relay, instructions ............................................................................................................................................ 704</p><p>Starting relay, replacing .......................................................................................................................................................... 704</p><p>4.3 Electronic air preheater, not including components Warm-up, indication ..................................................... 705</p><p>5 OTHER ELECTRONIC EQUIPMENTS ............................................................................................................................ 705</p><p>5.1 Sound warning from the speaker; assembly ..................................................................................................... 705</p><p>Electric horn, specifications ................................................................................................................................................. 705</p><p>Backup warning; walking warning (optional) ......................................................................................................................... 705</p><p>5.2 Windshield wiper ................................................................................................................................................ 706</p><p>Description of the windshield wipers ...................................................................................................................................... 706</p><p>Windshield wipers,position ..................................................................................................................................................... 706</p><p>Wiper control, indication ........................................................................................................................................................ 707</p><p>Upper wiper motor, indication ................................................................................................................................................ 707</p><p>Window limit switch, indication ............................................................................................................................................. 707</p><p>5.3 Switch; connector ............................................................................................................................................... 708</p><p>Battery disconnects switch (optional), Description ................................................................................................................. 708</p><p>Starting switch, specification .................................................................................................................................................. 708</p><p>Auto/manual selecting switch,instruction ............................................................................................................................... 708</p><p>5.4 Electrical standard component ........................................................................................................................... 708</p><p>E-ECU, replacement of ECU .................................................................................................................................................. 708</p><p>I-ECU, replace ECU ............................................................................................................................................................... 709</p><p>V-ECU, replace ECU .............................................................................................................................................................. 709</p><p>6. INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM ................................................................................... 710</p><p>6.1 Transmitter, monitoring system .......................................................................................................................... 710</p><p>Description of engine oil pressure sensor ................................................................................................................................ 710</p><p>Fuel level sensor, indicating ....................................................................................................................................................</p><p>710</p><p>Coolant temperature sensor, description ............................................................................................................................ 711</p><p>Engine speed sensor(Camshaft) ,instruction ........................................................................................................................... 711</p><p>Control lock lever switch, indication ...................................................................................................................................... 712</p><p>6.2 Warning / information devices, display unit ....................................................................................................... 712</p><p>Gauge board,instruction (equipped with I-ECU)..................................................................................................................... 712</p><p>I-ECU circuit ........................................................................................................................................................................... 712</p><p>Alarm, indication .................................................................................................................................................................... 713</p><p>Alarms, specifications ............................................................................................................................................................. 713</p><p>Failure message ....................................................................................................................................................................... 714</p><p>7.RADIO,CD PLAYER, VOLTAGE DIVIDER .................................................................................................................... 714</p><p>7.1 CD and MP3 player with radio .......................................................................................................................... 714</p><p>Conection ............................................................................................................................................................................... 715</p><p>7.2 Voltage divider ................................................................................................................................................... 715</p><p>DC-DC Transformer, indication .......................................................................................................................................... 715</p><p>Inspection methods ............................................................................................................................................................ 716</p><p>PARTS CATALOG: GENERATORS, BATTERIES, ELECTRONIC UNIT ............................................................................... 716</p><p>Parts list, heating coil ............................................................................................................................................................ 717</p><p>Parts list,lamp ........................................................................................................................................................................ 717</p><p>Parts list, indicating lights, warning lights .......................................................................................................................... 717</p><p>Parts list, solenoid valve ........................................................................................................................................................ 717</p><p>Parts list, motor ..................................................................................................................................................................... 718</p><p>Parts list, relay ....................................................................................................................................................................... 719</p><p>Parts list, sensor..................................................................................................................................................................... 719</p><p>Parts list, switch..................................................................................................................................................................... 720</p><p>Parts list, fuse ........................................................................................................................................................................ 721</p><p>Components table,other items .............................................................................................................................................. 722</p><p>Circuit .................................................................................................................................................................................... 723</p><p>SCH01 .................................................................................................................................................................................... 724</p><p>SCH02 .................................................................................................................................................................................... 726</p><p>SCH03 .................................................................................................................................................................................... 728</p><p>SCH06 .................................................................................................................................................................................... 730</p><p>SCH07 .................................................................................................................................................................................... 732</p><p>SCH07 .................................................................................................................................................................................... 734</p><p>SCH08 .................................................................................................................................................................................... 736</p><p>SCH10 .................................................................................................................................................................................... 738</p><p>SCH12 .................................................................................................................................................................................... 740</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>XV</p><p>SCH13 .................................................................................................................................................................................... 742</p><p>SCH14 .................................................................................................................................................................................... 744</p><p>SCH15 .................................................................................................................................................................................... 746</p><p>SCH16 .................................................................................................................................................................................... 748</p><p>SCH17 .................................................................................................................................................................................... 750</p><p>SCH18 .................................................................................................................................................................................... 751</p><p>2.FUSE;RELAY;CIRCUIT CUT-OFF ................................................................................................................................ 752</p><p>2.1 Fuse ....................................................................................................................................................................</p><p>752</p><p>Fuse,instruction ..................................................................................................................................................................... 752</p><p>Slow-melt fuse,instruction .................................................................................................................................................... 753</p><p>Replacement process of fuse .............................................................................................................................................. 753</p><p>Relay box,specification ......................................................................................................................................................... 754</p><p>Resistance box, indication..................................................................................................................................................... 754</p><p>Fault research(Troubleshooting) ............................................................................................................................ 755</p><p>UPGRADED ELECTRICALSYSTEM.................................................................................................................... 755</p><p>SCH01................................................................................................................... ................................................756</p><p>SCH02.................................................................................................................................................................... 757</p><p>SCH03.................................................................................................................................................................... 758</p><p>SCH04.................................................................................................................................................................... 759</p><p>SCH07.................................................................................................................................................................... 760</p><p>SCH08................................................................................................................... .................................................761</p><p>SCH10 ..................................................................................................................................................................762</p><p>SCH12................................................................................................................... .................................................763</p><p>SCH13................................................................................................................... .................................................764</p><p>SCH14.................................................................................................................................................................... 765</p><p>SCH15................................................................................................................... .................................................766</p><p>SCH16.................................................................................................................................................................... 767</p><p>SCH17................................................................................................................... .................................................768</p><p>SCH18................................................................................................................... .................................................768</p><p>SCH30................................................................................................................... .................................................769</p><p>Wire Harness_Main_Lg6210e/Lg6225e_Prime......................................................................................................770</p><p>Wire Harness_Assy Instr LH SDLG........................................................................................................................771</p><p>Wire Harness_Assy Instr RH SDLG.................................................................................................... ...................772</p><p>Cabin Wiring Harness................................................................................................................... .........................773</p><p>Wiring Harness_Switch.......................................................................................................................................... 774</p><p>Service Manual──6210E&6225E Hydraulic Excavator</p><p>I</p><p>Preface</p><p>Repair Manual contains specification, function</p><p>introduction of the system and components, repair</p><p>instruction, the method to check and adjust, diagram</p><p>and circuits.</p><p>The safety regulations about maintaining on the</p><p>machine refer to SAFE PART.</p><p>The safety problems refer to Operation &</p><p>Maintenance Manual.</p><p>Operation procedure is based on the special tool on</p><p>the market, e-tools and standard tools.</p><p>The schematic diagram of E-tools can be found in the</p><p>manual.</p><p>All the lifting devices, such as belts, slings, ratchet</p><p>housing, etc., must comply with related national</p><p>regulations for these devices.</p><p>If the lifting devices ,tool or operation methods are</p><p>applied, our company will not bear any responsibility.</p><p>Information and data given in the manual is effective</p><p>when publicating.</p><p>We reserve the right to not notice the change of</p><p>specifications and equipments in advance.</p><p>Security</p><p>ⅠWhole machine instruction</p><p>ⅡRepair and maintenance</p><p>Ⅲ Engine</p><p>Ⅳ Power transmission</p><p>Ⅴ Brake system（No）</p><p>Ⅵ Steering system（No）</p><p>Ⅶ Frame and track unit</p><p>Ⅷ Cab and internal equipment</p><p>Ⅸ Hydraulid equipments and other</p><p>equipment</p><p>Ⅹ Electrical and information system</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>1</p><p>Security</p><p>Common precaution</p><p>Warning!</p><p>Please comply with the following rules for the security.</p><p>Security precautions</p><p> If you have been drinking, eating some pills or other</p><p>narcotics, do not operate the machine.</p><p> Only trained and authorized people can be permitted to</p><p>operate and maintain the machine.</p><p> Read the Operation & Maintenance Manual carefully when</p><p>operating and maintaining the machine.Read the warning</p><p>labels fixed on the machine.</p><p>Safety Devices</p><p> Ensure that all guards and covers are in their proper position,</p><p>and repair them when they are damaged.</p><p> Use safety locking devices or safety belt properly.</p><p> Wear the safety belts when doing all the operations.</p><p>Clothing and Personal Protective Items</p><p> Avoid wear loose clothing, jewelry and loose long hair.</p><p>They can be caught on control levers or in moving parts and</p><p>cause serious injury or death. Also, avoid wearing oily</p><p>clothes, because they are flammable.</p><p> Wear a hard helmet, safety glasses, shoes, mask or gloves</p><p>when operating or maintaining the machine. Always wear</p><p>safety goggles, a hard helmet and heavy gloves if the</p><p>operation involves scattering metal chips or other minute</p><p>particle particularly when driving pins with a hammer or</p><p>cleaning the filter elements of air cleaner with compressed</p><p>air, be sure that there is no one near the machine. Check</p><p>properly all protective equipments before using.</p><p>Conform to safety</p><p>regulation</p><p>Protective Items</p><p>Emergency matter</p><p>preparation</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>2</p><p>Emergency matters preparation</p><p> Know the position of fire-fighting equipmentsand how to</p><p>use them.</p><p> Keep the emergency box and the tool used to wash the eyes</p><p>in the working site.</p><p> Keep the phone number of doctor, emergency car,hospital</p><p>and the fire department.</p><p>Fire Prevention for Oil and Fuel</p><p> Fuels, oils and antifreeze fluids are flammable. Fire</p><p>prevention is extremely necessary, especially for fuel.</p><p> Keep fire away from flammable fluids.</p><p> Stop</p><p>the engine and not smoke while refueling.</p><p> Tighten all fuel and oil tank caps firmly.</p><p> Add refueling and lubricating oiling in well ventilated areas.</p><p> Keep oil and fuel in determined place and do not allow</p><p>unauthorized people to enter</p><p>Properly dispose of scrap liquid</p><p> Improper treatment method for the wasted liquid may cause</p><p>environmental and ecological damages. Before discharging</p><p>any liquid before, we must understand the waste treatment</p><p>method of the local environmental protection department at</p><p>first.</p><p> Use appropriate container to receive discharges of fuel, oil</p><p>or other liquids.</p><p>Do not use food tank or plastic storage tank, to avoid people</p><p>mistakenly drink. Clean the spilled liquid on the ground</p><p>immediately.</p><p> Do not pour oil on the ground, or drain it into sewers or</p><p>streams, ponds or lake. When disposing of oil, fuel, coolant,</p><p>filters, batteries and other hazardous waste, comply with</p><p>relevant environmental requirements.</p><p>Avoid fire</p><p>Don’t spray the oil on</p><p>the ground</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>3</p><p>Working in the dusty environmental</p><p>Dust impurities in the work environment</p><p>• After the machine works in the environmetn containing</p><p>asbestos dust, or other hazardous impurities, put the used cab</p><p>and engine air filter into a sealed bag before placing it to the</p><p>specified location inside, then deliver the bag to the related</p><p>departments.</p><p>• If there are impurities or unhealthy materials in the</p><p>environment within the working area, the machine must be</p><p>equipped with the related devices before starting work. In</p><p>addition, there are special local regulations proper for the</p><p>machine's maintenance of such operations and working in this</p><p>environment.</p><p>Preparation</p><p>Warn other people in the work site：</p><p>• Unexpected machine motion could cause serious injury or</p><p>death.</p><p>•Before operating any action on the machine, attach warning</p><p>signs to the remote control lever.</p><p>• Regardless of the warning signs attached or not, be sure to</p><p>alarm before the operation.</p><p>• The workplace must have adequate and safe lighting</p><p>equipments.</p><p>When working inside or under the machine, use removable</p><p>safety lights. Make sure the light bulb is in an appropriate cage.</p><p>Accidentally broken the electric wire of bulb may spill the fuel</p><p>or oil.</p><p>Avoid absorbing the</p><p>dust.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>4</p><p>Reasonably and safely use of tools</p><p>• Only use the tools in accordance with the designed purpose of</p><p>tools</p><p>• Keep all tools in good condition, and understand their proper</p><p>uses.</p><p>• Set a place at the repair site used to store special tools and</p><p>removed parts.</p><p>• Always keep working area clean, make sure there is no sludge</p><p>or oil on the floor.</p><p>•Before filling the fuel or, or doing any repairs,stop the</p><p>machine at a solid flat ground.Put wedges before or after the</p><p>wheels or tracks to prevent the machine rolling.</p><p>• Before starting work, put the flat shovel, stone crusher, bucket</p><p>or other work equipments to the ground.</p><p>If they can not be lowered, we must insert a safety pin or</p><p>blocks to prevent working equipment fall down.</p><p>Security locking system</p><p>Warning!</p><p>Put the security lock lever firmly at the "Lock" position in order</p><p>to lock the control hydraulic lock before leaving the operator</p><p>seat. Unless the security lock lever in the "Lock" position,</p><p>otherwise the lever may be unintentionally touched to cause</p><p>serious injury.</p><p>• This system is used to lock the attachment, turning and</p><p>walking devices. Put the safety lock lever equipped on the left</p><p>console into the "Lock" (B) position to lock the operation lever</p><p>of the hydraulic system.</p><p>.Use handrails or ladders</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>5</p><p> Never jump on or off the machine. Never get on or off a</p><p>moving machine.</p><p> When getting on or off the machine, face the machine and</p><p>use the handrails and pedals to ensure that you support</p><p>yourself. Maintain three-point contact (two hands –one foot</p><p>or two feet one hand) with the handrails and pedals to</p><p>ensure body stable.</p><p> Never hold any control levers when getting on or off the</p><p>machine.</p><p> Never hold any tools or other items when climbing up and</p><p>down the loader, lift the tools needed using rope to the</p><p>operation flat roof.</p><p> Check the handrails and pedals, if there is oil, lubricant or</p><p>dirt; clean them first to prevent slip. Besides, repair the</p><p>broken items, fasten the loosen nuts.</p><p>Precautions when operating</p><p>Maintain the cooling system safety</p><p>•At the operating temperature, engine coolant is very hot, and</p><p>has high pressure. There is hot coolant in radiator and all the</p><p>Clean the dust and oil</p><p>on the ladder.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>6</p><p>pipes leading to the engine and heater. Contacting with these</p><p>parts can cause serious burns.</p><p>• Hot coolant can cause burns.</p><p>• Only the engine is stopped and the temperature of the radiator</p><p>pressure cap is so low that it can be removed by hand, you can</p><p>check the coolant level.</p><p>• Slowly remove the pressure cap of radiator to release</p><p>pressure.</p><p>•Additives of cooling system include alkali, which can cause</p><p>injury. Avoid skin, eye and mouth contact with it.</p><p>• Before draining the liquid, make sure the components of</p><p>cooling system cooled.</p><p>Avoid contacting with high-pressure liquid</p><p>•The spilled fluid under pressure may penetrate the skin,</p><p>causing serious injury.</p><p>•Release the pressure before disconnecting the hydraulic unit</p><p>and the other pipes, in order to avoid danger.</p><p>Before exerting pressure, tighten all connectors.</p><p>• The leakage of fluid under pressure may be invisible. Use a</p><p>thin cardboard or wood to check the leaking points, do not use</p><p>the hand directly.</p><p>Protect your hands and body to avoid damage by high-pressure</p><p>liquid.</p><p>• Be careful not to break, distort or damage the high-pressure</p><p>pipeline.</p><p>The injection of high-pressure oil may cause electrical fire.</p><p>Hoist goods</p><p> When hoisting the heavy components, use crane or hoist.</p><p> Make sure the wires, hanging lug and hooks are not</p><p>damaged.</p><p> Always use the hoisting equipments with enough capacity.</p><p>Hot coolant can cause</p><p>hurt.</p><p>Avoid contacting the</p><p>hot coolant.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>7</p><p>The assembly position of the components should be right.</p><p> Use a crane or a crane slowly to prevent the compoments</p><p>from hitting other parts.</p><p> When disassembling or assembling, use wedges, jack and</p><p>frames to support the machine.</p><p>Do not use concrete blocks to support the machine. Even</p><p>under the light loading they are also very easy to crash.</p><p> Before starting work, put the flat shovel, stone crusher,</p><p>bucket or other work equipments to the ground.</p><p> If the machine does not be supported firmly, do not work</p><p>under the machine.</p><p>Electric System</p><p> Keep main switch at OFF position when the electrical</p><p>system begins to work or remove the wire from “-”pole.</p><p> The main switch of battery is installed at the tools box at the</p><p>right side of machine.</p><p> When removing the components, be careful not to damage</p><p>the wires.</p><p>Damaged wires may cause fire.</p><p>--ON—Position (1)</p><p>Turn the key clockwise to offer power to electric system</p><p>--OFF-- Position (2)</p><p>Turn the key counterclockwise to cut off the power of</p><p>electric system</p><p> Wear safety glass and rubber gloves to deal with battery.</p><p> Sulfuric acid in battery electrolyte is very toxic.</p><p>Sulfuric acid can burn skin, the clothes, if sulfuric acid</p><p>splashes into the eyes, it also causes blindness.</p><p>Wash with lot of water to clean the sulfuric acid on the skin</p><p>or on the cloth, go to hospital if hurt severely.</p><p> Wash with lot of water to clean the sulfuric acid sprayed</p><p>into eyes, then go to hospital if hurt severely.</p><p> Do not make fire, lit matches</p><p>and open flames near the top</p><p>of the battery, in case that the battery (hydrogen) is</p><p>exploded.</p><p>Support the machine</p><p>well.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>8</p><p> If the battery electrode or wire touch with metal objects,</p><p>short circuit may occur, which may cause your harm.</p><p> Do not contact the tools with electrodes, wires and</p><p>terminals.</p><p> Tighten the battery terminals in order to keep good connect.</p><p> When removing or assembling the battery, make sure</p><p>battery terminals are properly connected</p><p>Welding on the machine</p><p>When welding on the machine or the tools connected with the</p><p>machine, if the ground wire is connected wrong,components</p><p>such as electrial units or storing unit may be damaged.</p><p>Take the following measures when welding:</p><p>1. Cut off the power with battery breaker.</p><p>2. Cut off the battery.</p><p>Attention! "+”and "-” must be disconnected both.</p><p>3. Cut off the following electrical components:</p><p>- Vehicle Control Unit (V-ECU)</p><p>- Engine control unit (EMR2)</p><p>- Instrument Control Unit (I-ECU)</p><p>4 .The grounding wire of welding equipments should be as</p><p>close to the welding point, and confirm that the current</p><p>comes through a bearing.</p><p>If it is necessary to weld on the boom and the bucket arm, the</p><p>following basic rules should be observed:</p><p>1 Welding melted beads should be arrayed longitudinal</p><p>2 If possible, when welding in the middle part of metal, the</p><p>distance from the edge of should not be less than 80 mm.</p><p>3 Do not weld near the ring near the welded joints in the</p><p>cylinder.Dsitance between the ring and the welding point of</p><p>welding plates is 100 mm.</p><p>4 Do not weld at the bend part of a metal plate.</p><p>If the water goes into the electronic system, it can cause</p><p>abnormal operation or failure.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>9</p><p>Do not rinse f the sensors, connectors, and gauge of cab with</p><p>water</p><p>Notes on operation</p><p>• When removing the lid with the internal pressure or pressure</p><p>from the spring, retain the two screws on other side in place.</p><p>Slowly release the pressure, and then slowly loosen the screw.</p><p>• High-pressure grease of chassis spring group may burst open,</p><p>which may bring you harm.</p><p>Be careful when opening the grease valve.</p><p>Do not loosen the grease valve more than 1circle before</p><p>releasing the pressure</p><p>• When assembling or installing parts, always use the specified</p><p>tightening torque.</p><p>• When installing protective devices or rotating components,</p><p>you should be especially careful to check whether they are</p><p>installed correctly.</p><p>• Make sure that your clothes or hair will not touch any rotating</p><p>parts.</p><p>• When aligning the two holes, do not insert your finger.</p><p>Be careful not to put your finger into the hole, or between the</p><p>parts or tools.</p><p>• Do not touch rotating parts, such as fan plates or fan belt.</p><p>Be careful when removing or installing the track of the machine.</p><p>When removing the track pin, the track will be suddenly</p><p>separated, so do not let anyone stand on either side of track.</p><p>Always do good protection at both ends of the track, in case of</p><p>suddenly controlled actions to cause unnecessary harm.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>10</p><p>Move and operate machinery safely</p><p>• Only allow the operator to operate on the machine. Do not let</p><p>other people get on the machine.</p><p>Before operating the machine, clear the position of other people</p><p>around the machine.</p><p>• Always make the walking alarm in working condition.</p><p>• When moving, turning or operating machinery in the working</p><p>site, need a signalman for help.</p><p>• Check the walking direction before walking.</p><p>In particular, when walking in reverse, confirm that there is</p><p>nobody in the entire region behind the car.</p><p>Make a warning sound before walking.</p><p>• Contacting with power lines can cause serious injury or death.</p><p>• For more detailed information, refer to "Operation and</p><p>Maintenance Manual”</p><p>Don’t contact with power</p><p>wire.</p><p>Be careful when removing or</p><p>installing the machine</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>11</p><p>Ⅰ.Whole machine</p><p>description</p><p>1. Summary</p><p>Components position</p><p>Fig.1 Components position</p><p>1. Boom 13 Engine hood 25 Tension spring</p><p>2 Bucket arm cylinder 14 Balancing weight 26 Guiding wheel</p><p>3 Boom cylinder 15 Hydraulic pump 27 Control</p><p>panel(Forward)</p><p>4 Operation lever 16 Track motor and gears 28 Cab</p><p>5 Operator seat 17 Radiator and fuel cooler 29 Bucket</p><p>6 Rotary gear circle 18 Main control valve 30 Linkage</p><p>7 Rotary motor and gears 19 Rotary joints 31 Rocker arm</p><p>8 Battery 20 Chain supporting wheel 32 Bucket cylinder</p><p>9 Fuel tank 21 Air filter 33 Bucket arm</p><p>10 Engine 22 Track pin 34 Track chains</p><p>11 Hydraulic oil 23 Supporting wheel</p><p>12 Silencer 24 Bottom frame</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>12</p><p>2. Specification</p><p>Standard tightening torque</p><p>The following table offers the standard tightening torque of the</p><p>screws and the nuts.</p><p>Additional circumstance will be shown in “Disassembly or</p><p>assembly”.</p><p>Table1 Tightening torque (m)</p><p>Grade 4.8T 8.8T 10.9T,12.9 T</p><p>Screw model</p><p>Size Tightening torque Tightening torque Tightening torque</p><p>mm Nm Nm Nm</p><p>M4 1.96±0.19 3.92 ±0.39</p><p>M5 2.94±0.29 5.88±0.59 7.84 ±0.78</p><p>M6 4.90±0.49 9.8 ±0.98 13.72 ±1.37</p><p>M8 11.76 ±1.17 23.541±2.35 32.36 ±2.94</p><p>M10 22.55 ±2.25 48.05 ±4.9 63.74 ±6.86</p><p>M12 39.22 ±3.92 85.32 ±8.83 110.81±10.78</p><p>M14 62.7±5.88 140.24 ±13.73 175.53±17.65</p><p>M16 93.16 ±8.82 219.67±21.57 261.83 ±26.47</p><p>M18 132.3±13.72 290.28± 29.42 372.65 ±37.26</p><p>M20 182.40±18.63 430.51±43.14 511.90±50.99</p><p>M22 242.22±24.51 579.57±57.85 680.58±67.66</p><p>M24 314.79±31.38 740.40±73.54 884.56±88.25</p><p>M30 613.80±61.78 1726.95 ±172.59</p><p>M36 1061.08 ±105.91 - 2984.16 ±298.12</p><p>M42 1684.78 ±168.67 - 4738.57±473.66</p><p>M45 2072.15 ±206.92 - 5828.09 ±582.51</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>13</p><p>Table2.Tghtening torque(inch)</p><p>Grade 4.8T 8.8T 10.9T,12.9 T</p><p>Size Tightening torque Tightening torque Tightening torque</p><p>mm Nm Nm Nm</p><p>1/4 9.80 ±0.98 23.53±2.35 16.67 ±1.96</p><p>5/16 11.76±1.17 19.61±1.96 29.42±2.94</p><p>3/8 19.61±1.96 40.20±3.92 54.91±4.90</p><p>7/16 31.38±3.13 59.82 ±5.88 87.27 ± 8.82</p><p>1/2 46.09±4.60 100.02 ±9.80 131.40 ±12.74</p><p>9/16 66.68 ±6.66 140.23 ±13.72 186.32 ±18.63</p><p>5/8 91.20 ±9.12 200.05±19.61 255.95±25.49</p><p>3/4 156.90 ±15.69 - 442.28 ±44.12</p><p>7/8 250.07 ±25.00 - 702.15 ±70.60</p><p>1 - 372.65 ±37.26 - 1048.33±104.93</p><p>1 1/8 - 530.54 ±53.05 - 1492.57 ±149.06</p><p>1 1/4 727.65 ±72.76 - 2048.61 ±204.95</p><p>1 3/4 968.89 ±96.88 - - 2724.29 ±272.62</p><p>1 1/2 1257.21 ±125.72 - - 3537.26 ±354.02</p><p>Attention! For screws with nylon packaging, the use of</p><p>non-metallic bushing, and the required different torque or a</p><p>different specified tightening degree, the torque table does not be</p><p>suitable.</p><p>Tightening torque of split flange screws</p><p>Split flange screws apply this tightening torque.</p><p>Table3. Tghtening torque (Split flange screws)</p><p>Screw diameter (mm) Width between two</p><p>sides(mm)</p><p>Tightening torque</p><p>Nm</p><p>10</p><p>12</p><p>16</p><p>14</p><p>17</p><p>22</p><p>65.7 ± 6.8</p><p>112 ± 9.8</p><p>279 ± 29</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>14</p><p>Tightening torque of hydraulic plug with O ring</p><p>Table 4. Tghtening torque (Hydraulic plug)</p><p>Thread Plug number Tightening torque Nm</p><p>1/8 9415–11012 24.51 ±1.96</p><p>1/4 9415–11022 49.03 ±4.90</p><p>3/8 9415–11032 73.54 ±4.90</p><p>1/2 9415–11042 107.87 ±9.80</p><p>3/4 9415–11052 176.52 ±9.80</p><p>1 9415–11062 205.94 ±19.61</p><p>Tightening torque of rotating nut device with O ring</p><p>Fig.3 Rotate nut device with O ring</p><p>1. Connect circle</p><p>2. O ring</p><p>3. Rotating nut</p><p>4. Soft hose</p><p>Fig.2 Hydraulic</p><p>plug with O ring</p><p>1. O ring</p><p>2. Plug Pf screw</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>15</p><p>Table 5.Tghtening torque of rotating nut device with O ring</p><p>Outer diameter of pipe Screw size(inch) Tightening torque Nm</p><p>1/2</p><p>UN 13/16 – 16 93.16 ±9.31</p><p>3/4</p><p>UN 1 3/16 – 12 176.52 ±17.65</p><p>1 UN 1 7/16 – 12 205.94 ±20.59</p><p>Engine, specifications</p><p>Table 6 Specification</p><p>Program Unit Specification</p><p>Model -- BF4M2012C</p><p>Brand -- DEUTV</p><p>Model -- 4-- stroke, 4 - cylinder, Direct injection, water</p><p>cooling,direct spraying, diesel, turbocharger</p><p>Rated output rpm /kW 2000 /120</p><p>Max torque rpm /N m 1500 /671</p><p>Hole of cylinder*Stroke mm 6---101 mm × 126 mm</p><p>Total displacement cc 6057</p><p>Lubrication Pressure circuit</p><p>Starter -- 24 V, 5.5 kW</p><p>Engine -- 28 V, 55 A</p><p>Engine speed (High/low idle) rpm 2100/850</p><p>Coolant capacity L 32</p><p>Engine fuel capacity L 25</p><p>Replacement volume of fuel on the</p><p>condition that is filtered by the</p><p>filter of dry engine fuel</p><p>L 22.5</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>16</p><p>Engine, specifications</p><p>Table 7 Specification</p><p>Program Unit Specification</p><p>Fuel injection pump -- BOSCH</p><p>Fuel pump setup, B.T.D.C -- MVS</p><p>Injector,starting pressure bar 220</p><p>Oil consumption ratio g/kW·h 216 at1900 r/min</p><p>Fuel tank Capacity L 350</p><p>Filter -- #60</p><p>Valve clearance, specifications</p><p>Table 8 Specification</p><p>Engine model Inlet</p><p>mm</p><p>Outlet</p><p>mm</p><p>BF6M2012C 0.3±0.05 0.5±0.05</p><p>Fuel pressure, specifications</p><p>Table9 Specification</p><p>Fuel returning pressure</p><p>Max.pressure under the condition of engine starting 0.03 MPa</p><p>Max.pressure under the condition of engine running 0.05 MPa</p><p>Table10 Specification</p><p>Output pressure of high pressure fuel pump when testing</p><p>Output pressure 55 ±5 MPa</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>17</p><p>Coolant, specifications</p><p>Table11. Specification</p><p>Items Unit Specification</p><p>Radiator Axle core model - 4-CF(Wave-shape plates)</p><p>Radiator core volume（W × H × D） mm 720 × 293 × 145.4</p><p>Dry weight kg</p><p>Hydraulic oil cooler Axle core model -- 1-CF(Wave-shape plates)</p><p>Radiator core volume（W × H × D） mm 735 ×320.4 ×145.4</p><p>Dry weight kg</p><p>Air cooler Axle core model --</p><p>Core material --</p><p>Hose model --</p><p>Radiator core volume（W × H × D） mm 729 ×155 × 145.4</p><p>Dry weight kg</p><p>Engine speed control switch, specifications</p><p>Table12. Specification</p><p>Items Specification</p><p>Power DC24V</p><p>Output voltage DC0~5V</p><p>Model Potentiometer</p><p>Electric consumption 0.5w</p><p>Electrical system, specifications</p><p>Table12.</p><p>Electrical system</p><p>Power DC24V</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>18</p><p>Engine control, specifications</p><p>Table14.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>19</p><p>Gauge control unit I-ECU, specifications</p><p>Table15. Gauge control unit, I-ECU connector, specification</p><p>Connector Attached connector</p><p>House：AMP 174657-2</p><p>Terminal：AMP 171661-1</p><p>Wire sealing：AMP 172888-2</p><p>House：AMP 174655-2</p><p>Terminal：AMP 171662-1</p><p>Wire sealing：AMP 172888-2</p><p>Connecting pins, specifications</p><p>Table15. Gauge control unit, I-ECU connector, specification</p><p>No. Specification No. Specification</p><p>1 CAN_H（J1939_H） 6 Connecting power: +24V</p><p>2 CAN_L（J1939_ L）（BL） 7 Working lamp</p><p>3 -- 8 Auto/manual switch input</p><p>4 -- 9 V-ECU condition signal</p><p>5 Clock power24V(R) 10 Grounding wire of battery</p><p>Fig.4 I-ECU Connector</p><p>Tightening torque（A）：0.5 Kgf m</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>20</p><p>Engine control unit E-ECU (EMR2 ), specification</p><p>Table15. E-ECU (EMR2 ) pin, specification</p><p>No. Specifications No. Specifications</p><p>E1 No connection M1 ECU grounding</p><p>E2 No connection M2 ECU grounding</p><p>E3 No connection M3 No connection</p><p>E4 No connection M4 No connection</p><p>E5 No connection M5 No connection</p><p>E6 No connection M6 No connection</p><p>E7 No connection M7 No connection</p><p>E8 Signal grounding to engine coolant sensor M8 No connection</p><p>E9 Engine coolant temperature signal M9 No connection</p><p>E10 Engine speed signal grounding M10 Shoottrouble joint</p><p>E11 Engine speed sensor M11 Shoottrouble joint</p><p>E12 Engine camshaft speed signal grounding M12 J1939 H control bus</p><p>E13 Engine camshaft speed sensor M13 J1939 H control bus</p><p>E14 Adjustor M14 Shoottrouble joint</p><p>E15 M15 No connection</p><p>E16 M16 No connection</p><p>E17 M17 No connection</p><p>E18 M18 No connection</p><p>E19 M19 No connection</p><p>E20 Engine fuel pressure signal grounding M20 No connection</p><p>E21 Engine fuel pressure signal connecting with power M21 No connection</p><p>E22 Engine fuel pressure signal sensor M22 No connection</p><p>E23 Pressurized pressure signal grounding M23 No connection</p><p>E24 Pressurized pressure signal connecting with power M24 No connection</p><p>E25 Pressurized pressure signal sensor M25 No connection</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>21</p><p>Vehicle control unit V-ECU, specifications (I-ECU has been</p><p>assembled.)</p><p>Table18. Vehicle control unit , V-ECU,, specification</p><p>Item Connector Housing</p><p>JB Tiny timer & JPT 70Pin</p><p>connector</p><p>AMP 1-963484-1，Terminal JPT（X10）</p><p>AMP 929939-1，JPT Wire sealing</p><p>AMP 828904-1，Terminal MT-2（X60）</p><p>AMP 962876-1，MT-2 Wire sealing</p><p>AMP 963530-1</p><p>JA JPT 16 Pin connector AMP 1-963215-1，Terminal</p><p>AMP 929939-1，Wire sealing</p><p>AMP 828904-1</p><p>Table19. Connector (JA) pin shaft , specification</p><p>No. specifications No. specifications</p><p>1 Engine starting key(Acc) 9 Fuse used for strengthening the solenoid</p><p>valve</p><p>2 Engine starting key(C) 10 Power relay</p><p>3 “D+” signal of AC generator 11 Fuse of control valve used for slow control</p><p>4 No connecting 12 No connecting</p><p>5 VECU signal checking 13 No connecting</p><p>6 CAN_L (J1939 L, Green) 14 CAN_H (J1939-H, Yellow)</p><p>7 Grounding wire of battery 15 Manual/auto switch</p><p>8 Grounding wire of battery 16 Manual/auto switch</p><p>Fig.5 I-ECU connector</p><p>E --Engine connector equipped with wiring harness connector AMP 346244 / 1</p><p>M --Cab connector equipped with wiring harness connector AMP 346245/5</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>22</p><p>Table20. Connector (JB) pins , specification</p><p>No. specifications No. specifications</p><p>1 No connecting 36 No connecting</p><p>2 X1 flow control proportional valve grounding 37 Attached pressure sensor</p><p>3</p><p>No connecting</p><p>38 EMR2 power checking</p><p>4 39 Hammer pressure switch</p><p>5 40 Floating position pressure switch</p><p>6 41 Traveling pressure switch</p><p>7 42 Coolant level switch</p><p>8 43 Max. model of power selecting switch</p><p>9 Manual/auto switch input Control signal of</p><p>proportional valve</p><p>44 Auto idle selecting switch</p><p>10 Manual/auto switch input Control signal of</p><p>proportional valve</p><p>45 No connecting</p><p>Fig.6 VECU, connector</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>23</p><p>11 X1 flow control proportional valve signal 46 Rapid assembly confirm switch</p><p>12 High speed selecting switch 47 Rapid assembly ending switch</p><p>13 Preheating relay grounding 48 No connecting</p><p>14 Speed solenoid valve 49</p><p>15 No connecting 50 Preheating relay</p><p>16 51 Overloading warning selecting switch</p><p>17 52 Speed control signal 1</p><p>18 53 Speed control signal 2</p><p>19 54 Speed control signal 3</p><p>20 Solenoid valve signal of hydraulic scissors 55 Speed control signal 4</p><p>21 Solenoid valve signal of hydraulic hammer 56 Speed control grounding</p><p>22 Solenoid valve of flow cutting 57 No connecting</p><p>23 Strengthened Solenoid valve 58</p><p>24 No connecting 59</p><p>25 60</p><p>26 Close signal of starting relay 61 Air filter</p><p>27 Floating position Solenoid valve 62 No connecting</p><p>28 No connecting 63</p><p>29 Traveling warning signal 64 Overloading warning switch</p><p>30 Rapid assembly switch 65 No connecting</p><p>31 Security lever position switch 66 GPS</p><p>32 Pressurized/hammer/scissor selecting switch 67 Fuel level sensor grounding</p><p>33 Preheating signal 68 Fuel level sensor and air filer sensor</p><p>grounding</p><p>34 Floating position switch 69 No connecting</p><p>35 Rotating switch 70 GPS</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>24</p><p>Battery, specifications</p><p>Table21.Battery, specifications</p><p>Items Specifications</p><p>Number 2 series</p><p>Voltage of battery(Rated) Min12.65V / .Battery</p><p>Max12.95V / .Battery</p><p>Capacity 150A/h, .Battery</p><p>Battery disconnector Connecting to “-”</p><p>Density of sour liquid at 27°C（81°F） MIN 1.265 g/ccm</p><p>MAX1.300 g/ccm</p><p>AC generator, specifications</p><p>Table22. AC generator, specifications</p><p>Items Specifications</p><p>Manufacuturer BOSCH</p><p>Model and name NC B1 28V 80A</p><p>Model AC</p><p>Adjustor NC B1 28V 80A</p><p>Voltage 28.0 V</p><p>Max. speed 8000 rpm</p><p>Rated current 1500 rpm--为 10A，6000 rpm -- 35A</p><p>Weight 6.8 kg</p><p>Rotating Rotate from the front clockwise</p><p>Starting motor, specifications</p><p>Table23.</p><p>Items Specifications</p><p>Model DC 24V，5.5 kW</p><p>Weight 9.2kg</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>25</p><p>Battery relay, specifications</p><p>Table24. Specifications</p><p>Items Specifications</p><p>Rated voltage DC 24V</p><p>Rated loading 100A (Continuous), 1000 A (30s)</p><p>Exciting current 0.5A or less（24 V，20°C）</p><p>Voltage of open circuit DC 9V or less</p><p>Min. working voltage DC 20V or less</p><p>Insulation resistance ≥1 MΩ</p><p>Security starting relay, specifications</p><p>Table25. Specifications</p><p>Items Specifications</p><p>Rated voltage DC 24V</p><p>Operating temperature -40 - 85 °C</p><p>Wire resistance 275 Ω ± 10%</p><p>Pulling voltage 16 V</p><p>Falling voltage 4-8 V</p><p>Preheating, specifications</p><p>Table26.</p><p>Items Specifications</p><p>Output 2.5kW</p><p>Battery relay, specifications</p><p>Table27. Specifications</p><p>Items Specifications</p><p>Rated voltage DC 24V</p><p>Volume 7 m --106 dB</p><p>Frequency 24 V --415 ± 20 Hz</p><p>Working voltage 20-28V</p><p>Insulation resistance 1 MΩ</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>26</p><p>Traveling warning, specifications</p><p>Table28. Specifications</p><p>Items Specifications</p><p>Working voltage DC 18~32V</p><p>Current 0.4A</p><p>Sound pressure 115 ± 5Hz</p><p>Operating temperature -20 - 50 °C</p><p>Upper wiper motor, specifications</p><p>Table29. Specifications without loading</p><p>Items Specifications</p><p>Starting torque ＜2.5kgNm</p><p>Rated voltage DC24V</p><p>n1 speed 34±3 rpm</p><p>n 2 speed 52±5 rpm</p><p>Current (n1 speed) ＜0.7A</p><p>Current (n2 speed) ＜1.3A</p><p>Cutting switch of battery, specifications</p><p>Operation voltage: DC6~36V</p><p>Starting switch, specifications</p><p>Table30. Specifications without loading</p><p>Items Specifications</p><p>Max.current B-BR, B-ACC : 30 A</p><p>B-R1, B-R2 : 60A</p><p>B-C : Instantaneous 75 A，Continuous22 A</p><p>Insulation resistance ≥1 MΩ</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>27</p><p>Security lever switch, specifications</p><p>Table32. AC generator, specifications</p><p>Items Specifications</p><p>Manufacuturer OMRON</p><p>Model and name D2VW-5L2A-1M</p><p>Operating force 230 gf</p><p>Reaction force 20 gf</p><p>Rated voltage DC 30 V，5 A</p><p>Environmental temperature -40 - 90 °C</p><p>Rated current 1500 rpm--为 10A，6000 rpm -- 35A</p><p>Insulation resistance ≥100 MΩ</p><p>Contact resistance ＜100 MΩ</p><p>Connector AMP EJ Serial 2 + RECEP Housing and Positive terminal（3）</p><p>Manual/auto switch, specifications</p><p>Table33. Manual/auto switch, specifications</p><p>Pin number Wire specifications Signal</p><p>1 AVS 0.85 W/SB V-ECU</p><p>2 AVS 0.85 W Power</p><p>3 AVS 0.85 W/Y Proportional Solenoid valve</p><p>4 AVS 0.85 W/R V-ECU</p><p>5 AVS 0.85 SB/R Proportional Solenoid valve</p><p>6 AVS 0.85 R/SB Resistance</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>28</p><p>Fuse specifications</p><p>Capacity and marks related to circuits.</p><p>No. Energ</p><p>y</p><p>Application/circuit No. Energy Application/circuit</p><p>F1 10 A I-ECU F 16 15 A Starting switch</p><p>F2 10 A Working lamp（Cab roof） F 17 5 A Cab lamps</p><p>F3 15 A Working lamp（Boom） F 18 10A Troubleshooting connector</p><p>F 4 10 A Water wiper and sprayer F 19 -- --</p><p>F 5 10 A Troubleshooting joints F 20 -- --</p><p>F 6 10 A Cigarette Lighter F 21 15 A Fuel filling pump</p><p>F 7 10 A Horn F 22 5 A Air conditioner condenser</p><p>F 8 15 A Air conditioner F 23 5 A Radio with CD player</p><p>F 9 10 A Extra working lamp(Back) F 24 5 A Power outlet</p><p>F 10 15 A Extra working lamp(cab) F 25 10 A X1 flow control valve</p><p>F 11 10 A Rotating warning beacon</p><p>light</p><p>F 26 -- --</p><p>F 12 5 A Safe solenoid valve F 27 10 A Hydraulic valve/Turbocharger</p><p>/Hydraulic scissor</p><p>F 13 10 A V-ECU F 28 10 A Rapid assembly, solenoid valve of</p><p>turner</p><p>F 14 5 A Overloading selecting switch F 29 15 A Walking warning</p><p>F 15 -- -- F 30 15A E-ECU</p><p>Slow melt fuse, specification</p><p>Table 34.Specification</p><p>Items Specifications</p><p>Rated voltage DC32V or less</p><p>Fuse capacity Current % Melting time</p><p>110% More than 4</p><p>hours</p><p>200% 5～100s</p><p>300% 0.5～15s</p><p>400% Less than 1s</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>29</p><p>Relay box, specifications</p><p>Table 35.Relay code of relay box</p><p>Relay number Name Description Type</p><p>R1 RE3611 Speaker Always open, NO</p><p>R2 RE3501 Front work lights Always open, NO</p><p>R3 RE3301 Starter Always closed, NC</p><p>R4 RE9106 X3/quick install safety devices Always open, NO</p><p>R5 RE4201 Walking warning(OPT) Always open, NO</p><p>R6 RE3502 Additional lights(OPT) Always closed, NC</p><p>R7 RE9104 Quick installation 1(OPT) Always open, NO</p><p>R8 RE9105 Quick installation 2(OPT) Always open, NO</p><p>Table 36.Specification</p><p>Items specifications</p><p>Rated Voltage DC 24V</p><p>Operating temperature -40 - 85℃</p><p>Coil resistance 275±10%</p><p>Pull in voltage 16V</p><p>Drop-out voltage 4V-8V</p><p>Resistance box, specification</p><p>Table.37.Specification</p><p>Items specification</p><p>Rated wattage 50W</p><p>Rated resistance 67±2（25℃）</p><p>Temperature -30-120℃</p><p>Insulation resistance ≥20M</p><p>Table.38.Wire specifications</p><p>Number wire specifications</p><p>1 AVS0.85RB</p><p>2 AVS0.85B</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>30</p><p>Radio with cassette or CD player specifications</p><p>CD and MP3 player with recorder</p><p>Table 39.Specifications</p><p>Items Specifications</p><p>Rated voltage DC 14V（negative grounding）</p><p>Operating temperature -30 - 75℃</p><p>Output 20W×2EA</p><p>Frequency range EU:MW531-1602KHZ/FM87.5-108MHZ/LW153-279KHZ</p><p>NA:FM87.7-107.9MHZ/AM530-1710KHZ</p><p>Antenna capacity 80PF 75</p><p>DC-DC converter specification</p><p>Table 40.Specifications</p><p>Items Specifications</p><p>Input voltage DC 20-32V</p><p>Output voltage DC 13±1V</p><p>Output current Maximum 4A</p><p>Operating temperature -30-70℃</p><p>Track gearbox specification</p><p>Table 41.Specifications</p><p>Items Unit specifications</p><p>Track gearbox Type - 2-order，planetary gear</p><p>Maximum speed Rpm 48.1/28.2</p><p>Reduction ratio - 50.5</p><p>Gear oil Liter 5.8</p><p>Rotary gearbox specifications</p><p>Table 42.Specifications</p><p>Items Unit specifications</p><p>Type - 2-order,differential planetary gear</p><p>Reduction ratio - 20.01</p><p>Theoretical output torque kgf.m 1103.7</p><p>Speed Rpm 82.2</p><p>Lubricants - SAE90,API GL-4 or GL-5</p><p>Fuel capacity Liter 8.6</p><p>Weight kg 190</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>31</p><p>Travel motor, specifications</p><p>Table 43.Travel motor, specifications</p><p>Items Unit specifications</p><p>Travel</p><p>Motor</p><p>Model - EM140V</p><p>Type - Variable swash plate piston</p><p>hydraulic motor</p><p>Displacement cm³/rev 82.4/140.5</p><p>Pressure reducing (Standard value /</p><p>reconstructed value)</p><p>Mpa 39.2+2.9/-1 when 15 l/min</p><p>Pressure reducing (Maintenance limit</p><p>value)</p><p>39.2+2.9/-2 when 15 l/min</p><p>Parking brake type - Wet brake disc ,application spring,</p><p>hydraulic release</p><p>Oil flow imp 200</p><p>Maximum speed rpm 2330/1395</p><p>Automatic control pressure kgf/cm² 260</p><p>Manual control pressure kgf/cm² 40</p><p>Release pressure of the parking brake kgf/cm² 6.0</p><p>Shell pressure(Normal/peak) kgf/cm² Max 2/7</p><p>Carry out rotational test of travel motor with track on the</p><p>machine</p><p>Displacement</p><p>of frame：5.7/pm.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>32</p><p>Rotary unit specifications</p><p>Table 44. Specifications</p><p>Items Unit Specification</p><p>Model - M5X130CHB</p><p>Type - Fixed swash plate，piston</p><p>motor</p><p>Pressure reducing valve-- model - KRD22EK10C</p><p>Rebound damping valve-- model - 2KAR6P72</p><p>Displacement cm³/rev 121.6</p><p>Rated pressure Map 34.3</p><p>Theoretical output torque Nm 664</p><p>Braking torque Nm 623</p><p>Release pressure of the brake Map 2.8</p><p>Maximum speed Rpm 1850</p><p>Time delay</p><p>valve</p><p>Rotation pressure of spool Map 0.44±0.098</p><p>Braking delay time s 5+3/0</p><p>Shell draining(when pressure 26.5Mpa,90℃) l/min 23</p><p>Engine pressure Map 0.3</p><p>Oil capacity Liter 0.8</p><p>Weight (with valve) kg 52.5</p><p>Frame and the track unit, specifications</p><p>Table 45. Specifications</p><p>Items Unit Specification</p><p>LG6210E LG6225E</p><p>Chassis length mm 4170 4460</p><p>Track--connection spacing mm 190</p><p>Connection serial EA 46×2 49×2</p><p>Number of track pieces EA 46×2 49×2</p><p>Number of top rollers EA 2×2</p><p>Number of bottom rollers EA 7×2 8×2</p><p>Spring Type - Hydraulic adjuster(grease)</p><p>Spring,(fixed length) mm 444</p><p>Spring,(free length) 555</p><p>Fixed loading kg 13309</p><p>Adjustment mm -20～+120</p><p>Sprocket Teeth EA 21</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>33</p><p>Diameter of pitch circle mm 644.6</p><p>Attention！ For contact pressure of the ground，refer to the</p><p>Operator Manual</p><p>Rotary gear ring，specifications</p><p>Table 46. Specifications</p><p>Items Unit Specification</p><p>Type - Ball bearings with internal gear</p><p>Teeth EA 92</p><p>Weight kg 281</p><p>Outer diameter mm 1327</p><p>Height mm 110</p><p>Bearing Material - SUJ-2</p><p>Outer ball diameter mm 31.75</p><p>Number of rollers EA 109</p><p>Fig 8 Rotary gear ring, structure</p><p>A injection port plug(soft zone) B grease section door C pin hole D grease section door</p><p>“S” soft zone</p><p>1 outer bearing sleeve 2 inner bearing sleeve 3 taper pin 4 injection port plug</p><p>5 ball 6 support 7 gasket 8 grease mouth</p><p>9 grease mouth</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>34</p><p>Regulator, specifications</p><p>Table.47. Specifications</p><p>Items Unit specifications</p><p>Model KR3G-9N2A</p><p>Maximum input torque kef m 60.9</p><p>Maximum oil output rate L/min 2×200</p><p>Minimum oil output rate L/min 2×38</p><p>Cab specifications</p><p>Table.48 specifications</p><p>Items Unit Specifications</p><p>Length mm 1800</p><p>Height External mm 1700</p><p>Internal mm 1612-（Front window is closed）</p><p>1505-（Front window is open）</p><p>Width External mm 980</p><p>Internal mm 933</p><p>Height from the basic position of seat to</p><p>the top</p><p>mm 1117-（Front window is closed）</p><p>1010-（Front window is open）</p><p>Distance between the basic position of</p><p>seat to both sides</p><p>mm Left：475 ，right：415</p><p>Window The front upper part - Fully open，mezzanine safety glass</p><p>The front bottom part - Rail-mounted removable mezzanine safety</p><p>glass</p><p>Side - Left：sliding is open，the lower door，rear，</p><p>tempered safety glass</p><p>Right：fixed，tempered safety glass</p><p>Rear - Fixed，tempered safety glass</p><p>Top - Polyester carbonate</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>35</p><p>Operator seat specifications</p><p>Table.49 specifications</p><p>Items Unit Specification</p><p>Type - Adjustable suspension，tilt backrest</p><p>and handrail with backrest</p><p>Base Setting Headrest Forward 。 60</p><p>Top mm 50</p><p>Backrest Forward 。 66</p><p>back 72</p><p>Handrail Top 。 5</p><p>below 25</p><p>Height Top mm 23</p><p>below 37</p><p>Suspension Stroke mm ±35</p><p>Load kg 50～130</p><p>Top sliding rail adjustment</p><p>stroke (S.I.P)</p><p>Forward/bac</p><p>kward</p><p>mm 80/80</p><p>Lower sliding rail adjustment</p><p>stroke (S.I.P)</p><p>Forward/bac</p><p>kward</p><p>mm 90/90</p><p>Attention! S.I.P: indicates the position of seat</p><p>Recommended hydraulic oil specifications</p><p>Table 50</p><p>System Hydraulic oil level Recommended viscosity of hydraulic oil used in different</p><p>atmospheric temperature</p><p>℃ -30 -20 -10 0 +10 +20 +30 +40 +50</p><p>℉ -22 -4 +14 +32 +50 +68 +86 +104 +122</p><p>Hydraulic</p><p>system</p><p>Hydraulic oil</p><p>（anti-wear hydraulic</p><p>oil with a high</p><p>viscosity index of</p><p>more than 160）</p><p>ISO VG32 HV</p><p>*ISO VG64 HV</p><p>ISO VG68 HV</p><p>Bio-oil（with synthetic</p><p>ester as a substrate）</p><p>Bio-oil VG32</p><p>Bio-oil VG64</p><p>Attention! I *：is installed at the factory</p><p>* ISO：International Organization for Standardization</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>36</p><p>*HV：High viscosity</p><p>Hydraulic oil, specifications</p><p>Table 51：Specification</p><p>Items Unit Specification</p><p>Type - Anti-wear mineral oil used in high-pressure hydraulic system</p><p>Level - ISO VG46</p><p>Viscosity at 40℃ cost 46</p><p>Viscosity index - 177</p><p>Hydraulic pressure，specifications</p><p>Hydraulic pressure，specifications：Please refer to Main control</p><p>valve specifications</p><p>Hydraulic tank, specifications</p><p>Table 52：Specifications</p><p>Items Unit Specification</p><p>Type - ·Closed type</p><p>·Automatic boost</p><p>Capacity L Hydraulic tank（hydraulic oil level） 160</p><p>All the hydraulic systems 295</p><p>Pressure kgf/cm² 0～0.5</p><p>psi 0～7</p><p>Absorbing filter - 80 sieves</p><p>Return oil filter - B10≥1.4</p><p>Air conditioning unit，specifications</p><p>Table 53．Specifications</p><p>Items specification</p><p>Coolin</p><p>g</p><p>system</p><p>Evaporator Type Laminates（aluminum）</p><p>Cooling capacity 6500 Kcal/h</p><p>Size Height×width×depth mm 220×324×94</p><p>Condenser Type Parallel flow</p><p>Draining heat （Kcal/h） 12000 0/-10%</p><p>Air inlet temperature,℃ 36～38</p><p>Refrigerant pressure(the inlet throttle)</p><p>kgf/cm²</p><p>15.2～15.8</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>37</p><p>Size: Height×width×depth mm 399×732×19</p><p>Compressor Model SD7H15WZ8045</p><p>Type Swing plate</p><p>Number of cylinders-diameter stroke，</p><p>mm</p><p>7-φ29.3×39.8</p><p>Displacement，cc 154.9</p><p>Pressure of e pressure reducing valve 38±2</p><p>Maximum permissible continuous</p><p>speed</p><p>5000r/min</p><p>Maximum downshift speed 5000r/min</p><p>Lubricating oil capacity, cc 240</p><p>Lubricating oil type SP10 or the same</p><p>products</p><p>Compressor clutch type electromagnetic</p><p>Direction of rotation clockwise</p><p>Rated voltage DC24V</p><p>Power consumption 42w</p><p>Belt type A</p><p>Drier capacity, cc 335</p><p>Safety</p><p>devices(Dual</p><p>pressure switch)</p><p>Low pressure</p><p>kgf/cm²</p><p>OFF 2.0±0.2</p><p>ON 2.25±0.25</p><p>High pressure</p><p>kgf/cm²</p><p>OFF 32±2</p><p>ON 26±2</p><p>Refrigerant, g R134a,1100±50</p><p>Heating system Heating capacity 7200 Kcal/h</p><p>Movement Type Laminates（aluminum）</p><p>size Height×width×de</p><p>pth mm</p><p>330×595.5×35</p><p>Blower motor Rated voltage DC24V</p><p>Rated</p><p>current</p><p>Unloaded 1.0～0.8A</p><p>Loaded ＜5.4A</p><p>Motor speed Unloaded ＞4200rpm</p><p>Loaded ＞3800rpm</p><p>Air flow，m³/h 600</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>38</p><p>Table 54.Tightening torque</p><p>Items NMS kgf.m</p><p>Central nut，electromagnetic clutch（SD7H15） 12 1.2</p><p>Install screws of valve cover 32 3.2</p><p>Oil filling plug 10 1.0</p><p>Hose connector 20 2.0</p><p>Expansion valve 15 1.5</p><p>Proportional solenoid calve specifications</p><p>Table 55. Specification</p><p>Category Unit Value Conditions of</p><p>use</p><p>Maximum supply pressure kgf/cm² 140 50±5</p><p>Rated pressure supply kgf/cm² 50</p><p>Minimum pressure supply kgf/cm² Maximum control pressure +5</p><p>Allowed rear pressure kgf/cm² 10 10</p><p>Control pressure range kgf/cm² 0～40 0～35</p><p>Maximum flow L/min 10</p><p>Hydraulic fluid Mineral hydraulic oil ISO VG</p><p>32,46,68</p><p>Temperature ℃ -20～+90 -20～+90</p><p>Viscosity cost 5～500</p><p>Permitted contamination level NAS Level10</p><p>Rated current mA 700</p><p>Coil resistance Ω 17.5 at 20℃</p><p>Main control valve specifications</p><p>Table 56. Model</p><p>Items Description Description</p><p>Model UX28</p><p>Type 7 spool servo-hydraulic control with single-limited block</p><p>Function ·Boom、arm flow regeneration</p><p>·To prevent the boom、stick move</p><p>·Boom priority</p><p>·Rotating priority</p><p>·Straight</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>39</p><p>Table 57.Specification</p><p>Component Mode Standard/reconstruction</p><p>value，unit：Mpa</p><p>Maintenance limit，unit：</p><p>Mpa</p><p>Main</p><p>control</p><p>valve</p><p>Main pressure</p><p>reducing valve</p><p>Low 32.4+1.5/-1 at 200l/min 32.4+1.5/-2</p><p>at 200l/min</p><p>High 34.3+1.5/-1 at 200l/min 34.3+1.5/-2 at 200l/min</p><p>Boom throttle</p><p>pressure reducing</p><p>valve</p><p>Raising 35.8+1.5/-1 at 28l/min 35.8+1.5/-2 at 28l/min</p><p>Dropping</p><p>Arm section pressure</p><p>reducing valve</p><p>Stretching 35.8+1.5/-1 at 28l/min 35.8+1.5/-2 at 28l/min</p><p>Extending</p><p>Bucket section</p><p>pressure reducing</p><p>valve</p><p>Bending 35.8+1.5/-1 at 28l/min 35.8+1.5/-2 at 28l/min</p><p>overhanging</p><p>Choice-2 order</p><p>pressure reducing</p><p>valve</p><p>(AL2)</p><p>Low 20.6+0.5/0 at</p><p>200l/min</p><p>_</p><p>High 35.8+1.5/-1 at</p><p>28l/min</p><p>35.8+1.5/-2 at 28l/min</p><p>(BL2) 35.8+1.5/-1 at 28l/min 35.8+1.5/-2 at 28l/min</p><p>Rotary motor switching valve Left 27.9+2.5/0 at 200l/min 27.9+2.5/1 at 200l/min</p><p>Turn right</p><p>Track motor pressure reducing</p><p>valve</p><p>Left 39.2+2.9/-1 at 15l/min 39.2+2.9/-2 at 15l/min</p><p>Turn right</p><p>Pressure of flow sensing valve 3.2±0.1 at 30lpm</p><p>3.4+0.3/0 at 44lpm</p><p>Pressure of servo pump pressure reducing</p><p>valve</p><p>3.9+0.3/0</p><p>1.‘Standard value’ is value set on the new machine in the</p><p>factory.</p><p>2 "Reconstructed value" is the target pressure value achieved on</p><p>the machine at the transformation or regeneration of hydraulic</p><p>components</p><p>3“Maintenance limit value”needs the required pressure value for</p><p>at least obtaining adequate performance of the machine.When</p><p>the measured pressure value does not meet the maintenance</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>40</p><p>tolerance limit, the worn or defective parts should be checked, or</p><p>adjusted the pressure.</p><p>4 Main throttle pressure reducing valve is affected by the</p><p>following 5</p><p>th</p><p>factors, so the pressure measurement conditions</p><p>should be ensured strictly.And if measured pressure on the</p><p>machine in the field is in the tolerance range on the table, do</p><p>not adjust the pressure unnecessarily.</p><p>5 The measured pressure of main throttle pressure reducing</p><p>pressure on the machine will be different from the measure</p><p>values on the test platform, and the reasons are as follows</p><p>- Rear pressure (Specially in the rotary pressure of pressure</p><p>reducing)</p><p>- Pressure drops in pipelines(Especially in the pressure of travel</p><p>pressure reducing)</p><p>- Flow and hydraulic oil temperature</p><p>- Measurement tools(Gauge error, etc.)</p><p>Note! Do not set the pressure at the max limit of the</p><p>maintenance tolerance limits.</p><p>Pump, specifications</p><p>Table 58. Specifications</p><p>Items Unit Specification</p><p>K3V-112-DT-1XJR-9N2D-V</p><p>Function - Full-power control</p><p>Type Different displacement， type of rotary</p><p>piston，piston pumps</p><p>Displacement cc/rev 2×111</p><p>Maximum flow ipm 2×200</p><p>Pressure （ Normal pressure/boost</p><p>pressure）</p><p>kgf/cm² 300/350</p><p>Pressure of pump housing 1</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>41</p><p>Servo pump specifications</p><p>Table 59.Specification</p><p>Items Unit</p><p>Model ZX10LGRZ1-07A</p><p>Type - Fixed gear</p><p>Displacement cc/rev 10</p><p>Oil flow l/min 20</p><p>Release pressure kgf/cm²</p><p>Accumulator specifications</p><p>Table 60.Specification</p><p>Description Unit Specification</p><p>Type of gas - N2</p><p>Gas volume cc 320</p><p>Boost pressure of gas Mpa 1.47±0.1</p><p>Maximum operating pressure 4.4(45)</p><p>Maximum actuation pressure 17.6</p><p>Servo-hydraulic selector valve, specifications</p><p>·Rated pressure :50 kgf/cm²</p><p>·Rated oil flow :30 lpm</p><p>·Servo-hydraulic operating pressure :19 kgf/cm²(full-stroke</p><p>pressure)</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>42</p><p>Solenoid valve, specifications</p><p>X1, solenoid valve 3 section</p><p>Table 61. X1, solenoid valve 3 section, specifications</p><p>Instructions Unit Specification</p><p>Maximum operating pressure kgf/cm² 50</p><p>Maximum flow l/min 16</p><p>Range of temperature ℃ -20～95</p><p>Normal voltage V DC28</p><p>Power source D28</p><p>Allowable Pressure DC20～30.8</p><p>Normal current A 1.0 at DC28V and 20 ℃</p><p>Spray line</p><p>P1—A1</p><p>P2—A2</p><p>P3—A3</p><p>Oil flow</p><p>1.6LPM</p><p>1.2LPM</p><p>1.2LPM</p><p>Pressure drop</p><p>1 kgf/cm²</p><p>2 kgf/cm²</p><p>2 kgf/cm²</p><p>Weight（about） kg 5.1</p><p>Fig.9 X1, solenoid valve 3 section</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>43</p><p>Remote control valve （lever）specifications</p><p>Table 62. Specification</p><p>Items Unit Specification</p><p>Remote control valve（bar）,left type - Hydraulic</p><p>Remote control valve（bar）,right Type hydraulic</p><p>Operating angle Degree 19(throttle 1-3),25(throttle 2-4)</p><p>Hydraulic oil - Mineral hydraulic oil</p><p>Engine oil temperature range ℃ -20～95</p><p>Weight kg 2.3</p><p>Remote control valve （pedal）specifications</p><p>Table 63.Specification</p><p>Items Unit Specification</p><p>Remote control valve （pedal） Type - Hydraulic</p><p>Operating angle Degree 12.4</p><p>Weight kg 7.8</p><p>Walking pedal specifications</p><p>Straight pedal specification</p><p>Fig. 10 Moving straight pedal</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>44</p><p>Table 64. Straight moving pedal, specification</p><p>Items Unit Instruction</p><p>Type - Mineral hydraulic oil</p><p>Operating angle Degree Backward：12.4，forward：12.4</p><p>Engine oil temperature range ℃ -20～90</p><p>Main operating pressure Mpa 3.2+0.2</p><p>Weight kg 3.2</p><p>Hydraulic oil cooling system, specifications</p><p>Refer to cooling systems, specifications</p><p>2 pump oil flow selector valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>45</p><p>Table 65.Specification，2 pump oil flow selector valve</p><p>Instruction Unit Specification</p><p>Normal operating pressure Mpa 34.32</p><p>Normal flow l/min 250</p><p>Maximum oil flow at 140 kgf/cm² in section C cc/min 30</p><p>Maximum pressure loss when flow rate is 100lpm Mpa 0.07</p><p>Minimum cracking pressure of spool Mpa 0.69</p><p>Rotary oil pump, specifications</p><p>Table 66.Specification</p><p>Items Unit Specification</p><p>Model - P315BB20FM1007L</p><p>Type - Fixed gear</p><p>Displacement Cc/rev 20.3</p><p>Rated pressure kgf/cm² 246</p><p>Allowable suction pressure kgf/cm² -0.2～0.3</p><p>Allowable operating temperature（Intermittent cycle） C -20～93</p><p>Rotation（ Crankshaft rotation observed from shaft</p><p>end）</p><p>- Counterclockwise rotation</p><p>Weight Kg 8.2</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>46</p><p>Rotary solenoid valve</p><p>Table 67.Specification，solenoid valve</p><p>Instruction Unit Specification</p><p>Maximum operating pressure kgf/cm² 350</p><p>Operating flow Lpm 50</p><p>Allowed regressive pressure kgf/cm² 210</p><p>Internal leakage at pressure 140 kgf/cm² and viscosity 20</p><p>cSt</p><p>Cc/min 70</p><p>Oil temperature ℃ -20～90</p><p>Viscosity range cSt 5～500</p><p>Power source - D28G</p><p>Normal voltage DC V 28</p><p>Normal current A 1.0 at DC28V and</p><p>20℃</p><p>Fig. 12 Rotary solenoid valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>47</p><p>Solenoid valve, specifications</p><p>Table 68.Solenoid valve block 1</p><p>Items Specification</p><p>Maximum pressure 50 kgf/cm²</p><p>Maximum oil flow and</p><p>pressure loss (viscosity 20</p><p>cSt)</p><p>The direction of oil flow Maximum oil</p><p>flow l/min</p><p>Pressure loss</p><p>kgf/cm²</p><p>P1→A1</p><p>（A1→T）</p><p>16 5 maximum</p><p>P2→A2</p><p>（A2→T）</p><p>1.2 5 maximum</p><p>P2→A2</p><p>（A2→T）</p><p>1.2 5 maximum</p><p>Leakage rate 50cc/min</p><p>Solenoid valve Rated voltage DC 28V</p><p>Voltage fluctuation DC 22～20V</p><p>Rated current（28V，28℃） 1.2A</p><p>Servo-hydraulic selector valve, specifications</p><p>·Rated pressure: 50 kgf/cm²</p><p>·Rated oil flow: 30 lpm</p><p>·Servo-hydraulic operating pressure: 19 kgf/cm²(full-stroke</p><p>pressure)</p><p>Boom specifications</p><p>Fig.13 Boom</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>48</p><p>Table 70. Specification，boom</p><p>Items Unit LG6210E LG6225E</p><p>5.7m GP 5.7m HD</p><p>Length mm 5700 5700</p><p>A 5910 5910</p><p>B 1585 1585</p><p>Width 670 670</p><p>Weight kg 1750 1890</p><p>Boom cylinder specifications</p><p>Table 71. Specification</p><p>Items Unit Specification</p><p>Boom cylinder Quantity EA 2</p><p>Inner diameter ×live bar × stroke mm Φ125×φ80×1235</p><p>Align the center</p><p>distance of the pin</p><p>Fully retracted（A） 1790±2</p><p>Fully stretched（B） 3025±4</p><p>Mat Unilateral （ Already</p><p>stretching out-boom up）</p><p>Use Standard</p><p>Fig. 14Length，boom</p><p>up cylinder</p><p>A Retracted length</p><p>B Stretched length</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>49</p><p>Bucket arm, specifications</p><p>Table 72. Size，arm</p><p>Items Unit LG6210E LG6225E</p><p>2.9 m GP 2.9 m HD</p><p>Length mm 2900 2900</p><p>A 3910 3910</p><p>B 860 860</p><p>Width 440 440</p><p>Weight kg 1000 1085</p><p>Bucket arm cylinder, specifications</p><p>Table 73.Specification</p><p>Items Unit Specification</p><p>Stick cylinder Quantity EA 2</p><p>Internal diameter ×live</p><p>lever × stroke</p><p>mm φ135×φ95×1540</p><p>Mat - Two studios</p><p>Align the center distance</p><p>of the pin</p><p>Fully retracted（A） mm 2110±2</p><p>Fully stretched（B） mm 3650±4</p><p>Use Standard</p><p>Fig.15 Bucket arm</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>50</p><p>Bucket cylinder, specifications</p><p>Table 74. Specification</p><p>Items Unit Specification</p><p>Bucket cylinder Quantity EA 1</p><p>Internal diameter ×live lever</p><p>× stroke</p><p>mm φ120×φ80×1065</p><p>Make the center</p><p>distance of the pin</p><p>centered</p><p>Fully retracted（A） mm 1655±2</p><p>Fully stretched（B） mm 2720±4</p><p>Mat Unilateral（Already stretching</p><p>out-boom up）</p><p>Use Standard</p><p>Fig. 16 Cylinder length</p><p>A Retracted length</p><p>B Stretched length</p><p>A Retracted length</p><p>B Stretched length</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>51</p><p>3 Tools</p><p>NET 8940-00200 remote control valve connector</p><p>replacement tools</p><p>Items Quantity Name remarks</p><p>1 1 Socket wrench SAE 4130（QT）</p><p>2 1 Baffle SAE 4130（QT）</p><p>Fig.17.Cylinder length</p><p>A Retracted length</p><p>B Stretched length</p><p>A Retracted length</p><p>B Stretched length</p><p>Fig. 18 Remote control valve connector replacement tools</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>52</p><p>NET 8940-00190 Moving motor guide pins</p><p>Items Quantity Name Remarks</p><p>1 2 Guide bar SAE 4130（25～35 HRC）</p><p>2 2 Screw M8×16</p><p>NET 8940-00270 rotating ring replacement tool</p><p>Items Quantity Name Remarks</p><p>1 2 Ring SAE 1045（QT）</p><p>2 2 Rod SAE 1045（QT）</p><p>3 2 Screw M18</p><p>4 2 Cleaner</p><p>Fig. 9 Moving motor guide pins</p><p>Fig. 20 Rotary ring replacement tool</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>53</p><p>NET 8940-00290 alignment pins of track motor</p><p>Items Quantity Name Remarks</p><p>1 2 Guide bar SAE 4130（25～35 HRC）</p><p>2 2 Screw M8×16</p><p>NET 8940-00300 Rotary gear alignment pins</p><p>Items Quantity Name Remarks</p><p>1 2 Guide bar SAE 4130（25～35 HRC）</p><p>2 2 Screw M8×16</p><p>Fig.22 Rotating gear ring, guide pin</p><p>Fig. 21 Track motor, pins</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>54</p><p>4 Maintenance instructions；Security</p><p>instructions</p><p>Maintenance position</p><p>Park the machine in a horizontal solid place.</p><p>The appropriate positions of machine are described in a variety</p><p>of maintenance instructions.</p><p>Fig.23 Maintenance position A</p><p>Fig. 25 Maintenance position C</p><p>Fig.24 Maintenance position B</p><p>Fig. 26 Maintenance position D</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>55</p><p>Fig. 27 Maintenance position E</p><p>Fig. 28 Maintenance position F</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>56</p><p>ⅡRepair and maintenance</p><p>1 Lubricating; fuel; other liquids</p><p>1.1 Overview</p><p>Recommend lubricants</p><p>Note!</p><p>1) Recommended engine oil level (VDS-3, or Global DHD-1</p><p>+VDS-2, or ACEA-E5 + VDS-2, or API CH-4 + VDS-2)</p><p>Note! *: is installed in the factory.</p><p>• ASTM: American Society for Testing and Materials</p><p>• SAE: Society of Automotive Engineers</p><p>• ISO: International Organization for Standardization</p><p>• API: American Petroleum Institute</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>57</p><p>Table 2. Filling capacity</p><p>Tank Type of fluid About filling capacity</p><p>Liters</p><p>Engine oil disc with filter Engine oil 19.5</p><p>Hydraulic oil tank Hydraulic oil 160</p><p>Hydraulic system (specified) Hydraulic oil 295</p><p>Rotary gear box Gear oil 8.6</p><p>Track gearbox Gear oil 5.8 x 2</p><p>Fuel tank Diesel fuel 155</p><p>Rotating gear ring Grease 17</p><p>Pin and bushing Grease -</p><p>Cooling system Coolant 23.3</p><p>• Specified capacity: Total amount of oil, including oil used for</p><p>components and oil in the pipeline of system.</p><p>• Filling capacity: Fuel is needed to be filled in the tank during</p><p>periodic inspection and maintenance.</p><p>Note! When the sulfur percentage of fuel is below 0.3%, fuel</p><p>should be replaced every 500 hours. If the sulfur percentage of</p><p>fuel is higher than 0.3%, the replacement of oil is based on the</p><p>following table.</p><p>Table 3. Sulfur percentage of fuel and replacement intervals</p><p>Sulfur content of fuel Oil replacement intervals in the engine oil pan</p><p>0.3% to 0.5% 1/2 the normal interval</p><p>＞0.5% 1/4 the normal interval</p><p>Note! Under the conditions that temperature is below 0°C, start</p><p>the engine, to confirm oil is used with SAE10W, SAE 10W-30</p><p>and SAE 15W-40, even if the temperature rises around 10 °C as</p><p>well during the day.</p><p>Note! Fuel should at least meet the regulatory requirements, and</p><p>the country or International standards for trading, such as:</p><p>EN590 (With country-specific adaptation temperature</p><p>requirements), ASTM D 975 No 1D and 2D, JIS KK 2204.</p><p>Note! Please use the API level of CF or CG as the engine oil. If</p><p>the API Level is CD, then the replacement intervals of engine oil</p><p>should be half.</p><p>2) Cooling System</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>58</p><p>• Cooling system is filled with the coolant. To avoid the damage</p><p>of the engine, when filling or replacing, it is very important to</p><p>use the same coolant of the system.</p><p>• Do not mix different coolant or anti-corrosion protective,</p><p>which can cause engine damage.</p><p>Note! Refer to the operation and maintenance manuals for</p><p>detailed information on coolant.</p><p>2. Maintenance</p><p>2.1 Warranty services</p><p>Guarantee View</p><p>During the first test, further examination of the machine is very</p><p>important, which is the reason to implement two guaranteed</p><p>examinations. First examination is on the basis of 100 operating</p><p>hours, and the second is on the basis of 1000 operating hours.</p><p>The inspection time can be changed, and it is not needed to</p><p>inform our company of these specially.</p><p>Warranty checking 100 hours</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Engine, oil level, checking</p><p>5 Coolant level, checking</p><p>6 Hydraulic oil level, checking</p><p>7 Additional fuel filter (oil-water separator core), checking /</p><p>draining</p><p>8 Fuel tank, draining</p><p>9 The main filter of air filter, cleaning</p><p>10 Battery status, checking</p><p>11 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>12 Coolant freezing point, checking</p><p>13 Lubrication, refer to the lubrication chart</p><p>14 Oil level of rotating gearbox, checking</p><p>15 Track board bolts, checking</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>59</p><p>16 Track tension / condition, checking</p><p>17 Oil level of track gearbox, checking</p><p>18 Loose and lost bolts, checking.</p><p>Warranty checking 1000 hours</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel and filter of engine.</p><p>7. Fuel filter,replacing</p><p>8 Oil-water separator filter element, replacing</p><p>9. Fuel tank, draining</p><p>10 Hydraulic oil servo filter, replacing</p><p>11. Main filter of air filter, cleaning</p><p>12. Battery status, checking</p><p>13 Seat belts and tension of seat belt, checking, replacing</p><p>44</p><p>Rotary oil pump, specifications .............................................................................................................................................. 45</p><p>Rotary solenoid valve .............................................................................................................................................................. 46</p><p>Solenoid valve, specifications ................................................................................................................................................. 47</p><p>Servo-hydraulic selector valve, specifications ....................................................................................................................... 47</p><p>Boom specifications ................................................................................................................................................................. 47</p><p>Boom cylinder specifications .................................................................................................................................................. 48</p><p>Bucket arm, specifications ...................................................................................................................................................... 48</p><p>Bucket arm cylinder, specifications ....................................................................................................................................... 49</p><p>Bucket cylinder, specifications ............................................................................................................................................... 50</p><p>3 TOOLS .......................................................................................................................................................................... 51</p><p>NET 8940-00200 remote control valve connector replacement tools .................................................................................. 51</p><p>NET 8940-00190 Moving motor guide pins ........................................................................................................................... 52</p><p>NET 8940-00270 rotating ring replacement tool .................................................................................................................. 52</p><p>NET 8940-00290 alignment pins of track motor ................................................................................................................... 53</p><p>NET 8940-00300 Rotary gear alignment pins ....................................................................................................................... 53</p><p>4 MAINTENANCE INSTRUCTIONS；SECURITY INSTRUCTIONS ....................................................................................... 54</p><p>Maintenance position .............................................................................................................................................................. 54</p><p>ⅡREPAIR AND MAINTENANCE ................................................................................................................................. 56</p><p>1 LUBRICATING; FUEL; OTHER LIQUIDS ........................................................................................................................ 56</p><p>1.1 Overview ............................................................................................................................................................... 56</p><p>Recommend lubricants ........................................................................................................................................................... 56</p><p>2. MAINTENANCE ............................................................................................................................................................ 58</p><p>2.1 Warranty services ................................................................................................................................................. 58</p><p>Guarantee View ....................................................................................................................................................................... 58</p><p>Warranty checking 100 hours ................................................................................................................................................ 58</p><p>Warranty checking 1000 hours .............................................................................................................................................. 59</p><p>2.2 Maintenance ........................................................................................................................................................ 60</p><p>Regular maintenance .............................................................................................................................................................. 60</p><p>Conditions for testing and maintenance plan ....................................................................................................................... 60</p><p>2.2.1 Maintenance plan ........................................................................................................................................................... 60</p><p>Daily maintenance ................................................................................................................................................................... 60</p><p>Maintenance every 50 hours ................................................................................................................................................... 61</p><p>Maintenance every 250 hours ................................................................................................................................................. 61</p><p>Maintenance every 500 hours ................................................................................................................................................. 62</p><p>Maintenance every 1000 hours ............................................................................................................................................... 62</p><p>Maintenance every 2000 hours ............................................................................................................................................... 63</p><p>Maintenance every 4000 hours ............................................................................................................................................... 64</p><p>Maintenance every 6000 hours ............................................................................................................................................... 65</p><p>Test running and checking ..................................................................................................................................................... 66</p><p>Machine, checking the external damage, cracking and worn damage................................................................................ 67</p><p>Cleanser level, checking .......................................................................................................................................................... 67</p><p>Engine oil level, checking ........................................................................................................................................................ 68</p><p>Coolant level, checking ........................................................................................................................................................... 68</p><p>Hydraulic oil level, checking .................................................................................................................................................. 68</p><p>Engine oil and filter, replacing ............................................................................................................................................... 69</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>III</p><p>Draining ...............................................................................................................................................................................</p><p>it if</p><p>necessary</p><p>14. External radiator/external hydraulic oil cooler</p><p>15. Hydraulic tank, oil return filter replacing</p><p>16. Hydraulic oil draining filter, replacing</p><p>17. Hydraulic oil absorbing mesh, cleaning</p><p>18. Main filter of air conditioning, cleaning</p><p>19. Main filter of air conditioning, cleaning</p><p>20. Cab, pre-filter, cleaning</p><p>21. Cab, pre-filter, replacing</p><p>22 Lubrication, refer to the lubrication chart</p><p>23 Rotary gearbox oil level, checking</p><p>24 Rotary motor gear box, changing the oil</p><p>25 Rotating ring gear bearings, lubrication</p><p>26 Rotary oil bath grease, checking</p><p>27 Cab; door, lid, hinges, fittings and locks, lubricating</p><p>28 Track board bolts, checking</p><p>29 Track tension / condition, checking</p><p>30 Track gearbox oil level, checking</p><p>31 Loose and missing bolts, checking</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>60</p><p>32 Hydraulic pressure, checking</p><p>33 X1 oil return filter (optional equipment), replacing</p><p>2.2 Maintenance</p><p>Regular maintenance</p><p>Regular maintenance must be performed as recommended</p><p>advice，in order to maintain the best working state of machine to</p><p>ensure safe operation.</p><p>Improper lubrication, maintenance and operation of the machine</p><p>will be dangerous, which will cause casualties of you and other</p><p>persons in present.</p><p>Note! For more information about regular maintenance, refer to</p><p>"Operation and Maintenance Manual."</p><p>Conditions for testing and maintenance plan</p><p>Except for the measures described in maintenance procedures of</p><p>this manual, agents authorized by our company can also provide</p><p>you with a maintenance system. The maintenance system bases</p><p>on the test of overall status information of machine.</p><p>Further description of the system can be obtained from the most</p><p>nearest agents authorized by our company.</p><p>2.2.1 Maintenance plan</p><p>Daily maintenance</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Additional fuel filter (oil-water separator core), checking /</p><p>draining</p><p>6 Track plate bolts, checking</p><p>7 Engine, oil level, checking</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>61</p><p>Maintenance every 50 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Engine, oil level, checking</p><p>5 Coolant level, checking</p><p>6 Hydraulic oil level, checking</p><p>7 Additional fuel filter (oil-water separator core), checking /</p><p>draining</p><p>8 Additional oil filter core, checking / draining</p><p>9 Lubrication, refer to the lubrication chart</p><p>10 Track plates bolts, c checking</p><p>Maintenance every 250 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Engine, fuel filter and fuel, replacing(First time:50h)</p><p>5 Coolant level, checking</p><p>6 Hydraulic oil level, checking</p><p>7 Additional fuel filter (oil-water separator core), checking /</p><p>draining</p><p>8 Main filter element of air filter, cleaning</p><p>9 Battery status, checking</p><p>10.Cab,pre-filter,cleaning</p><p>11 Lubrication, refer to the lubrication chart</p><p>12 Rotary gearbox oil level, checking</p><p>13 Rotating ring gear bearings, lubricating</p><p>15 X1 oil return filter (optional equipment), replacing</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>62</p><p>Maintenance every 500 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel and filter of engine.</p><p>7.Fuel filter,replacing</p><p>8 Filter element of oil-water separator, replacing</p><p>9.Fuel tank dust, draining</p><p>10 Main filter element of air filter, cleaning</p><p>11. Battery status, checking</p><p>12 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>13.External radiator/external hydraulic oil cooler</p><p>14. Hydraulic oil draining filter, replacing</p><p>15.Main filter of air conditioning, cleaning</p><p>16.Cab,pre-filter,cleaning</p><p>17 Lubrication, refer to the lubrication chart</p><p>18Rotary gearbox oil level, checking</p><p>19 Rotating ring gear bearings, lubricating</p><p>20Track board bolts, checking</p><p>22 X1 oil return filter (optional equipment), replacing</p><p>Maintenance every 1000 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel of engine.</p><p>7.Fuel filter,replacing</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>63</p><p>8 Oil-water separator filter element, replacing</p><p>9. Fuel tank sediment , draining</p><p>10 Hydraulic oil servo filter, replacing</p><p>11. Main filter of air filter, cleaning</p><p>12. Battery status, checking</p><p>13 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>14. External radiator/external hydraulic oil cooler</p><p>15. Hydraulic tank,oil return filter replacing</p><p>16. Hydraulic oil draining filter, replacing</p><p>17. Hydraulic oil absorbing mesh,cleaning</p><p>18. Inlet gap, checking /adjusting</p><p>19. Main filter of air conditioning,cleaning</p><p>20. Lubrication, refer to the lubrication chart</p><p>21 Rotary gearbox oil level, checking</p><p>22 Rotary motor gear box, changing the oil</p><p>23 Rotating ring gear bearings, lubrication</p><p>24 Rotary oil bath grease, checking</p><p>25 Cab; door, lid, hinges, fittings and locks, lubricating</p><p>26 Track board bolts, checking</p><p>27 Track tension / condition, checking</p><p>28 Track gearbox oil level, checking</p><p>29 Loose and missing bolts, checking</p><p>30 X1 oil return filter (optional equipment), replacing</p><p>Maintenance every 2000 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel and filter of engine.</p><p>7.Fuel filter,replacing</p><p>8 Oil-water separator filter element, replacing</p><p>9. Fuel tank, draining</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>64</p><p>10 Ventilation filter of fuel tank, replacing</p><p>11Hydraulic oil servo filter, replacing</p><p>12.Main filter of air filter, cleaning</p><p>13. Battery status, checking</p><p>14 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>15. External radiator/external hydraulic oil cooler</p><p>16. Hydraulic tank, oil return filter replacing</p><p>17. Hydraulic oil draining filter, replacing</p><p>18. Hydraulic oil absorbing mesh, cleaning</p><p>19 Hydrauic tank, replacing ventilation filter</p><p>20. Hydrauic tank, replacing the oil</p><p>21 Inlet gap, checking/adjusting</p><p>22. Frozening point of coolant</p><p>23. Main filter of air conditioning, cleaning</p><p>24. Cab, pre-filter,cleaning</p><p>25 Lubrication, refer to the lubrication chart</p><p>26Rotary motor gear box, changing the oil</p><p>27 Rotating ring gear bearings, lubrication</p><p>28 Rotary oil bath grease, checking</p><p>29 Cab; door, lid, hinges, fittings and locks, lubricating</p><p>30 Track board bolts, checking</p><p>31 Track tension / condition, checking</p><p>32 Track gearbox oil level, checking</p><p>33 Loose and missing bolts, checking</p><p>34 Hydraulic pressure, checking</p><p>35 X1 oil return filter (optional equipment), replacing</p><p>Maintenance every 4000 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the</p><p>calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel and filter of engine.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>65</p><p>7. Fuel filter, replacing</p><p>8 Oil-water separator filter element, replacing</p><p>9. Fuel tank, draining</p><p>10 Ventilation filter of fuel tank, replacing</p><p>11Hydraulic oil servo filter, replacing</p><p>12. The main filter of air filter, cleaning</p><p>13. Battery status, checking</p><p>14 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>15. External radiator/external hydraulic oil cooler</p><p>16. Hydraulic tank, oil return filter replacing</p><p>17. Hydraulic oil draining filter, replacing</p><p>18. Hydraulic oil absorbing mesh, cleaning</p><p>19 Hydrauic tank, replacing ventilation filter</p><p>20. Hydrauic tank, replacing the oil</p><p>21 Inlet gap, checking/adjusting</p><p>22. Frozening point of coolant</p><p>23. Main filter of air conditioning,cleaning</p><p>24. Cab,pre-filter,cleaning</p><p>25 Lubrication, refer to the lubrication chart</p><p>26Rotary motor gear box, changing the oil</p><p>27 Rotating ring gear bearings, lubrication</p><p>28 Rotary oil bath grease, checking</p><p>29 Cab; door, lid, hinges, fittings and locks, lubricating</p><p>30 Track board bolts, checking</p><p>31 Track tension / condition, checking</p><p>32 Track gearbox oil level, checking</p><p>33 Loose and missing bolts, checking</p><p>34 Hydraulic pressure, checking</p><p>35 X1 oil return filter (optional equipment), replacing</p><p>Maintenance every 6000 hours</p><p>Maintenance points marked as "Optional equipment" is not</p><p>included in the calculated maintenance interval.</p><p>1 Try to run and check</p><p>2 Machine, check the external damage, cracking and worn</p><p>damage</p><p>3 Cleanser level, checking</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>66</p><p>4 Coolant level, checking</p><p>5 Hydraulic oil level, checking</p><p>6 Replace the fuel and filter of engine.</p><p>7. Fuel filter, replacing</p><p>8 Oil-water separator filter element, replacing</p><p>9. Fuel tank, draining</p><p>10 Ventilation filter of fuel tank, replacing</p><p>11Hydraulic oil servo filter, replacing</p><p>12.The main filter of air filter, cleaning</p><p>13. Battery status, checking</p><p>14 Seat belts and tension of seat belt, checking, replacing it if</p><p>necessary</p><p>15. External radiator/external hydraulic oil cooler</p><p>16. Hydraulic tank,oil return filter replacing</p><p>17. Hydraulic oil draining filter, replacing</p><p>18. Hydraulic oil absorbing mesh, cleaning</p><p>19 Hydrauic tank, replacing ventilation filter</p><p>20. Hydrauic tank, replacing the oil</p><p>21 Inlet gap, checking/adjusting</p><p>22. Frozening point of coolant</p><p>23. Main filter of air conditioning, cleaning</p><p>24. Cab, pre-filter,cleaning</p><p>25 Lubrication, refer to the lubrication chart</p><p>26Rotary motor gear box, changing the oil</p><p>27 Rotating ring gear bearings, lubrication</p><p>28 Rotary oil bath grease, checking</p><p>29 Cab; door, lid, hinges, fittings and locks, lubricating</p><p>30 Track board bolts, checking</p><p>31 Track tension / condition, checking</p><p>32 Track gearbox oil level, checking</p><p>33 Loose and missing bolts, checking</p><p>34 X1 oil return filter (optional equipment), replacing</p><p>Test running and checking</p><p>1 Starting and stopping functions (including warm-up function)</p><p>2 Instruments</p><p>3 Lighting</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>67</p><p>4 Direction instruction</p><p>5 Danger flash lamp</p><p>6 Wiper</p><p>7 Appliances</p><p>8 Speakers</p><p>9 Rear mirror</p><p>10 Stickers / signs and mirrors</p><p>11 Warning system</p><p>12. Fuel tank, hoses and pipes. Check whether there are leakage,</p><p>gripping and scratches.</p><p>13 Temperature control system, checking</p><p>14 Ways of maintenance</p><p>Machine, checking the external damage, cracking and worn</p><p>damage</p><p>1 Check whether there are external damage, cracks and wear on</p><p>the upper structure, chassis and attachments.</p><p>Cleanser level, checking</p><p>1 Turn the left side door on the machine.</p><p>2Check the cleanser level</p><p>Add cleanser inside the cleaner.</p><p>Fig.1</p><p>Fig.2</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>68</p><p>Engine oil level, checking</p><p>1 Open the hood.</p><p>2 Pull out the dipstick (1), wipe it with a clean cotton cloth.</p><p>3 Insert the dipstick, and then pull it out.</p><p>4 Check the oil level, if the oil level is low, re-fill the right</p><p>amount of oil through the filler (2).</p><p>Note! Engine oil capacity: 19.5 liters</p><p>Coolant level, checking</p><p>1 Open the engine hood.</p><p>2 Check the coolant level in expansion tank. Level should be</p><p>between MAX (maximum) and MIN (minimum) tags of the</p><p>expansion tank.</p><p>Note! Hot coolant should be cooled after the engine is running,</p><p>then check the coolant level.</p><p>Note! Cooling system filling capacity: 23.5L</p><p>Hydraulic oil level, checking</p><p>1. Park the machine on hard ground.</p><p>2. Stop the machines in the repair location C. Refer to</p><p>maintenance position.</p><p>3 Push the safety control lock lever down and fix it firmly in the</p><p>locked position, then stop the engine.</p><p>4 Move the left/right operation levers with full stroke towards all</p><p>the directions to release the residue pressure within the hydraulic</p><p>circuit.</p><p>5 Check the oil level through level gauge.</p><p>Note! If the height of oil level gauge is between the lower and</p><p>upper limit, the oil level is normal.</p><p>Note! If the oil level is low, open the lid of tank, add hydraulic</p><p>oil.</p><p>Fig.3</p><p>1 Dipstick</p><p>2 Engine oil filler</p><p>Fig.5</p><p>Fig.6</p><p>Fig.4 Check the coolant level</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>69</p><p>Note! Refilling capacity of hydraulic tank maintenance: 160L</p><p>Engine oil and filter, replacing</p><p>Tool</p><p>9996672 oil filter wrench</p><p>Note! Change the oil every 250 operating hours.</p><p>Draining</p><p>Important! Oil and other environmentally hazardous liquids</p><p>must be dealt in environmental and friendly way.</p><p>Note! When the engine is heating, the oil is drained.</p><p>WARNING!</p><p>Be careful when replacing oil, hot oil will cause hurt to</p><p>unprotected skin.</p><p>1 Start the engine, warm up for two minutes.</p><p>2 Open the cover (1) and the oil drain valve cap (12), install the</p><p>engine oil draining hose (23), then drain the oil from the engine</p><p>to an appropriate oil containers.</p><p>Note! Please use the environmental and friendly to deal with</p><p>waste oil and the used oil filters.</p><p>3 Open the right door on the machine.</p><p>Fig. 7 Engine oil, draining</p><p>1 Cover</p><p>2 Oil drain valve cover</p><p>3 Engine oil draining hose</p><p>Fig.8</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>70</p><p>4 Replace oil filter with 9,996,672 wrench , fill the new oil filter</p><p>with engine oil.</p><p>Clean the base of filter housing. Make sure that all the old filter</p><p>gaskets are removed.</p><p>Note! Coat the new gasket of the filter with engine a layer of oil.</p><p>Tighten the filter until the gasket just contacts the sealing surface.</p><p>And then tighten 1 / 2 turn by hands.</p><p>Filling oil</p><p>5 Fill the engine oil through the engine oil filler.</p><p>6 Make the engine warm up, check whether oil leaks.</p><p>7 Check the oil level of the dipstick.</p><p>Figure 9 Engine oil filter, replacing</p><p>Fuel filter, replacing</p><p>Tool</p><p>9996671 oil filter wrench</p><p>Fuel filter may be clogged, which may cause engine power</p><p>reduced. If the filter is clogged quickly, check whether the fuel</p><p>is contaminated, if necessary, clean the tank.</p><p>1 Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>2 Use a 9,996,671 oil filter wrench to loosen the fuel filter, then</p><p>remove it.</p><p>3 Clean the sealing surface of filter head.</p><p>4 Coat the new rubber seal of filter with a little oil, or make it</p><p>wet with diesel fuel.</p><p>5 Tighten the filter by hand until the seal contacts tightly, and</p><p>then tighten a half circle.</p><p>6 Perform exhausting operation. Refer to fuel system, leakage.</p><p>Fig.10 Engine oil, filling fully</p><p>1 Dipstick</p><p>table</p><p>2 Engine oil filler</p><p>Fig.9 Engine oil and filter, replacing</p><p>Fig.11Remving, the filter</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>71</p><p>Additional fuel filter (oil-water separator core), checking /</p><p>draining</p><p>1 Open the right door on the machine.</p><p>2 Check the water and sediment in oil-water separator tank (2).</p><p>3 Open the water draining valve (1), when necessary, drain the</p><p>water and sediment</p><p>4 Perform exhausting operation. Refer to fuel system, leakage.</p><p>5 Close the right side door on the machine..</p><p>Water separator filter element, replacing</p><p>Tool</p><p>9996671 oil filter wrench</p><p>11666167 removal tool</p><p>Note! Fuel filter may be clogged, which may cause engine</p><p>power reduced. If the filter is clogged quickly, check whether</p><p>the fuel is contaminated, if necessary, clean the tank.</p><p>1 Turn the main pump (1) counter clockwise, until the plunger is</p><p>unlocked.</p><p>2 Disconnect the cable connector (1).</p><p>3 Loosen the drain valve (2), and discharge the sediment from</p><p>the oil-water separator tank (3).</p><p>4 Use an oil filter wrench to loosen 9996671 oil-water separator</p><p>tank (3), then remove it.</p><p>5 Use a 11,666,167 removal tool to release oil-water separator</p><p>filter, and then remove it.</p><p>6 Clean the sealing surface of filter head.</p><p>7 Coat the new rubber seal of filter with a little oil, or make it</p><p>wet with diesel fuel.</p><p>8 Tighten the filter by hand until the seal contacts tightly, and</p><p>then tighten a half circle.</p><p>9 Tighten the filter tank by hand until the seal contacts tightly,</p><p>and then tighten a half circle.</p><p>Fig.12</p><p>A Water draining valve</p><p>2 Oil-water separator tank</p><p>Fig.13</p><p>1Main pump</p><p>Fig.14</p><p>1 Wiring harness connector</p><p>2 Draining valve</p><p>3 Oil bowl</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>72</p><p>10 Perform exhausting operation. Refer to fuel system, leakage.</p><p>Fuel tank sediment, draining</p><p>1 Turn the machine to the right about 45 ° ~ 60 °.</p><p>2 Open the draining valve, drain the water and sediment into a</p><p>suitable container.</p><p>Note! Draining valve of fuel tank is located below the fuel tank.</p><p>Note! Deal with the discarded liquid according to local laws and</p><p>regulations.</p><p>Fuel tank ventilation filter, replacing</p><p>1 Remove the screws (2) and air filter cover (1) of fuel tank.</p><p>2 Remove the clamping screw (2) and air filter (1) of fuel tank.</p><p>3 Install the new fuel tank air filter (1) and the rubber connector</p><p>(2).</p><p>4 Install the clamping screw and the fuel tank air filter.</p><p>Fig.15</p><p>Fig.18</p><p>Fig.16</p><p>Fig.17</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>73</p><p>Hydraulic oil servo filter, replacing</p><p>Note! After 500 operating hours, replace the servo-hydraulic</p><p>filter element, and replace one time every 1000 operating hours.</p><p>1 Turn the left side door on the machine.</p><p>2 Put a container below the filter, and remove the filter bowl.</p><p>3 Replace the core of servo-hydraulic oil filter.</p><p>4 Reinstall the filter bowl.</p><p>Main element air filter, cleaning</p><p>1 Turn the left side door on the machine.</p><p>2 Open the air filter hood.</p><p>3 Pull out the main filter element of air filter and place it in a</p><p>soft, clean surface,</p><p>Carefully beat the end of the main element.</p><p>4 Use clean dry compressed air to clean the main filter,</p><p>maximum pressure 500 kPa</p><p>Note! If there are even the smallest holes, scratches, cracks or</p><p>other damage, the main filter must be replaced with new one.</p><p>5 Install the main filter and air filter cover.</p><p>6 Close the side door.</p><p>Main filter of air filter, replacing</p><p>Note! After cleaning at most 5 times, the main filter should be</p><p>replaced, or at least it should be replaced once a year.</p><p>1 Open the left side door on the machine.</p><p>2 Open the air filter cover.</p><p>Fig.19</p><p>Fig.20</p><p>Fig.21</p><p>Fig.22</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>74</p><p>3 Remove the main filter of\ air filter and clean housing of filter.</p><p>Note! Press the main filter with both thumbs together, and pull it</p><p>out, which can prevent the auxiliary filter also being brought out</p><p>from the main filter.</p><p>4 Install a new main filter.</p><p>5 Close the air filter cover and side door.</p><p>Safety filter element of air filter, replacing</p><p>Note! After replacing the main filter element every 3 times,</p><p>security filter should be replaced, or at least once every two</p><p>years.</p><p>1 Open the left side door on the machine.</p><p>2 Open the air filter cover.</p><p>3 Remove the main filter element of air filter.</p><p>Note! Press the main filter with both thumbs together, and pull it</p><p>out, which can prevent the auxiliary filter also being brought out</p><p>from the main filter.</p><p>4 Remove the safety filter element of air filter and clean the</p><p>filter housing.</p><p>5 Install a new security filter element and main filter.</p><p>6 Close the air filter cover and side door.</p><p>Fig.23</p><p>Fig.26</p><p>Fig.25</p><p>Fig.24</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>75</p><p>Battery status, checking</p><p>WARNING!</p><p>The battery electrolyte contains corrosive sulfuric acid solution.</p><p>Electrolyte splashed on the skin should be removed at once.</p><p>Wash it with soap and plenty of water. If electrolyte gets in your</p><p>eyes or other parts that are easily injured, wash them</p><p>immediately with plenty of water and contact a doctor</p><p>immediately for help.</p><p>1 Open the cover of battery on the right side of fuel tank.</p><p>2 Remove the battery cover.</p><p>3 Remove the battery cover (1).</p><p>Electrolyte level should be approximately exceeding the panels</p><p>about 10 mm.</p><p>4 When necessary, use distilled water to fill.</p><p>5 Operate the machine after filling fully, so that water can be</p><p>mixed in the battery electrolyte, which is even more important in</p><p>cold weather.</p><p>6 Check whether the cable terminals and the electrode is clean,</p><p>fixed firmly or coated with Vaseline or similar product.</p><p>Belts and belt tension, checking, replace it if necessary</p><p>1 Open the hood.</p><p>2 Check the belt tension, cracking, worn or damaged. If</p><p>damaged, replace the conveying belt.</p><p>3 Close the hood.</p><p>Fig.28 Removing the battery</p><p>Fig.27</p><p>Fig.29</p><p>Fig. 30</p><p>1. Belt of air conditioning compressor</p><p>2 Alternator/fuel pump/cooling pump belt</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>76</p><p>External radiator / oil cooler outside, cleaning</p><p>WARNING!</p><p>Compress air. Do not point directly to exposed skin. Use</p><p>protective equipment.</p><p>1 Open the left door on the machine.</p><p>2 Remove the screws (1), and open the radiator cap (2).</p><p>3 Remove the wing nut (5 EA).</p><p>4 Pull up the filter mesh and remove it</p><p>5 Blow the outside of the radiator / hydraulic oil cooler and</p><p>inflatable cooler with compressed air or water flow net cleanly.</p><p>Fig.32</p><p>Fig.31</p><p>Fig.33</p><p>Fig. 34 Filter</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>77</p><p>Hydraulic tank, oil returning filter, replacing</p><p>Note! When using a hydraulic hammer, refer to the table to</p><p>replace the oil return filter.</p><p>Hammer the frequency of use Replacement interval</p><p>50% Every 500 hours</p><p>100% Every 300 hours</p><p>Note! Add hydraulic oil, maintenance of the system requires to</p><p>be very clean. Even small impurities go into the system, it will</p><p>also cause damage and failure of system. Before adding the new</p><p>hydraulic oil into the hydraulic tank, filler should be cleaned.</p><p>1 Release the residue pressure in the hydraulic tank from the</p><p>respirator.</p><p>2 Remove the screw (1) and remove cover (2).</p><p>3 Remove the spring (4), valves (3), filters (2) and the filter</p><p>element (1).</p><p>4 Install a new filter element, filter mesh, valves and springs.</p><p>5 Install the cover.</p><p>Hydraulic oil draining filter, replacing</p><p>Note! After 500 operating hours, replace the filter element of</p><p>hydraulic oil draining filter,</p><p>and then replace it every 1000</p><p>operating hours.</p><p>1 Put a container under the oil draining filter, turn the filter</p><p>counterclockwise to remove it.</p><p>2 Fill the new filter with hydraulic oil, coat the O-ring with</p><p>hydraulic fluid.</p><p>3 Install the new filter.</p><p>Fig.35 Remove the cover</p><p>1 Screw 2 Cover</p><p>Fig.36 Removing, springs, valves, filters and filter elements.</p><p>1Filter element 2 Filter mesh3 Spring 4 Valve</p><p>Fig.37</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>78</p><p>Hydraulic oil absorbing filter, cleaning</p><p>Note! Clean once every 2000 hours to clean, replace it if</p><p>necessary.</p><p>1 Release the residue pressure in the hydraulic tank from the</p><p>respirator.</p><p>2 Remove the cover</p><p>3 Remove the absorbing mesh. Use non-flammable cleaner to</p><p>clean and dry with compressed air.</p><p>4 Install the mesh.</p><p>Note! If there is any damage to the absorbing mesh (even small</p><p>damage), it must be replaced with new one.</p><p>Note! If the O-ring needs to be replaced, only replace with new</p><p>O-ring.</p><p>5 Install the cover.</p><p>Hydraulic tank, replacing the ventilation filter</p><p>Removing</p><p>1 Release the residue pressure in the hydraulic tank from the</p><p>respirator.</p><p>2 Remove the rubber cover (1) and nut (2).</p><p>Fig.38</p><p>Fig.39</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>79</p><p>3 Remove the cover by rotating respirator cover (3), and remove</p><p>the filter components (4) of respirator.</p><p>Installing</p><p>4 Install the new filter respirator, respirators cover (3), nuts (2)</p><p>and the rubber cover (1).</p><p>Hydraulic tank, hydraulic oil replacing</p><p>Important! Use the same hydraulic oil in the system. If you mix</p><p>different brands of hydraulic oil, hydraulic system may be</p><p>damaged.</p><p>Note! Refer to the table below to replace the hydraulic oil.</p><p>Hydraulic oil Replacement interval</p><p>Mineral oil Every 2000 hours</p><p>Fig.40 Remove the rubber cap and nut</p><p>1. Rubber nut 2. Nut</p><p>of hydraulic tank</p><p>Fig.41 Remove the respirator cap of hydraulic tank and filter element of filter.</p><p>3 Respirator cover 4 Filter element</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>80</p><p>Note! When using a hydraulic hammer, refer to the table to</p><p>replace the hydraulic oil.</p><p>Use frequency of hammer Replacement interval</p><p>50% Every 1000 hours</p><p>100% Every 600 hours</p><p>Note! Add hydraulic oil, maintenance of the system requires to</p><p>be very clean. Even small impurities go into the system, it will</p><p>also cause damage and failure of system. Before adding the new</p><p>hydraulic oil into the hydraulic tank, filler should be cleaned.</p><p>1 Release the residue pressure in the hydraulic tank from the</p><p>respirator.</p><p>2 Park the machine in the repair location C, refer to maintenance</p><p>position</p><p>3 Install the oil draining hose (1), and drain the oil to a suitable</p><p>container.</p><p>Important! Hydraulic oil and other environmentally hazardous</p><p>liquids must be dealt in environmental and friendly way.</p><p>4 Refill the hydraulic tank ,and drain the hydraulic oil through</p><p>the filler (1) on the cover hood.</p><p>5 Perform the test running procedures to check for hydraulic oil</p><p>leakage.</p><p>6 Remove hydraulic oil draining hose, turn off the bottom lid.</p><p>Fig.43</p><p>Fig. 42 Hydraulic tank, draining</p><p>1 Oil draining hose</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>81</p><p>Valve clearance, checking / adjusting</p><p>Tool</p><p>9,998,681 Rotary tool</p><p>885,812 Timing Tool</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then make the</p><p>necessary operations.</p><p>1. Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>2 Open the engine hood.</p><p>3 Remove the inlet hose (1) of the turbocharger.</p><p>4 Remove the ventilation pipe (1) of crankcase.</p><p>5 Remove the cable bracket (1).</p><p>6 Remove the rocker cover (1).</p><p>7 Open the right side door on the machine.</p><p>Fig.44</p><p>Fig.46</p><p>Fig.47</p><p>Fig.45</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>82</p><p>8 Removing gear cover (1) of camshaft, install the steering gear</p><p>(2).</p><p>Note! Steering gear must be fully meshed with the gear of</p><p>camshaft.</p><p>9 Set the overlap angle of engine valve</p><p>Rotate the crankshaft with the steering gear until it reaches the</p><p>overlap angle of cylinder valve1 .</p><p>Valve overlap means that the exhausting valve opens, while the</p><p>inlet valve is open. If the cylinder is faulty in this position, it</p><p>can’t rotate the putter by hand.</p><p>Fig.50 Valve overlap</p><p>Fig.49</p><p>Fig.48</p><p>1 Camshaft gear cover 2 Steering gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>83</p><p>10 According to the black mark in the figure, adjust the valve</p><p>clearance for each cylinder. Adjustment steps are as follows:</p><p>1 Loosen the locking bolts on the adjusting screw of the rocker.</p><p>2 Install the protractor on adjustment screws.</p><p>3 Turn the adjustment screw until the gap between the rocker</p><p>and the valve is zero. Reset the protractor to zero.</p><p>4 For the inlet valve, rotate the adjustment screw</p><p>counterclockwise 90 °;For the exhaust valve rotate the</p><p>adjustment screw counterclockwise 150 °.</p><p>5 Hold the adjusting screw, and tighten the lock nut. Tightening</p><p>torque: refer to Engine, tightening torque</p><p>Fig. 53</p><p>1 885 812 timing tool</p><p>2 Adjustment screws</p><p>Fig.52</p><p>Fig. 51</p><p>1,3,5,7,9 and 11 are exhaust valve</p><p>2,4,6,8,10 and 12 is the inlet valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>84</p><p>11 Rotate the crankshaft one full circle until the valves of</p><p>cylinder overlap. According to the black mark in the figures,</p><p>adjust the valve clearance of each cylinder.</p><p>Note! When all the valves are adjusted, do not rotate the engine.</p><p>Continue to install directly.</p><p>Assembly</p><p>12 Order of assembly is opposed to the order of disassembly.</p><p>Note! Do not reuse O-ring and gasket.</p><p>13 After the maintenance work is completed, start the engine,</p><p>check for leakage and operation state.</p><p>Coolant freezing point, checking</p><p>1 Using a refractometer to measure the proportion of coolant</p><p>specifications, do not use a hydrometer table, because readings</p><p>may be inaccurate.</p><p>Note! Check once every 1000 operating hours or once a year.</p><p>Note! Different brands of antifreeze can not be mixed, if mixed</p><p>sue may cause negative effects.</p><p>Note! Always use antifreeze,r efer to Part 1, anti-corrosion</p><p>coolant antifreeze, S part.</p><p>Coolant, replacing</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then</p><p>make the necessary operations.</p><p>WARNING!</p><p>When the expansion tank cap (cooler cover) is opened,</p><p>because of the high pressure of cooler within the</p><p>system, it has the risk of scalding.</p><p>1. Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>Coolant draining</p><p>2 Open the engine hood, slowly remove the cover from the</p><p>expansion tank cap (1).</p><p>3 Open the left side door on the machine.</p><p>Fig.55</p><p>Fig.54</p><p>Fig.56</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>85</p><p>Open the coolant drain valve (1) to drain the coolant into a</p><p>suitable container.</p><p>Note! Prepare a suitable container.</p><p>Note! After emptying the cooling system, do not prevent</p><p>freezing. There may also be accumulated coolant within the</p><p>system.</p><p>Note! Use environmentally safe manner to deal with the waste</p><p>oil / fluid.</p><p>Filling the empty system with coolant</p><p>Note! Different brands of antifreeze can not be mixed, if mixed</p><p>sue may cause negative effects.</p><p>Note! Always use antifreeze,r efer to Part 1, anti-corrosion</p><p>coolant antifreeze, S part.</p><p>4 Re-add the coolant by expansion tank.</p><p>Note! Re-add the capacity of the coolant is about 32 liters</p><p>Note! Fill the coolant to 2 / 3 volume of the</p><p>expansion tank.</p><p>5 Start the engine, run to the operating temperature, and fill the</p><p>enough coolant, so that cooling system will be filled with</p><p>coolant to drain the air.</p><p>6 Check the coolant level after the engine is running and be</p><p>heated to operating temperature, and then cooled down.</p><p>Note! Do not fill the cold coolant when the engine is warming</p><p>up, which may cause cracks of engine body and cylinder heads.</p><p>Main filter of air conditioning, cleaning</p><p>1 Move driver's seat to the front position and fold the backrest</p><p>forward front.</p><p>2 Remove the screws and pre-filter cover of cab.</p><p>3 Remove the floor mats</p><p>Fig.57</p><p>Fig.59</p><p>Fig.58</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>86</p><p>4 Remove the five screws (1) and cover (2).</p><p>5 Disconnect the wiring harness (4) of air actuator. Remove the</p><p>pipe (1) of air conditioning and the upper shell (3).</p><p>Note! When removing the lid, refer to the method of top lid.</p><p>6 Remove the filter and blow the filter with compressed air ----</p><p>maximum pressure of 0.2 Mpa.</p><p>7 Restore the machine to the operating state.</p><p>Note! Be careful not to damage the components.</p><p>Note! If the air filter is clogged, airflow reduces, and cooling</p><p>and heating capacity will decrease. Therefore, clean regularly.</p><p>Fig.60</p><p>Fig.61</p><p>1.Pipeline 2 Open method instruction of housing</p><p>3 Upper housing 4 Wire harness</p><p>Fig.63</p><p>Fig.62</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>87</p><p>Main filter of air conditioning, replacing</p><p>1 Move driver's seat to the front position and fold the backrest</p><p>forward front.</p><p>2 Remove the screws and pre-filter cover of cab.</p><p>3 Remove the floor mats</p><p>4 Remove the five screws (1) and cover (2).</p><p>5 Disconnect the wiring harness (4) of air actuator. Remove the</p><p>pipe (1) of air conditioning and the upper shell (3).</p><p>Fig.59</p><p>Fig.64</p><p>Fig.66</p><p>Fig.65</p><p>. Fig. 67</p><p>1 Pipeline 2 Open method of housing</p><p>3 Upper shell 4 Wire harness</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>88</p><p>Note! When removing the lid, refer to the method of top lid.</p><p>6 Replace the old filter with a new one.</p><p>Note! Be careful not to damage the components.</p><p>Note! If the air filter is clogged, airflow reduces, and cooling</p><p>and heating capacity will decrease. Therefore, clean regularly.</p><p>Cab, pre-filter, cleaning</p><p>1 Move driver's seat to the front position and fold the backrest</p><p>forward front.</p><p>2 Remove the screws and pre-filter cover of cab.</p><p>3.Remove the filter and blow the filter with compressed air ----</p><p>maximum pressure of 0.2 Mpa.</p><p>Note! If the air filter is clogged, airflow reduces, and cooling</p><p>and heating capacity will decrease. Therefore, clean regularly.</p><p>Cab, pre-filter, replacing</p><p>1 Move driver's seat to the front position and fold the backrest</p><p>forward front.</p><p>2 Remove the screws and pre-filter cover of cab.</p><p>Fig. 68</p><p>Fig.70</p><p>Fig.69</p><p>Fig.71</p><p>Fig.72</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>89</p><p>3.Remove the filter and blow the filter with compressed air ----</p><p>maximum pressure of 0.2 Mpa.</p><p>Note! If the air filter is clogged, airflow reduces, and cooling</p><p>and heating capacity will decrease. Therefore, clean regularly.</p><p>Lubrication, refer to the lubrication chart</p><p>1 Operate according to the form of lubrication and maintenance</p><p>operations in operator's manual.</p><p>Rotary gearbox oil level, checking</p><p>1 Pull out the dipstick of gear oil, wipe with a clean cotton cloth.</p><p>Re-insert the dipstick, and then pull it out.</p><p>2 Check the gear oil level and fill it fully as needed.</p><p>Note! After adding gear oil, wait about 5 minutes, then check</p><p>the gear oil level.</p><p>Rotary motor gear box, changing the oil</p><p>Important! Drain when the gear oil is heated to rush out the</p><p>dirt.</p><p>1. Park the machine parked in the maintenance position C, refer</p><p>to maintenance position.</p><p>2 Remove the lid below.</p><p>3 Open the gear oil draining valve cap (1), and install the gear</p><p>oil draining valve (2). Drain the oil of gear box into a suitable</p><p>container.</p><p>4 After draining completely, remove gear oil draining hose (2),</p><p>and install the gear oil drain valve cover (1).</p><p>5 Install the bottom cover and tighten to specified torque.</p><p>Fig.75</p><p>Fig.74</p><p>Fig.73</p><p>Fig.76</p><p>1 Gear oil drain valve cover</p><p>2 Oil drain hose</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>90</p><p>6 Pull out the dipstick, use a gear oil gear pump to fill the oil to</p><p>correct level through the oil filling throttle (3).</p><p>7 Use gear oil dipstick to check gear oil level, add it if</p><p>necessary.</p><p>Note! After adding gear oil, wait about 5 minutes, and then</p><p>check the gear oil level.</p><p>Rotarying ring bearings, lubricating</p><p>1 Clean the grease mouth.</p><p>2 Apply the grease on the rotary gear ring bearing until you can</p><p>see grease overflow from the seals of rotary bearing.</p><p>Note! Do not use too much grease.</p><p>3 After lubrication, thoroughly clean the excessive grease.</p><p>Rotary oil bath grease, checking</p><p>1 Open the battery cover on the right side of the machine.</p><p>2 Remove the lid.</p><p>3 Check the grease level.</p><p>Note! If the grease is contaminated, or water is under</p><p>discoloration, grease should be replaced.</p><p>Cab; door, lid, hinges, fittings and locks, lubricating</p><p>Fig. 77</p><p>3 Gear oil filling throttle</p><p>Fig.78</p><p>Fig.79</p><p>Fig.80</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>91</p><p>1 Lubricate the hinges with grease.</p><p>Track plate bolts, checking</p><p>1 Park the machine in the maintenance position F, refer to</p><p>maintenance position.</p><p>2 Rotate the superstructure to one side , and fall the boom to</p><p>lift the track. Rotate the track plate forward and backward</p><p>several times slowly. Check whether the track plates and screws</p><p>are loose or missing or damaged.</p><p>3 If the track plate bolts (A) are loose, then the track plate is</p><p>likely to be damaged.</p><p>4 Check loosening.</p><p>Replace with new bolts and nuts, if necessary, tighten the bolts</p><p>to the specified torque.</p><p>Fig. 81</p><p>1 Grease gun with a muzzle</p><p>Fig.82</p><p>Fig.83</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>92</p><p>Note! Tightening torque: 833.5 ± 49 Nm</p><p>Note! Tighten the bolts in the order shown in the figure.</p><p>5 After tightening, check whether the nut and track plate contact</p><p>with the surface of linkage completely.</p><p>Track tension / condition, checking</p><p>1 Park the machine in the maintenance position F, refer to</p><p>maintenance position.</p><p>2 Rotate the track plate forward and backward several times</p><p>slowly. Check whether the track plates and screws are loose or</p><p>missing or damaged. Stop the track when rotating back.</p><p>3 Measure the track tension between the track plate in the center</p><p>of track frame and the assembling surface of track bearing</p><p>wheel..</p><p>4 Adjust the track tension according to soil characteristics.</p><p>Recommended track tension is as follows.</p><p>Fig.85</p><p>Fig.84</p><p>Fig.86</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>93</p><p>Table 9, Adjust the track tension according to soil characteristics,</p><p>unit: mm</p><p>Working conditions Gap (A), unit: mm</p><p>General soil 320 ~ 340</p><p>Rocky ground 300 ~ 320</p><p>Level and soft soil, such as sand and gravel, snow, etc. 340 ~ 360</p><p>Oil level of track gearbox, checking</p><p>1 Put the machine on a hard ground.</p><p>2 Rotate the gearbox as shown in the figure.</p><p>Remove the cover on the plug (2), check if there is gear oil</p><p>spilling.</p><p>3 If the gear oil is about to overflow from the hole, the oil level</p><p>is correct.</p><p>4 If</p><p>the gear oil level is too low, fill gear oil through the plug (2)</p><p>of filling hole to the correct oil level.</p><p>5 Install the plug.</p><p>Walking motor gearbox, gear oil replacing</p><p>1 Park the machine in the maintenance position B, refer to</p><p>maintenance position.</p><p>Rotate the gearbox until draining is at the bottom and plug and</p><p>filling plug is located in the horizontal axis.</p><p>2 Remove the two plugs on the end cap and drain the gear oil</p><p>into a suitable container.</p><p>Note! Oil capacity: 5.8 L</p><p>Fig. 87</p><p>1Draining throttle</p><p>2 Filling holes and oil level checking hole</p><p>Fig. 88 Removing, the plug</p><p>1 oil drain plug</p><p>2 filling holes and gear oil level</p><p>check plug</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>94</p><p>3 After completely emptying, install draining plug and tighten it</p><p>to specified torque.</p><p>4. Fill gear oil through the filling hole (2) until gear oil</p><p>overflows from the checking hole (2).</p><p>5 Install filling plug and level checking plug and tighten them to</p><p>specified torque.</p><p>Loose and missing bolts, checking</p><p>1. Check the loose and missing assembly bolts of the engine</p><p>visually.</p><p>2 Check the loose and missing assembly bolts of the seal cap</p><p>visually.</p><p>3 Check whether the bolts of the hydraulic pump, motor, main</p><p>control valve are loose or missing.</p><p>Hydraulic pressure, checking</p><p>1 Measure the hydraulic pressure with pressure gauge, and</p><p>adjust it if necessary, refer to main pressure reducing valve</p><p>adjustment.</p><p>2.2.2 Conditional test</p><p>Measurement conditions</p><p>The purpose of this chapter is to explain how to evaluate the</p><p>performance of various hydraulic excavators of our company.</p><p>Tolerance listed is used for new machines.</p><p>For a machine in use, the requirement is not so strict according</p><p>to site conditions.</p><p>Unless special instruction, the measurement must be carried out</p><p>under the following conditions:</p><p>• Engine speed: High rpm, "P" mode</p><p>• Hydraulic oil temperature: 50 ± 5 ° C</p><p>• Location: Firm, flat surface</p><p>Fig.89</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>95</p><p>Cylinder speed</p><p>Preparation</p><p>Boom cylinder</p><p>• Arm cylinder is fully retracted.</p><p>• Bucket cylinder is completely extended.</p><p>Bucket arm cylinder</p><p>• Bucket cylinder is completely extended.</p><p>Fig.90 Measurement conditions, boom cylinder</p><p>A B→A: Lifting</p><p>B A→B: Lowering</p><p>Fig.91 Measurement conditions, bucket arm cylinder</p><p>A B→A: Arm is retracted</p><p>B A→B: Arm is extended</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>96</p><p>Bucket cylinder</p><p>Measuring</p><p>• Operate the control lever with full stroke</p><p>• Measure the time of full stroke of cylinder with a watch.</p><p>• Measure 3 times and calculate the mean.</p><p>Operating Standard Allowable value Remarks</p><p>Boom Lifting 2.6±0.3 2.9 From the ground to the fully extended.</p><p>Lowering 2.5±0.3 3.0 From fully extended to the ground.</p><p>Bucket</p><p>arm</p><p>Bending inside 3.5±0.3 4.1 From fully retracted to fully extended.</p><p>Bending out 2.5±0.3 3.0 From fully extended to fully retracted.</p><p>Bucket Bending inside 3.5±0.3 4.1 From fully retracted to fully extended.</p><p>Bending out 2.1±0.3 2.7 From fully extended to fully retracted.</p><p>Peristaltic of cylinder</p><p>Preparation</p><p>Fig.92 Measurement conditions, bucket arm cylinder</p><p>A B→A: Bending out</p><p>B A→B: Bending inside</p><p>Fig. 93 Measurement conditions, peristaltic</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>97</p><p>•Bucket is with full load, place the front digging device as</p><p>shown in the picture.</p><p>Exerted load: 1440 kg</p><p>Measuring</p><p>• Stop the engine.</p><p>• Wipe the oil on the piston rod, and mark the measure starting</p><p>point with tape.</p><p>• Measure the peristaltic of piston rod for 5-minute.</p><p>• After measurement, remove the tape and carefully clean it.</p><p>Standard Allowable value Maximum</p><p>Boom cylinder Less than 10 15 20</p><p>Bucket arm cylinder Less than 10 15 20</p><p>Bucket cylinder Less than 40 50 70</p><p>Rotation speed</p><p>Preparation</p><p>• Bucket cylinder is completely retracted.</p><p>• Bucket cylinder is completely extended.</p><p>Measuring</p><p>• Full stroke operates rotary operation lever.</p><p>Fig.94 Measurement conditions, peristaltic</p><p>1 Tape 3 Piston rod 5 Retracted (L = A - a)</p><p>2 Seal sleeve of cylinder 4 Starting position 6 Extending (H = b - A)</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>98</p><p>• Measure the entire rotation of the upper body at a constant</p><p>speed for 4 times. (Except for the first full rotation)</p><p>• Measuring the right and left alternately.</p><p>Standard Allowable value Maximum</p><p>15.5±1.5 17 18</p><p>Rotation towards left/right at idle</p><p>Preparation</p><p>• Bucket is with full load.</p><p>• Bucket arm cylinder is completely retracted.</p><p>• Bucket cylinder is completely extended.</p><p>• Make the mark (A) on the outer bearing sleeve of rotary</p><p>bearing, and mark (B) on the chassis under it directly.</p><p>• Rotate the upper structure to make the angle between arm and</p><p>boom as 180°.</p><p>Fig. 95 Measurement conditions, rotation speed</p><p>Fig. 96 measurement conditions, inertial rotation</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>99</p><p>Measuring</p><p>•• Full stroke operates rotary operation lever.</p><p>and turn 180 °.</p><p>• When the two markers is aligned together, pull the control</p><p>handle back in neutral position.</p><p>• Measure the distance between mark on the rotary bearings and</p><p>the mark on chassis.</p><p>Standard Allowable value Maximum</p><p>Moment of inertia (D) ＜1332 1465 1520</p><p>Measuring clearance of bearing</p><p>Gap</p><p>Axial direction of the bearing</p><p>Direction</p><p>Removable status Standard 0.05 ~ 0.2 mm</p><p>Allow spacing 0.4 mm</p><p>Installation conditions Standard 0.2 ~ 1.7 mm</p><p>Allow spacing 2.5 mm</p><p>Tightening torque External screw kgf·m 52.2 ± 5.2</p><p>Internal screw</p><p>Fig.97 Moment of inertia</p><p>A Mark position (bearings) C Stopping position of rotary device E Starting rotation device</p><p>B Mark position (chassis frame) D Moment of inertia F 180 ° rotation</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>100</p><p>Measuring</p><p>Note! Before operating, make sure all the screw mounting</p><p>screws have been tightened.</p><p>Removal condition</p><p>1 Put the rotary gear on a flat surface, and then put magnetic</p><p>base on bearing sleeve every 120 °.</p><p>2 Put three dial indicators on the inner bearing sleeve.</p><p>3 Lift outside bearing sleeve vertically, axial clearance of</p><p>bearing is dynamic process.</p><p>4 Read the value on the dial indicator.</p><p>Installation conditions</p><p>Clean the bearing sleeve and lower part of chassis of outer rotary</p><p>gear.</p><p>Wear of rotary gear are uneven on the entire circumference.</p><p>To obtain accurate results, measure twice and rotate the upper</p><p>structure around the axis 90 °.</p><p>1st measurement</p><p>1. Align the upper structure with the midline of chassis.</p><p>2 Fall the mining equipment to the ground until the wheels leave</p><p>the ground.</p><p>3 Place the magnetic base.</p><p>4 Adjust the lower side of the chassis and adjust dial indicator on</p><p>outer bearing sleeve of rotary gear to zero.</p><p>5 Lower the excavator to the ground gradually, keep the arm</p><p>stretched out and raise the bucket to the height of cab floor.</p><p>Read that value on the dial indicator.</p><p>6 Make the excavating devices against the ground again, check</p><p>whether the dial indicator returns to completely zero.</p><p>2nd measurement</p><p>• Put the upper structure to the position that keeps 90 ° with the</p><p>first measure position.</p><p>• Measure the gap based on the described methods above</p><p>paragraphs (1st measurement) .</p><p>Fig.98 Measurements, bearing</p><p>spacing (removing)</p><p>1 Inner bearing sleeve</p><p>2 Dial indicators</p><p>3 Magnetic base</p><p>4 Lifting</p><p>5 Outer bearing sleeve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>101</p><p>Allowed spacing</p><p>Measure the gap twice in each location and record in the</p><p>following table.</p><p>Superstructure in the 1st</p><p>reading of the gap position</p><p>At the 2nd reading of the</p><p>gap position superstructure</p><p>A (1st measurement)</p><p>B (2nd measurement)</p><p>Total A + B A + B</p><p>The average gap Total / 2 Total / 2</p><p>If the measured value between A and B are quite different, it is</p><p>most likely to be wrong, and repeat the measurements several</p><p>times.</p><p>Note! The most important factors for rotary gear failure are</p><p>related to axial gap. Therefore, regularly lubricate the bearings</p><p>and rotary gear.</p><p>Fig.99 Measurements, bearing clearance (Installation)</p><p>1 Outer bearing sleeve 2 Superstructure</p><p>3 Inner bearings sleeve 4 Chassis</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>102</p><p>Walking speed</p><p>Preparation</p><p>Measuring</p><p>Travel time</p><p>Standard Allowed value Maximum</p><p>1 Speed 23 25 27</p><p>2 Speed 13 15 17</p><p>Fig. 101 Measurements, running speed</p><p>1 Initial distance --3 ~5 meters</p><p>2 Travel distance of test --20 meters</p><p>3 Initial distance --3 ~5 meters</p><p>Fig. 100 Measurement conditions, the travel speed</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>103</p><p>Performance of moving straight</p><p>Preparation</p><p>• Bucket cylinder / bucket arm cylinder are fully extended</p><p>• Fix the excavating device to the move gesture.</p><p>Measuring</p><p>1 Operate two travelling control lever with full-stroke.</p><p>2 Measuring the distance(A) between the machine track and the</p><p>line.</p><p>3 Repeat three times and get means of them.</p><p>4 Rotate the superstructure 180 ° and measure in the backwards.</p><p>Standard Allow the value Maximum</p><p>Deviation distance: A ＜200 240 300</p><p>Fig.102 Measurement conditions, performance of moving straight</p><p>Fig.103 Performance of moving straight</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>104</p><p>Track running speed</p><p>Preparation</p><p>• Mark any of the track piece in the test side.</p><p>• Top up the track to be tested.</p><p>Measuring</p><p>• Accelerate the engine to maximum speed.</p><p>• Measure the time that track rotates three laps completely.</p><p>(Excluding first lap)</p><p>• Test both sides of the track, forward and backward.</p><p>Running time</p><p>Standard Allow the value Maximum</p><p>1 speed Left 31.3 34 35</p><p>Right</p><p>1 speed Left 18.3 20.1 21</p><p>Right</p><p>2.3 Emergence measures</p><p>2.3.1 Jump connection starting</p><p>Start the engine with the actuating cable</p><p>Check the following before connecting the actuating cable:</p><p>• Dimension of actuating clamp is proper for battery capacity.</p><p>• Check whether the cables and clamps have cracks, surface</p><p>corrosion, etc.</p><p>• Ensure that the cables and clamps are firmly grounded.</p><p>• Keep the start switch in "OFF " position (Both of the</p><p>machines).</p><p>Fig.104 measurement conditions, track speed</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>105</p><p>• The battery capacity of running engine must be the same as the</p><p>battery capacity of the actuating engine.</p><p>• When another machine is starting, do not make two machines</p><p>contact with each other.</p><p>Connect the actuating cable as follows:</p><p>1 Connect the clamp (1) of the actuating cable (A) with (+) pole</p><p>of battery on the machine that is started with actuator.</p><p>2 Connect the clamp (2) with (+) pole of battery on the running</p><p>machine.</p><p>3 Connect the clamp (3) of the actuating cable (B) with (-) pole</p><p>of battery on the running machine.</p><p>4 Connect the clamp (4) to the upper structure of the running</p><p>machine.</p><p>Important! Ensure that the clamp is firmly connected to the</p><p>battery terminals. Start the engine with a fully charged battery,</p><p>then use crank to start the engine with actuator.</p><p>When connecting cables, do not let the positive (+) and negative</p><p>(-) pole contacted with each others.</p><p>Important! Ensure that the actuating cable is connected</p><p>correctly. Connect the actuating cable with the engine as far</p><p>away from the battery. After engine is started, the actuating</p><p>cable must be disconnected in reverse order.</p><p>Starting the engine</p><p>1 Turn the key switch to "START " position and start the engine.</p><p>2 Turn the crank for 30 seconds at most, wait two minutes</p><p>before the next operation.</p><p>3 After engine is started, the actuating cable must be</p><p>disconnected in reverse order.</p><p>Disconnecting the cable according to the following:</p><p>1 Disconnect the clamp (1) of the actuating cable (B) from the</p><p>superstructure.</p><p>2 Disconnect the clamp (1) from the negative (-)pole of the</p><p>battery on the running engine.</p><p>3 Disconnect the clamp (3) of the actuating cable (A) from (+)</p><p>pole of the battery on the running engine.</p><p>4 Disconnect the clamp (4) from (+) pole of the battery on the</p><p>engine started with actuator.</p><p>Fig.105 Connecting, actuating cable</p><p>Fig.106 Disconnecting, actuating cable</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>106</p><p>Ⅲ Engine system</p><p>1 Overview of the engine</p><p>BF6M2012C Engine</p><p>The engine is 4- stroke, six-cylinder, turbocharged, direct</p><p>injection, water-cooled diesel engine, equipped with inflatable</p><p>cooling and wet replaceable cylinder.</p><p>The electronically controlled diesel engine is controlled by the</p><p>electronic control unit (EMR2) software of engine.</p><p>Fig.106 Disconnecting, actuating cable</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>107</p><p>Cylinder is coded from the flywheel end. Engine Rotation</p><p>direction of engine is counterclockwise seen from the flywheel</p><p>side.</p><p>Fig. 2 Engine, side view of starting motor</p><p>1 Fuel intake throttle 2 Single injection pump 3 Fan drive</p><p>4 Coolant supplement throttle 5 Coolant exit (To the radiator) 6 Leaking gas pipe</p><p>7 Air inlet (From the air filter) 8 Turbocharger 9 Gas export</p><p>10 Exhaust manifold 11.Intake manifold 12 Air inlet (From air cooler)</p><p>13 Lug (Front) 14 Generator 15Fuel supply pump</p><p>16 Cooling pump 17 Belt tension wheel 18 Pulley with the damper</p><p>19 Belt wheel of air conditioning compressor 20 Fan drive pulley</p><p>21 Air outlet (leading to the inflatable cooler) 22 Flywheel</p><p>23 Lug (Rear) 24 Crankcase ventilation tube 25 Coolant temperature sensor</p><p>throttle</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>108</p><p>Fig. 3 Engine, side view of air heater</p><p>1 Coolant inlet (from radiator) 2 Coolant exit (to the radiator) 3 Coolant supplement throttle</p><p>4 Air inlet (from the air filter) 5 Turbocharger 6 Intake manifold</p><p>7 Exhaust manifold 8 Starter 9 Polyester belt</p><p>10 Oil pipe (supply) 11 Oil return pipe 12 Engine oil pan</p><p>13 Engine speed sensor 14 Fuel pressure retaining valve 15 Crankcase ventilation tube</p><p>16 Air inlet (from inflatable cooler)17 Generator 18Fuel supply pump</p><p>19 Belt tension wheel 20 Engine oil cooler 21Engine oil pressure sensor</p><p>22 EMR223 Leaking gas pipe 24 Air heater relay 25 Oil drain hosethrottle</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>109</p><p>Engine characteristics curves</p><p>BF6M2012C engine</p><p>Basic examination, engine</p><p>Note! Some testing and safety inspection is carried out when the</p><p>lock lever is not locked. If the lock lever is not locked in a safe</p><p>situation, ensure that the machine will not be operated</p><p>accidentally.</p><p>Purpose of the basic examination</p><p>The purpose of the basic examination is to provide fast and</p><p>accurate information on the general situation of the engine.</p><p>Basic examination should be in accordance with guidance in PC</p><p>Tools SERDIA.</p><p>Fig.4 Engine characteristics curve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>110</p><p>Testing of the basic examination</p><p>Basic examination divided into the following test items should</p><p>be done after reading the fault code and checking parameters.</p><p>Troubleshooting</p><p>Troubleshooting overview</p><p>If a function has been felt to fail, it is very important to identify</p><p>the cause as soon as possible.</p><p>All the starting point for troubleshooting failure symptoms is the</p><p>existence of a malfunction.</p><p>Malfunction can be instructed as follows:</p><p>• Generating fault code</p><p>• Detecting the failure symptoms.</p><p>Troubleshooting operation</p><p>The first step in troubleshooting is to collect the information on</p><p>the failure symptoms from the operator, try to pinpoint the cause</p><p>by examination in a certain order.</p><p>Different inspection steps are:</p><p>• Check the fault code</p><p>• Check the parameters</p><p>• Perform basic checks</p><p>Troubleshooting information</p><p>The following included in the "Electrical and Information</p><p>System", when used in troubleshooting:</p><p>1 Maintenance Strategy</p><p>Describe the troubleshooting steps.</p><p>2 Troubleshooting, auxiliary equipment</p><p>Describe in brief the auxiliary equipment that can be used to</p><p>troubleshoot.</p><p>3 Function checking and testing, SERDIA</p><p>Describe SERDIA in brief. Detailed instructions refers to</p><p>"SERDIA User Manual."</p><p>4 Fault codes information</p><p>Contain design information of error code, all fault codes table</p><p>and each fault code information.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>111</p><p>5 Components, repair and specifications</p><p>Contain troubleshooting methods and numerical measurements</p><p>of components. Also contain some circuits and certain</p><p>regulations</p><p>6 Parameters</p><p>Wrong setting of parameters will result in the failure symptoms.</p><p>Parameters table includes all the limits of the parameters and the</p><p>target value.</p><p>7 Function control components,instruction</p><p>Describe the functions, input and output of the control</p><p>component and communications between components.</p><p>8 Control components, measuring</p><p>Contain the ECUvalues.</p><p>9 Software function</p><p>Instruct the prerequisites of the ECU control and monitoring</p><p>functions in the software.</p><p>1.1 Cylinder head</p><p>Cylinder cover, indication</p><p>BF6M2012CEngine</p><p>Cylinder cover is made of gray cast iron, which are the same on</p><p>all cylinders. Inhaled air goes into from the vertical direction (A),</p><p>while air is exhausted from the horizontal direction (B). Air inlet</p><p>and exhaust outlet are in the same side of the cylinder. The</p><p>dimensions of intake and exhaust valve are increased, making</p><p>the process of gas exchange and combustion more optimial.</p><p>Valve guide components can be replaced. Cooling flow of the</p><p>cylinder head is guide and flow to a exit controlled by the</p><p>cooling system.</p><p>To allow the engine to achieve the emission standards under</p><p>current laws, and install three gaskets with different thickness</p><p>between cylinder head and the piston.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>112</p><p>Valve</p><p>• Each cylinder of engine has one intake valve and an exhaust</p><p>valve. Guide lever of the valve guide is retracted in the cylinder</p><p>cover. Valve embedded body is made of high-quality steel and</p><p>also is retracted in the cylinder cover.</p><p>• Valve rotates through the rocker by the centrifugal effect. The</p><p>new compression cone connection can easily turn the valve even</p><p>under heavy load.</p><p>• Lubrication rocker arm and oil circuit is a whole. Oil supply</p><p>can be done through lever .</p><p>Table 1 Angle of valve seat</p><p>Import Exhaust</p><p>30 ° 45°</p><p>Decisive cylinder cover gasket</p><p>• Thickness of cylinder cover gasket determines the correct</p><p>piston clearance of engine. Piston clearance (0.65 mm) affects</p><p>the combustion fundamentally, and therefore affects:</p><p>- Power</p><p>- Fuel consumption</p><p>- Gas emissions</p><p>• The piston gap is adjusted by measuring the projection of</p><p>cylinder and the gasket thickness of cylinder cover.</p><p>Measuring projection of piston</p><p>• Measuring projection of piston needs a dial indicator of</p><p>locator.</p><p>• Piston is located on the dead point position on the surface of</p><p>the piston.</p><p>Fig.5</p><p>Fig.4 Engine characteristics curve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>113</p><p>Distance X = 90mm</p><p>The measurement should be on each piston. The largest</p><p>measured projection will determine the thickness of gasket of</p><p>the cylinder cover(refer to table). There are three different</p><p>thickness of gasket, which is identified by the hole (4):</p><p>• 1 hole = 1.2 mm</p><p>• 2 hole = 1.3 mm</p><p>• 3-hole = 1.4 mm</p><p>Table 2 piston projection</p><p>Piston projection Identification cylinder head gasket</p><p>0.33 ~ 0.55 mm 1 hole</p><p>0.56 ~ 0.65 mm 2 holes</p><p>0.66 ~ 0.76 mm 3 holes</p><p>Installing cylinder cover</p><p>Tool</p><p>1 Install the cylinder cover to the crankcase, sealing surfaces of</p><p>cylinder cover gasket must be clean and without dust. Note pin</p><p>sets.</p><p>2Coat the cylinder cover bolts with a thin layer of oil.</p><p>3 It is absolutely necessary to follow the tightening sequence in</p><p>next diagram.</p><p>Tightening sequence</p><p>Fig. 6 Measurement, piston projection</p><p>1 Dial indicator A. Set the dial indicator on the surface of cylinder to "zero".</p><p>2 Bridger B Put dial indicator at the measurement point (C)on the piston pin, and determine the projection.</p><p>3 Two intervals board C. Measurement point on the piston.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>114</p><p>1.2 Pistons</p><p>Piston, indication</p><p>BF6M2012C Engine</p><p>Piston is made from special aluminum alloy. Combustion</p><p>chamber of position is located slightly off-center relative to the</p><p>piston (eccentric).</p><p>Piston is equipped with three rings. The first ring has a ring prop</p><p>made of cast iron.</p><p>Piston is cooled by the oil sprayed on the piston.</p><p>Piston cooling nozzle is made of plastic, and install the main</p><p>bearing on the cylinder.</p><p>The first piston ring has an asymmetrical cross section (A). The</p><p>cross section of the second piston is tapered. Install piston rings,</p><p>the mark TOP on the port must be up. The third ring is an oil</p><p>ring with beveled edges.</p><p>Fig.7 Tighten sequence (exhaust manifold side)</p><p>Tightening torque specifications:</p><p>- Step 1:30 N · m</p><p>- Step 2:80 N · m</p><p>- Step 3:90 ° Rotation</p><p>Fig.8</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>115</p><p>Piston rings, indication</p><p>All pistons are equipped with two compression rings and one oil</p><p>ring. The top compression ring is "Regis formula" type (double</p><p>trapezoidal forms the cross section). Compression ring should be</p><p>placed with context up.</p><p>Oil ring is equipped with two scraper edges, which can use the</p><p>spring force press to cylinder wall, and there is an expanding</p><p>ring, located inside the ring. Oil ring can be placed on both sides,</p><p>but the angle between expansion ring and oil ring to 180 °.</p><p>Piston cooling</p><p>Piston is cooled by spraying the oil to the inner part of the</p><p>piston.</p><p>Plastic 2-hole piston cooling nozzle is installed in the main</p><p>bearing base.</p><p>Fig. 10 Piston cooling</p><p>Fig.9</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>116</p><p>1.3 Valves mechanery</p><p>Valves, indication</p><p>Engine</p><p>Each cylinder of engine is</p><p>equipped with an inlet and an exhaust</p><p>valve.</p><p>The valve guide is installed with an O-ring seal (A) close to the</p><p>stem, to prevent a large number of oil consumption and reduce</p><p>emissions of hydrocarbons.</p><p>Valve is rotated by centrifugal movement.</p><p>The new flat tapered will make the valve rotate effortlessly</p><p>under load.</p><p>Lubrication of rocker arm is part of the lubrication system of</p><p>engine. Oil is provided by the tappet and lever.</p><p>If the valve guide is replaced, they can use another style (B) for</p><p>installing easily.</p><p>Figure 1 shows the installed guide during the process of</p><p>manufacturing, Figure 2 shows a replaced guide.</p><p>Valve, adjusting</p><p>Tool</p><p>9,998,681 Rotary tool</p><p>885,812 Timing Tool</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then make the</p><p>necessary operations.</p><p>1.Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>2 Open the engine hood.</p><p>3 Remove the turbocharger inlet pipe (1).</p><p>Fig.11</p><p>Fig.12</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>117</p><p>4 Remove the ventilation pipe (1) of crankcase.</p><p>5 Remove the cable bracket (1).</p><p>6 Remove the rocker cover (1).</p><p>7 Turn the right side door on the machine.</p><p>8 Remove gear cover (1) of camshaft, install the steering gear</p><p>(2).</p><p>Fig. 16</p><p>1Gear cover of camshaft 2 Steering gear</p><p>Fig.15</p><p>Fig.14</p><p>Fig.13</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>118</p><p>Note! Steering gear must be fully meshed with the teeth of</p><p>camshaft gear.</p><p>9 Set the overlap angle of engine valve</p><p>Rotate the crankshaft using the steering gear 1 until it reaches</p><p>the overlap angle of cylinder valve.</p><p>Valve overlap means that the exhaust valve opens,while the</p><p>intake valve is open. If the cylinder is faulty in this position, do</p><p>not rotate the lever by hand.</p><p>Fig. 18 Valve overlap</p><p>Fig. 19</p><p>1,3,5,7,9 and 11 are the exhaust valve</p><p>2,4,6,8,10 and 12 are the intake valve</p><p>Fig.17</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>119</p><p>10 According to the black mark in the figure, adjust the valve</p><p>clearance for each cylinder. Adjustment steps are as follows:</p><p>1 Loosen the locking bolts on the adjusting screw of the rocker.</p><p>2 Install the protractor on adjustment screws.</p><p>3 Turn the adjustment screw until the gap between the rocker</p><p>and the valve is zero. Reset the protractor to zero.</p><p>4 For the inlet valve, rotate the adjustment screw</p><p>counterclockwise 90 °; For the exhaust valve rotate the</p><p>adjustment screw counterclockwise 150 °.</p><p>5 Hold the adjusting screw, and tighten the lock nut. Tightening</p><p>torque: refer to Engine, tightening torque</p><p>11 Rotate the crankshaft one full circle until the valves of</p><p>cylinder overlap. According to the black mark in the figures,</p><p>adjust the valve clearance of each cylinder.</p><p>Note! When all the valves are adjusted, do not rotate the engine.</p><p>Continue to install directly.</p><p>Assembly</p><p>12 Order of assembly is opposed to the order of disassembly.</p><p>Note! Do not reuse O-ring and gasket.</p><p>13 After the maintenance work is completed, start the engine,</p><p>check for leakage and operation state.</p><p>Fig.20</p><p>Fig. 21</p><p>1 885 812 timing tool</p><p>2 Adjustment screws</p><p>Fig. 22</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>120</p><p>1.5 Engine Assembly</p><p>Engine Assembly</p><p>Table 3 tightening torque, unit: kgf· m</p><p>No. Installation location Tightening torque</p><p>1 Screws (fan and flywheel side) 70±7</p><p>2 Liner -</p><p>3 Washer -</p><p>4 Nut -</p><p>5 Plate -</p><p>6 Engine mounting bracket (fan side) -</p><p>7 Rack (fan side) -</p><p>8 Screw 26±0.5</p><p>9 Screw 11.5±0.5</p><p>10 Engine mounting bracket (flywheel side) -</p><p>11 Rack (flywheel side) -</p><p>12 Screw 11.5±0.5</p><p>Fig. 23 Engine Assembly</p><p>Fan side: Yellow and white</p><p>Flywheel side: Blue and white</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>121</p><p>2 Lubrication system</p><p>Lubrication system, indication</p><p>•By the forced lubrication through the oil pump, engine oil is</p><p>supplied to the rotating parts, such as the turbocharger,</p><p>crankshaft, camshaft, pistons, intake / exhaust valves, rocker</p><p>arms and the contact surface of timing gear.</p><p>Oil flow process chart</p><p>Fig. 24 Oil flow process chart</p><p>1 oil pan 2 oil collector pipes</p><p>3 oil pumps 4 oil cooler</p><p>4-1 shut-off valve (pressure relief valve) 4-2 oil cooler bypass valve</p><p>4-3 oil filter 4-4 Oil Pressure Sensor</p><p>5 main oil 6 crankcase bearings (main bearings)</p><p>7 linkage bearing 8 camshaft bearings</p><p>9 pipe to the piston cooling nozzle 10 Piston cooling nozzle</p><p>11 the valve column of rocker lubrication 12 lever, supplying oil for the rocker</p><p>13 rocker 14 oil return to sump</p><p>15 turbocharger inlet pipe 16 turbocharger</p><p>17 pipes leading to the air compressor or hydraulic pump tubing</p><p>19 hydraulic pump 21 (2X) pipes leading to the balance shaft bearings</p><p>22 from the turbocharger return line to the crankcase</p><p>23 Mass balance shaft</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>122</p><p>Diagram, oil circuit</p><p>Table 4 Specifications</p><p>Items Explain Remarks</p><p>1 Oil Pump Rotary pumps:</p><p>Volume flow in the n = 2500 min-1: 65 l / min</p><p>2 Oil radiator</p><p>3 Oil cooler bypass valve Opening pressure: p = 2.1 ± 0.35 bar</p><p>4 Oil filter With bypass valve (5)</p><p>5 Oil filter bypass valve Opening pressure: p = 2.5 ± 0.3 bar</p><p>6 Main oil pressure limiting valve Opening pressure: p = 5.0 ± 0.5 bar</p><p>7 Exhaust turbocharger</p><p>Lubrication system, working principle</p><p>Oil pipeline</p><p>BF6M2012C engine is equipped with pressure oil lubrication</p><p>system with oil radiator and oil filter during the whole process.</p><p>Supply of oil comes from the oil pump from the oil cooler to the</p><p>Fig.25 Schematic, oil circuit.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>123</p><p>oil filter. These two parts are mounted on the oil cooler on the</p><p>crankcase with flange. Downstream from the filter, oil flows into</p><p>the main oil and secondary pipeline. From here, the oil pipeline</p><p>will be guided to the lubrication points.</p><p>Main oil provides lubrication:</p><p>- Crankshaft</p><p>- Camshaft</p><p>- Valve tappet</p><p>- Roller tappet</p><p>Secondary pipes provide lubrication:</p><p>- Exhaust turbocharger</p><p>Lubrication of rocker is carried out by the lifters and pushrods.</p><p>Lubricating oil pump</p><p>Rotary oil pump is installed inside the front cover. Inner rotor (1)</p><p>is fixed on the crankshaft, driven by the crankshaft.</p><p>Its driving wheel contour (4) has no 120 ° partition, that is, the</p><p>rotor can slide to a fixed position of crankshaft.</p><p>This is because the deviation of the rotor width.</p><p>Unit Specification</p><p>Rotor width mm 12.3</p><p>Volume flow l/min 65 at 2500 rpm / min</p><p>At 120 ° C minimum oil pressure, measure it in the oil filter</p><p>bracket.</p><p>Fig 26 oil pump, sections</p><p>1 Inner rotor 2 From sending room to the crankcase</p><p>3 Intake chamber 4 Driving wheel contour</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>124</p><p>Oil cooling tank</p><p>Pressure relief valve of oil cooling tank and oil cooler, cooperate</p><p>with each other.</p><p>Table 6 oil cooling tank</p><p>Item Explain Remarks</p><p>1 Oil filter Components: the filter shell, oil filter and filter element.</p><p>Cap tightening torque = 25 N · m (Nm)</p><p>2 Filter bypass valve Opening pressure: p = 2.5 ± 0.3 bar</p><p>3 Drain valve Loosen the filter cover one or two laps. Oil in oil filter</p><p>housing will be drained to oil span.</p><p>4 Radiator bypass valve Protect the cooler to prevent high pressure point.</p><p>Opening pressure: p = 2.1 ± 0.35 bar</p><p>5 Main oil pressure</p><p>limiting valve</p><p>Opening pressure: p = 5.0 ± 0.5 bar</p><p>6 No return valve When the engine is not running, prevent oil draining.</p><p>Maximum opening :0.12 bar</p><p>7 Oil radiator Aluminum radiator</p><p>8 Channel water Between the oil tank and oil cooler</p><p>9 Channel oil Between the oil tank and oil cooler</p><p>Fig.27.Oil cooling tank</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>125</p><p>3 Fuel system</p><p>3.1 Overview</p><p>Fuel system, indication</p><p>Fuel supply system is composed of a low and a high pressure</p><p>circuit.</p><p>Low pressure circuit</p><p>Fuel comes out from the fuel tank, goes into fuel filter 5 through</p><p>fuel pump 3, goes into the injection 7 through inlet pipe of</p><p>injection pump, one part of the oil goes into high pressure</p><p>pipelines, namely, high-pressure pipelines - injector -</p><p>combustion in the cylinder.While the other most of the fuel goes</p><p>into oil return chamber through the injection pump, which can</p><p>form low pressure pipes, low pressure of pipes is 5bar.</p><p>Low-pressure supply circuit includes a fuel tank, oil-water</p><p>separator filter, fuel transport pumps driven by belt, fuel filters</p><p>and inject pump.</p><p>The stability of low pressure oil is important for power output of</p><p>engine. When the power of engine is not enough, measure the</p><p>pressure of low pressure oil controlled by the pressure control</p><p>valve 10. The leakage of injector or corrosion is primarily due to</p><p>low oil pressure in the low pressure oil pipes, it should ensure to</p><p>timely replace fuel filter and clean.</p><p>High-pressure pipeline</p><p>Low-pressure fuel flows from the injection pump 7 to the</p><p>injector after very short high-pressure pipe 8, when the pressure</p><p>gets to 220bar, the injector 9 opens, the fuel is injected into</p><p>combustion chamber.</p><p>Fuel return pipeline</p><p>As the output of transmission pump is more than 10 times as the</p><p>oil output of injection pump, most of fuel returns to the tank</p><p>through the pressure control valve 10 and oil return pipe 11,</p><p>small amount of fuel leaked from clearance of fuel injector work</p><p>goes back into the fuel tank, which plays a role as cooler, and</p><p>drain the air in the circuit through a large number of fuel, with</p><p>automatic exhaust function.</p><p>Fuel flow system diagram</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>126</p><p>Fuel flows from the pump (9) to the tank (2) to the supply pipe</p><p>of each cylinder injection pump on the crankcase through a filter</p><p>(7). Fuel is provided by the six individual injection pumps to</p><p>reach injector (5) through the pipelin. The end of the supply tube</p><p>fitted with a pressure valve (4).</p><p>Fuel level sensor is installed in the fuel tank.</p><p>When the fuel level gauge shows EMPTY, the tank there is</p><p>about 40 liters of fuel left.</p><p>Fig. 28 Fuel tube</p><p>1 Hand pump 2 Fuel tank</p><p>3 Pre-filter 4 Check Valve</p><p>5 Inejector 6 Return hose of ector</p><p>7 Fuel filter 8 Supply hoses (leading to the injectors)</p><p>9 Oil supply pump 10 Supply hoses (leading to the fuel filter)</p><p>11 Absorbing hose (from fuel tank) 12 Oil return hose</p><p>Note!</p><p>Torque of hose clip: 0.12 ~ 0.17 kgf · m</p><p>Note!</p><p>Do not tighten the hose clip with a force exceeding the specified torque, which</p><p>may ay cause leakage.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>127</p><p>Fuel injection system, indication</p><p>• BF6M2012C works according to direct injection.</p><p>• Piston deviates from the piston axis a little. Fuel is injected by</p><p>six single-cylinder fuel injection pumps. Maximum injection</p><p>pressure can get to 1350 bar. Which can get e a good emission</p><p>values, in line with European standards for Class II</p><p>requirements.</p><p>Oil supply pump</p><p>• Oil supply pump is a rotary pump, driven by the polyester fiber</p><p>V-belt.</p><p>• Oil supply pump is equipped with dual -way valve (1 to Pop. 6</p><p>± 0.5 bar, to 2 Pop.: 0.5 bar).</p><p>• Super pressure relief valve (1) is a plunger valve and open at</p><p>5.5 bar.. The valve also limits the system pressure at 9.5 bar.</p><p>• Bypass valve (2) is a ball valve. Once the fuel lines are empty,</p><p>and fuel pump system can be filled can be filled by hand, which</p><p>avoids the start-up procedure of engine. (Starting protection).</p><p>Note! Do not reduce cross-section of pipe and connect to pump</p><p>(refer to installation instructions), which will cause the engine</p><p>power loss.</p><p>Fig. 29Charts, fuel injection system</p><p>Fig. 30 Oil supply pump</p><p>1 Pressure reducing valve</p><p>2-Bypass valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>128</p><p>3.2 Fuel pump; filter; oil mesh</p><p>Fuel system, leakage</p><p>1 Park the machine in the maintenance position B, refer to</p><p>maintenance position</p><p>2 Use battery break to cut off the main power.</p><p>3 Turn the main pump counterclockwise to make the plunger</p><p>unlocked. Pump gets to about 200 to 300 strokes, until you feel</p><p>the heavy resistance. Push down on the plunger, rotate clockwise</p><p>to the locked position.</p><p>Note! Exhaust may not to perform by starting engine.</p><p>4 Turn on the power, start the engine, run the engine at low idle</p><p>for several minutes. If the engine is difficult to start, and then</p><p>use the main pump to exhaust.</p><p>Note! The main pump can not be used with the engine running.</p><p>Oil supply pump, replacing</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then make the</p><p>necessary operations.</p><p>1 Open the hood and radiator cover.</p><p>2 Remove the hose boost air cooler.</p><p>3 Remove the screw (1) and fan protective pieces.</p><p>Fig. 31</p><p>1.Main pump of filter head</p><p>Fig. 32</p><p>Fig. 33</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>129</p><p>4 Use a socket wrench handle (1 / 2 ") to rotate the belt tension</p><p>devices (3) clockwise, then remove the belt (4) from pulley from</p><p>the alternator.</p><p>Note! Belt tension is very strong. Therefore, after removing, pay</p><p>attention to avoiding injury.</p><p>5 Remove the pipes(1), screws (3) and fuel supply pump (2).</p><p>Note! Cover the port of hose, to prevent debris from entering the</p><p>fuel system.</p><p>Note! Do not let the fuel dripping on the belt when removing</p><p>supply pump.</p><p>6 Install the new feedback pump.</p><p>7 Install hose and pipe in the fuel feed pump.</p><p>Note! Removed coppers washers must be replaced with new</p><p>gasket.</p><p>8 Install the boost air cooler hose and fan protective pieces.</p><p>9 Perform to exhaust air. Refer to fuel system, oil leakage.</p><p>10 Start the engine and check for leakage.</p><p>11 Close the hood and radiator cover.</p><p>Fuel filter, replacing</p><p>Tool</p><p>9996671 oil filter wrench</p><p>Fig. 34</p><p>1 generator 2 socket wrench handle</p><p>3 belt tension 4 tape</p><p>5 fuel supply pump</p><p>Fig.35</p><p>1 Fuel input / output pipeline</p><p>2 Fuel supply pump</p><p>3 Mounting screws</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>130</p><p>Fuel filter is clogged, which may cause engine power reduced. If</p><p>the filter is clogged quickly, check fuel for contamination, if</p><p>necessary, clean the tank.</p><p>1 Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>2 Use a 9,996,671 oil filter wrench to loosen the fuel filter, then</p><p>remove it.</p><p>3 Clean the sealing surface of filter head.</p><p>4 Coat the rubber seal on the new filter with a little oil, or wet</p><p>with diesel fuel.</p><p>5 Tighten screw on the filter</p><p>69</p><p>Filling oil ............................................................................................................................................................................. 70</p><p>Fuel filter, replacing ................................................................................................................................................................ 70</p><p>Additional fuel filter (oil-water separator core), checking / draining ................................................................................. 71</p><p>Water separator filter element, replacing ............................................................................................................................. 71</p><p>Fuel tank sediment, draining .................................................................................................................................................. 72</p><p>Fuel tank ventilation filter, replacing .................................................................................................................................... 72</p><p>Hydraulic oil servo filter, replacing ....................................................................................................................................... 73</p><p>Main element air filter, cleaning ............................................................................................................................................ 73</p><p>Main filter of air filter, replacing ........................................................................................................................................... 73</p><p>Safety filter element of air filter, replacing ........................................................................................................................... 74</p><p>Battery status, checking .......................................................................................................................................................... 75</p><p>Belts and belt tension, checking, replace it if necessary ....................................................................................................... 75</p><p>External radiator / oil cooler outside, cleaning ..................................................................................................................... 76</p><p>Hydraulic tank, oil returning filter, replacing ...................................................................................................................... 77</p><p>Hydraulic oil draining filter, replacing ................................................................................................................................. 77</p><p>Hydraulic oil absorbing filter, cleaning ................................................................................................................................. 78</p><p>Hydraulic tank, replacing the ventilation filter .................................................................................................................... 78</p><p>Removing............................................................................................................................................................................. 78</p><p>Installing .............................................................................................................................................................................. 79</p><p>Hydraulic tank, hydraulic oil replacing ................................................................................................................................ 79</p><p>Valve clearance, checking / adjusting .................................................................................................................................... 81</p><p>Assembly ............................................................................................................................................................................. 84</p><p>Coolant freezing point, checking ............................................................................................................................................ 84</p><p>Coolant, replacing ................................................................................................................................................................... 84</p><p>Main filter of air conditioning, cleaning ................................................................................................................................ 85</p><p>Main filter of air conditioning, replacing .............................................................................................................................. 87</p><p>Cab, pre-filter, cleaning .......................................................................................................................................................... 88</p><p>Cab, pre-filter, replacing ........................................................................................................................................................ 88</p><p>Lubrication, refer to the lubrication chart ............................................................................................................................ 89</p><p>Rotary motor gear box, changing the oil ............................................................................................................................... 89</p><p>Rotarying ring bearings, lubricating ..................................................................................................................................... 90</p><p>Rotary oil bath grease, checking ............................................................................................................................................ 90</p><p>Cab; door, lid, hinges, fittings and locks, lubricating ........................................................................................................... 90</p><p>Track plate bolts, checking ..................................................................................................................................................... 91</p><p>Track tension / condition, checking ....................................................................................................................................... 92</p><p>Oil level of track gearbox, checking ....................................................................................................................................... 93</p><p>Walking motor gearbox, gear oil replacing........................................................................................................................... 93</p><p>Loose and missing bolts, checking ......................................................................................................................................... 94</p><p>Hydraulic pressure, checking ................................................................................................................................................. 94</p><p>2.2.2 Conditional test............................................................................................................................................................... 94</p><p>Measurement conditions ......................................................................................................................................................... 94</p><p>Cylinder speed ......................................................................................................................................................................... 95</p><p>Preparation ........................................................................................................................................................................... 95</p><p>Measuring ................................................................................................................................................................................. 96</p><p>Peristaltic of cylinder .............................................................................................................................................................. 96</p><p>Preparation</p><p>by hand until the seal contacts</p><p>tightly, then turn a half circle.</p><p>6 Perform to exhaust air. Refer to fuel system, oil leakage</p><p>Additional extra oil filter, replacing</p><p>Tool</p><p>9996671 oil filter wrench</p><p>11666167 Removal Tool</p><p>Note! Fuel filter is clogged, which may cause engine power</p><p>reduced. If the filter is clogged quickly, check fuel for</p><p>contamination, if necessary, clean the tank.</p><p>1 Turn the main pump (1) counter clockwise, making the</p><p>plunger unlocked.</p><p>2 Disconnect the cable connector (1).</p><p>3 Loosen the drain valve (2), and drain the sediment from the</p><p>oil-water separator tank (3).</p><p>4 Use an 9996671 oil filter wrench to loosen oil-water</p><p>separator tank (3), then remove it.</p><p>5 Use a 11666167removal tool to release oil-water separator</p><p>filter, and then remove it.</p><p>6 Clean the sealing surface of filter head</p><p>7 Coat the rubber seal on the new filter with a little oil, or wet</p><p>with diesel fuel.</p><p>8 Tighten screw on the filter by hand until the seal contacts</p><p>tightly, then turn a half circle.</p><p>Fig. 37</p><p>1 Main pump</p><p>Fig.36 Removing, filter</p><p>Fig. 38</p><p>1 Wiring harness connector</p><p>2 Drain valve</p><p>3 Oil Bowl</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>131</p><p>9.Tighten the filter tank by hand until the seal contacts tightly,</p><p>then turn a half circle.</p><p>10 Perform to exhaust air. Refer to fuel system, oil leakage</p><p>3.3 Fuel Tank</p><p>Description of the fuel tank</p><p>Note! Coat the screw (7) with Loctite 277.</p><p>Note! When assembling fuel tank, use the gasket (8) to adjust</p><p>the height.</p><p>Note! When installeing into the frame, adjust the gap "A":</p><p>10mm.</p><p>Tightening torque</p><p>• Level gauge (11): 1.5 ± 0.2 kgf · m)</p><p>• Screws (7): 52.2 ± 5.2 kgf · m</p><p>• Emissions cock (4): 1.6 ~ 1.9 kgf · m</p><p>Fig.39 Structure, fuel tank</p><p>1 fuel tank 2 mesh filter 3 fuel tank lid 4 emissions knob</p><p>5 handle 6 oil output throttle 7 screws 8 shims</p><p>9 flat gasket10 spring washers 11 Fuel level indicator 12 hydraulic oil tank</p><p>13 Toolbox 14 fuel tank ventilation devices</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>132</p><p>• Drain valve clamp (4): 0.6 kgf · m</p><p>• Flange screw (14), (2 EA): 6.5 ± 0.7 kgf · m</p><p>3.4 Injectors; oil supply pipelines</p><p>Injector, indication</p><p>Injection nozzle has 6 holes, which is designed to provide a</p><p>fixed standard of the injection surface shape, regardless of the</p><p>angle of injector and injector nozzles.</p><p>Fig. 40</p><p>Fig. 41</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>133</p><p>Injector, replacing one</p><p>1 Park the machine in the maintenance position B, refer to</p><p>maintenance position</p><p>Important! Note to keep clean as far as possible!</p><p>2 Open the engine hood.</p><p>3 Remove the cable bracket (1) from the valve cover.</p><p>4 Remove the injector connector yoke (2) and carefully remove</p><p>the injectors (1).</p><p>Note! Ensure that copper washers at the lower part of injector is</p><p>exposed.</p><p>5 Install the O-ring on the injector. Coat the O-ring with a little</p><p>oil.</p><p>6 Install the copper washers on new injector. Install injector and</p><p>connecting yoke. For the tightening torque, refer to fuel system,</p><p>tightening torque</p><p>7 According to the fuel system, exhaust the air in the system,</p><p>andrefer to the fuel system exhaust.</p><p>8 Start the engine and check for leakage.</p><p>Fuel rail pressure, checking</p><p>Test conditions</p><p>1 Battery is in good condition and is fully charged.</p><p>2 There is no malfunction displaying on the I-ECU.</p><p>Pressure checking procedure</p><p>1.Park the machine in the service position B. Refer to the</p><p>maintenance position.</p><p>2 Use the battery off switch cuts off the power.</p><p>3 By a maintenance outlet (1), connect SIEDIA to the machine.</p><p>Start the testing of SIEDIA engine.</p><p>Fig. 46 SIEDIA, connection</p><p>1 Maintenance outlet</p><p>Fig.45</p><p>1 Injector 2 Attached frame</p><p>Fig. 42</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>134</p><p>Engine starting conditions</p><p>Note! This test can only be used for engine has problems about</p><p>starting.</p><p>4 Remove the injectors cover (1) from the engine, disconnect all</p><p>the cables (2)of injector.</p><p>Note! Do separate the disconnected cables.</p><p>5 Start the engine 15-20 seconds with a starting motor, then</p><p>check whether the fuel pressure can meet specifications. Please</p><p>refer to fuel pressure specifications.</p><p>Note! The speed of engine crankshaft: 150 ± 30 rpm</p><p>If the starting speed of the engine is not normal:</p><p>Check the battery cables, starter and load of engine.</p><p>Note! If testing results are not normal, check the fuel pressure</p><p>sensor and the electronic control unit (E-ECU) of engine.</p><p>6 Stop the engine.</p><p>7 Store the operation cards, connect the cable of injector.</p><p>The engine is running, but without load.</p><p>8 Begin the testing of SIEDIA engine.</p><p>9 Start the engine.</p><p>10 Put the operation lever into the unlocked (up) position.</p><p>When the load is less than 28%, check whether the fuel pressure</p><p>can meet specifications. Please refer to fuel pressure</p><p>specifications.</p><p>Note! Under the maintenance mode of instrument -- electronic</p><p>control unit (I-ECU), check the load of engine.</p><p>Note! Check the pressure values of engine speed control switch</p><p>in different locations, please refer to fuel pressure specifications.</p><p>In the case of low inflation pressure</p><p>Check the air intake system.</p><p>In the case that the load of engine is too high</p><p>Check the hydraulic system and engine load.</p><p>Fig.47 Injectors cables, disconnecting</p><p>1 Injectors cover</p><p>2 Injectors cable</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>135</p><p>Note! If test results are not normal, check the fuel pressure</p><p>sensor and the engine electronic control unit (EMR2).</p><p>11 Stop the engine.</p><p>12 Store the operation cards.</p><p>The engine is running, but without load.</p><p>13.Begin the testing of SIEDIA engine.</p><p>14.Start the engine.</p><p>15 When the load is more than 60%, check whether the fuel</p><p>pressure can meet specifications. Please refer to fuel pressure</p><p>specifications.</p><p>Note! Under the maintenance mode of instrument -- electronic</p><p>control unit (I-ECU), check the load of engine.</p><p>Note! Engine speed: 1900 rpm</p><p>Note! Move the bucket arm and bucket to its full stroke position,</p><p>which can form a hydraulic load.</p><p>In the case of low inflation pressure</p><p>Check the air intake system.</p><p>In the case that the load of engine is too high</p><p>Check the hydraulic system and engine load.</p><p>Note! Note! If test results are not normal, check the fuel pressure</p><p>sensor and the engine electronic control unit (EMR2).</p><p>16 Stop the engine.</p><p>17 Store operation cards, disconnect SIEDIA cable.</p><p>18 Restore the machine to the operating state.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>136</p><p>4 Air intake system; exhaust system</p><p>4.1 Overview</p><p>Air intake system, instruction</p><p>• Air used for combustion is filtered by pre-filter, air filter, then</p><p>provide into the combustion chamber of engine through the air</p><p>cooler.</p><p>• To provide convenience to the operator, blocking of the</p><p>intake system will be perceived and start a \ warning light on</p><p>the gauge.</p><p>Fig. 48 Air intake system</p><p>1 air filter</p><p>2 pre- filter</p><p>3 sensors</p><p>4 hose</p><p>5 turbocharger</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>137</p><p>Exhaust System, instruction</p><p>BF6M2012C engine</p><p>1 The exhaust system is designed to make noise is significantly</p><p>reduced when the waste air goes through exhaust manifold and</p><p>the muffler.</p><p>Seal clamp, installing</p><p>1 Assemble the turbocharger side pipe into the side pipes of</p><p>muffler side about 25 mm, as shown.</p><p>2 Insert the seal gasket matching with clamp into the clamp.</p><p>3 Tighten the two screws alternately.</p><p>Note! Tightening torque: 6.9 ~ 10.4 kgf · m</p><p>Fig. 49 Installing, the muffler</p><p>1 turbocharger</p><p>2 pipes</p><p>3 U-bolt of muffler</p><p>4 exhaust manifold</p><p>5 turbocharger side</p><p>6 muffler side</p><p>7 clamp</p><p>8 screws</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>138</p><p>4.2 Air cleaner with the connecting pipe; air</p><p>preheater</p><p>Preheating coil, replacing</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then make the</p><p>necessary operations.</p><p>1 Open the hood.</p><p>2 Remove the outlet pipe (1) and hose (2)of boost air cooler.</p><p>3 Remove the wiring harness (3), and mounting screws (1) of</p><p>pre-heating coil.</p><p>Note! Check the gaskets of preheating coil (each side), if</p><p>necessary, replace them.</p><p>4 Install the new preheating coil and wire harness.</p><p>5 Install the outlet pipes and hoses of boost air cooler.</p><p>6 Close the hood.</p><p>4.3 Inflatable cooler and connecting pipe</p><p>Boost air cooler, indication</p><p>The function of the intercooler is to reduce the temperature of air</p><p>before the air is pushed into the cylinder.</p><p>Turbocharger of engine(meaning that turbocharger pushes the</p><p>air into the cylinder) will increase the air temperature. When the</p><p>air after the turbine is cooled, the volume air reduces, which can</p><p>push more air (oxygen) into the cylinder.</p><p>This cooling process is called inflation cooling (intercooling),</p><p>and to spray more fuel into the cylinder, which has significantly</p><p>increased the power.</p><p>Fig. 50</p><p>Fig. 51 Removing the connector of wire harness</p><p>1 Screw</p><p>2 Preheating</p><p>3 Wire harness</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>139</p><p>Intercooler reduces the air temperature about 100 ° C (212 ° F),</p><p>which can increase engine power by about 10%. Torque of</p><p>engine will increase, and fuel consumption is also reduced.</p><p>Turbo diesel engine with inflation cooling (intercooling) is the</p><p>most efficient during all diesel</p><p>engines.</p><p>Boost air cooler connections (hoses, rigid tube), replacing</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then make the</p><p>necessary operations.</p><p>1 Open the hood.</p><p>2 Remove the inlet / outlet hose (1,2) of intercooler.</p><p>3 Install the new inlet / outlet hose of intercooler.</p><p>4 Close the hood.</p><p>Fig.52 Inflatable Cooler</p><p>1 inflatable cooler</p><p>2 Inlet hose of inflatable cooler</p><p>3 Outlet hose inflatable cooler</p><p>Fig. 53 Removing, the inlet / outlet hose</p><p>1 Inlet hose of intercooler</p><p>2 Outlet hose of intercooler</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>140</p><p>5 Cooling System</p><p>5.1 Overview</p><p>Cooling System,instruction</p><p>Chamber and boxes of cooling unit are made of aluminum.</p><p>Hydraulic oil cooler and boost air cooler is installed on the</p><p>radiator frame.</p><p>As the fan rotates, the air goes through the radiator, oil cooler</p><p>and inflatable cooler ,and then be absorbed into the engine.</p><p>Fig. 54 Cooling devices</p><p>1 inlet of coolant 2 inlet of pressurized air 3 outlet of pressurized air \</p><p>4 inlet of coolant exit 5 outlet of hydraulic oil 6 inlet of hydraulic oil</p><p>7 hydraulic oil cooler 8 drain plug of radiator 9 radiators</p><p>10 inflatable cooler 11 drain plug of hydraulic oil cooler</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>141</p><p>Cooling system, operating</p><p>Coolant</p><p>• Engine cooled by liquid shoulde be filled with treated coolant,</p><p>or the engine will be damaged in the condition of frozening,</p><p>cavitation and corrosion.</p><p>•Coolant is prepared by adding antifreeze.</p><p>Fig.55 Cooling System (1)</p><p>1 cooling fan 2 radiator 3 vent hose 4 outlet hose of coolant</p><p>5 thermostat6 fan belt 7 cylinder cooling chamber 8 filters of engine and oil cooler</p><p>9 inlet hose of coolant 10 water pump 11 additional hose</p><p>Note! Tightening torque (clip): 0.5 ~ 0.6 kgf · m</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>142</p><p>• Other cooling system regulator must be clearly identified by</p><p>the company.</p><p>• Concentration of the coolant can be detected by commercial</p><p>detector.</p><p>When filling and replacing the coolant, only use the coolant</p><p>VCS of SDLG. Do not mix different coolants or corrosion</p><p>protection agent, as this may cause damage to engine. If you use</p><p>the VCS coolant and pure water, the mixture should contain</p><p>40-60% concentrated coolant and 60-40% water.</p><p>The percentage of the coolant is not less than 40% of the total,</p><p>refer to the table.</p><p>Min frosting protection Percentage of coolant</p><p>-25 °C （-13 °F） 40%</p><p>-35 °C （-31 °F） 50%</p><p>-46 °C （-51 °F） 60%</p><p>Concentrated coolant VCS of SDLG can not contain a high</p><p>percentage of hard water, and can’t be mixed with the water</p><p>containing salt or metal.</p><p>Water for the cooling system must also meet the following</p><p>requirements:</p><p>Explain Value</p><p>The total number of solid particles</p><p>Thermostat, replacing</p><p>WARNING!</p><p>Open the expansion tank cap carefully. There is the</p><p>danger of scalding because of the high-pressure in</p><p>cooling system.</p><p>1. Park the machine in the maintenance position B. Refer to</p><p>maintenance position</p><p>2 Drain the coolant. See coolant, replace the P131</p><p>3 Open the hood.</p><p>4 Remove the screws (2), and remove the thermostat housing (1)</p><p>at the outlet hose (3) of the radiator.</p><p>Fig.58</p><p>Fig.59</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>145</p><p>5 Remove the cover from the engine cylinder thermostat (1).</p><p>6 Install a new thermostat with a new gasket (2).</p><p>7 For installation, its order is opposed to the order of dissambly.</p><p>8 After completing the repair work, start the engine and check</p><p>for leakage.</p><p>Thermostat, checking</p><p>1. Put the thermostat in a container filled with water.</p><p>Fig.60</p><p>Fig.61</p><p>1 thermostat 2 rubber gasket</p><p>Fig.62 Thermostat, checking</p><p>1 Thermometer</p><p>2 Thermostat</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>146</p><p>2. Heat when measuring the water temperature, then see actions</p><p>listed in the table.</p><p>About operating temperature, refer to thermostats,</p><p>specifications.</p><p>Note! Opening temperature of valve is engraved on the flange.</p><p>3 Put the thermostat in a container filled with antifreeze or oil.</p><p>Heat it, and measure the temperature of liquid.</p><p>Note! If the multimeter shows the continuity when the liquid</p><p>temperature is between 107 ~ 113 ° C, then it is normal to turn</p><p>on/off.</p><p>5.4 Fan; fan cover; fan coupler</p><p>Fan belt and / or generator belt, compressor belt, replace all</p><p>belts</p><p>WARNING!</p><p>Risk of burns - stop diesel engine and let it cool, then</p><p>make the necessary operations.</p><p>1 Open the hood and radiator cover.</p><p>2 Remove the hose of boost air cooler.</p><p>3 Remove screw (1) and fan protective pieces.</p><p>Fig.63 Thermostat, checking</p><p>1 thermometer</p><p>2 thermostat</p><p>3 tube of tester</p><p>Fig.65</p><p>Fig. 64 Removing, pipe of boost air</p><p>cooler</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>147</p><p>4 Loosen two mounting screws for 2 laps.</p><p>5 Use the belt adjusting nut (3) to remove the compressor belt</p><p>(1).</p><p>Note! Belt tension of adjuster is very strong. Therefore, after</p><p>removing the belt, pay attention to injury.</p><p>Fig.66</p><p>Fig.67</p><p>1 tape</p><p>2 air conditioning compressor</p><p>3 adjusting nut of belt (2 EA)</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>148</p><p>6 Use a socket wrench handle (1 / 2 ") rotate belt tension</p><p>(3)clockwise, remove the belt (4), then install a new belt.</p><p>Note! Belt tension of adjuster is very strong. Therefore, after</p><p>removing the belt, pay attention to injury.</p><p>7 Install a new air conditioning belt, and then adjust the belt</p><p>tension.</p><p>Tighten mounting screws of compressor.</p><p>8 Install the fan protective pieces and the hose of boost air</p><p>cooler.</p><p>9 Close the engine hood and radiator cover.</p><p>6 Engine control</p><p>6.1 Overview</p><p>Normal conditions (auto position)</p><p>Engine speed is controlled by the engine speed control panel</p><p>switch.</p><p>Emergency</p><p>When control system is defective, turn auto / manual switch up</p><p>to MANUAL position.</p><p>Note! After repair, set the auto / manual switch to "Automatic"</p><p>shfit</p><p>.</p><p>Fig.68</p><p>1 generator</p><p>2 socket wrench handle</p><p>3 belt tension wheel</p><p>4 belt</p><p>5 fuel supply pump</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>149</p><p>6.2 Speed control</p><p>Engine speed control switch description</p><p>· VECU automatic operating position, the operator can easily</p><p>control operation mode, the engine speed and maximum</p><p>horsepower by the engine speed control switch.</p><p>· Switch can control engine speed and maximum horsepower</p><p>according to the programs of each mode of VECU.</p><p>· Engine speed control switch changes to voltage input of VECU</p><p>according to the selected location (shift).</p><p>Table 9. Engine speed control switch</p><p>No. Electric wire</p><p>specifications</p><p>Signal</p><p>1 0.85 R G</p><p>2 0.85 W A</p><p>3 0.85 SB F</p><p>4 0.85 R/W B</p><p>5 0.85 BN ND</p><p>Fig. 69 Engine Control</p><p>1 Engine speed control switch</p><p>2 Auto / Manual switch</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>150</p><p>Engine speed control switch, checking</p><p>Checking</p><p>· Measuring the connector on the connection site.</p><p>Fig. 70 Engine speed control switch</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>151</p><p>Ⅳ Power transmission</p><p>1 Gear box</p><p>1.1 Track gearbox</p><p>Track gearbox, instruction</p><p>Track gear box is made up of 2 -order planetary gear devices,</p><p>which can turn the high speed of hydraulic motor to low speed,</p><p>high torque rotational force in the centre of sprocket teeth.</p><p>Fig.1 2-order planetary gear</p><p>1 Travel motor</p><p>2.No.1 planetary gear drive device</p><p>3 No. 2 planetary gear drive devices</p><p>4 Ring gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>152</p><p>Table 1 Direction of rotation</p><p>E-axis view Import Export</p><p>Clockwise A B</p><p>Counterclockwise rotation Ｂ A</p><p>Fig. 2 Port connector</p><p>1.Gear oil level checking throttle (PF 3 / 4)</p><p>2 Gear oil filling and discharge throttle (PF 3 / 4)</p><p>3 High-speed</p><p>4 Low-speed</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>153</p><p>Table 2 Throttle connection</p><p>Throttle sign Dimension of the throttle Throttle</p><p>（A）（B） PF 1 Oil supply(oil return)</p><p>（P</p><p>1）（P</p><p>2） PT1/4 Pressure checking</p><p>（P） PF1/4 Displacement conversion valve --oil</p><p>supply</p><p>（D</p><p>1）（D</p><p>2） PF1/4 Draining oil</p><p>Fig.4 Track gear box, cross section</p><p>1 housing 2 corner bearing 3 seal 4 shims</p><p>5 locator 6 screws 7 parallel pin 8 ring gear</p><p>9 coupler 10 No. 2 planetary gear drive 11 No. 2 bracket 12 No. 2 planetary gear</p><p>13 No.2 needle bearing 14 thrust washer 15 No. 2 pin 16 spring pin</p><p>17 thrust ring 18 No. 1 planetary gear drive 19 No. 1 bracket 20 No. 2 star gear</p><p>21Positioning ring gear 22 No. 1 planetary gear 23 No. 1 needle bearing 24 thrust washer</p><p>25 No. 1 selling 26 spring pin 27 No. 1 star gear 28 cover</p><p>29 pads (thrust) 30 screw 31 screw 32 plug</p><p>33 plate</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>154</p><p>Power from the output shaft of hydraulic motor will be delivered</p><p>to prime epicyclic gear (27) → No.1 bracket rack (19)</p><p>→secondary epicyclic gear (20) →secondary planetary gear (12)</p><p>→ ring gear (8).</p><p>At this point, reduction rate of gear reducer are as the following:</p><p>(1) First reduction ratio</p><p>i = ((Zs1 + Zr) · (Zs2 + Zr) / (Zs1 · Zs2) -1</p><p>• Zs1 = the number of teeth of prime epicyclic gear</p><p>• Zs2 = the number of teeth of secondary epicyclic gear</p><p>• Zr = the number of teeth of ring gear</p><p>Notes of track gearbox operation</p><p>Installation</p><p>• Check that the mating surfaces are clean.</p><p>• Check and confirm the motor gear reducer is installed correctly</p><p>in the frame.</p><p>• If the gearbox installed in the frame is very tight, install the</p><p>assembly into frame with the mounting screws.</p><p>• Tighten the screws to the specified torque.</p><p>• When installing sprocket teeth, follow the same precautions.</p><p>Fig. 5 Track gearbox, exploded view</p><p>Fig. 7 Track gear box, torque flow</p><p>Fig. 8 Iinstallation</p><p>A Installation area of machine</p><p>B Installation area of sprocket</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>155</p><p>Tightening torque</p><p>Table 4 tightening</p><p>torque</p><p>Deceleration screws (A) Quantity</p><p>30</p><p>Thread</p><p>M16(P2.0)</p><p>Torque, kgf · m</p><p>27±3</p><p>Sprocket bolt (B) 20 M16(P2.0) 27±3</p><p>Note! The intensity level of screws must be greater than 10.9</p><p>KS.</p><p>Lubricating oil</p><p>Important! Before operating the travel function, fill the gearbox</p><p>to the correct level with the gear oil.</p><p>Note! Gear oil specifications</p><p>Use the gear oil equivalent to SAE 90 GL4 or GL5 or 140API.</p><p>Gear oil, period</p><p>• The first (initial) oil replacement: 500 hours</p><p>• The next oil replacement: 2000 hours</p><p>• After repair (initial): 250 hours</p><p>Note! Regardless of the operating hours, gear oil is changed at</p><p>least once a year.</p><p>Note! Do not mix gear oil with different types and levels or</p><p>brands.</p><p>Note! Drain the gear oil when oil is not decomposed into any</p><p>impurities.</p><p>Replacement procedure of gear oil</p><p>• Turn the gear box until the drain plug and level checking plug</p><p>is located on the vertical axis.</p><p>• Remove the two plugs on the end cap and drain the gear oil</p><p>into a suitable container.</p><p>• Fill the gearbox with oil by the level checking throttle until the</p><p>gearbox oil overflows from the hole.</p><p>• Ensure that each O-ring on the plug are not damaged, and then</p><p>install the plug and tighten to the torque specifications.</p><p>Note! Oil capacity: 5.8 Lit</p><p>Fig.10 Oil replacement location</p><p>1 Liquid lever checking throttle</p><p>2 Draining throttle</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>156</p><p>Operation Checking</p><p>• Check the oil level before operating the travel function</p><p>• Check whether gear box assemblies is leaked.</p><p>• Check whether the mounting screws are tight.</p><p>• Check whether there is abnormal sound or vibration during the</p><p>operation.</p><p>• Check whether the temperature increases abnormally after the</p><p>short operation.</p><p>WARNING!</p><p>The temperature of running gearbox is high after</p><p>running. Use the thermometer to measure.</p><p>Never touch by hands to prevent burns.</p><p>Note! In continuous operation, the temperature of tank must be</p><p>below 90 ° C.</p><p>Track gearbox, maintenance standards</p><p>All parts are machined with precision, be careful to operate.</p><p>Put the planetary gear bracket parts together, do not mix</p><p>bearings, gears, pins and thrust washers.</p><p>Seal washer</p><p>Even no visible damage, replace the gaskets, oil seals and</p><p>O-ring.</p><p>Components, replacement standard</p><p>Replace all damaged components within the range of values.</p><p>Replace certain components, namely, gears, bearings, pins and</p><p>thrust washers.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>157</p><p>Table 5 Components, replacement standard</p><p>Items No. Component Status Allow the</p><p>value</p><p>8</p><p>12</p><p>20</p><p>22</p><p>27</p><p>Ring gear</p><p>No.2, planetary gear</p><p>No.2 epicyclic gear</p><p>No.1 planetary gear</p><p>No.1 epicyclic gear</p><p>There is dents or uneven wear on the teeth</p><p>surface.</p><p>Gear is broken.</p><p>Area ratio:</p><p>5%</p><p>23</p><p>13</p><p>2</p><p>Needle Roller Bearings</p><p>Needle Roller Bearings</p><p>Bearing angle</p><p>Ball, roller or sleeve bearings is worn or</p><p>erosed.</p><p>Rotating by hand is not smooth.</p><p>3 Gasket Sliding surface is rusted or damaged.</p><p>O-ring is distorted or damaged.</p><p>15</p><p>25</p><p>2 off</p><p>1 off</p><p>Pin is broken, worn or damaged.</p><p>24</p><p>14</p><p>Thrust washer Excessive surface wear.</p><p>Common tools</p><p>Table 6 Common tools</p><p>No. Explain Size Quantity</p><p>1 Socket wrench 19 mm 1</p><p>2 L-shaped wrench 5 mm</p><p>10 mm</p><p>1</p><p>3 Torque Wrench 400 ~ 1800 kgf · cm 1</p><p>4 Eyebolts PT 1 / 2</p><p>M10</p><p>M12</p><p>2</p><p>5 Plastic hammer About L = 300 ~ 500 mm 1</p><p>6 Screwdriver About L = 200 mm 1</p><p>7 Depth gauge</p><p>(Caliper)</p><p>Measurement range is about 300 mm</p><p>Minimum scale 0.01 mm</p><p>1</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>158</p><p>Special tools</p><p>Table 7. Special tools</p><p>No. Explain Size Quantity</p><p>1 Bearing shim adjustors Refer to the next figure 1</p><p>Gasket thickness measurement fixtures</p><p>Track gear box, removing</p><p>1 Remove cover screws (2), and remove the cover (1).</p><p>2 Remove the track.</p><p>3 Put a piece of wood in the track and put the drum on the block</p><p>next to lift the sprocket teeth away from track.</p><p>4 Disconnect the hydraulic hoses of running motor. Plugged the</p><p>nozzle and screws to prevent oil from outflow and prevent</p><p>pollution from entering.</p><p>5 Remove the mounting screws of travel motor from the chassis.</p><p>Fig.11 Gasket thickness, measurement tool</p><p>Fig.12 Remove the cover</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>159</p><p>6 Entangle around the gear box with a rope, and then lift it.</p><p>Remove the motor. Then, push the gearbox out with the screws</p><p>in the thread hole of the chassis.</p><p>Note! Lift gear box sprocket to be as close as possible to</p><p>maintain balance.</p><p>Note! Mounting screws of gearbox can be used for threaded</p><p>screw holes on the frame</p><p>.</p><p>Note! Make symmetrical sign on the frame and gear box ,which</p><p>will help to re-install.</p><p>Track gear box, installing</p><p>Note! Carefully check whether there are burrs, mud and rust on</p><p>the mating surfaces between chassis and gearbox .</p><p>1 Entangle around the gear box with a rope, and then lift it.</p><p>2 Coat the mounting screws of gear box with Loctite 277, and</p><p>tighten them according to the specified torque.</p><p>Note! Tightening torque: 27 ± 3 kgf · m</p><p>3 Connect the hydraulic hoses of the travel motor.</p><p>4 Install the walking motor cover.</p><p>5 If necessary, check the oil level of gear box gear.</p><p>Fig.14 Removing, track gearbox</p><p>Fig.13 Remove the hydraulic hose and screw</p><p>Fig.15 Installing, track gear box</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>160</p><p>Track gear box, replacing the lid</p><p>1.Park the machine in the maintenance position B, refer to</p><p>maintenance position.</p><p>Turn the gear box until the drain plug and level plug is located</p><p>on the vertical axis.</p><p>2 Remove the two plugs (1,2)on the end cap and drain the gear</p><p>oil into a suitable container.</p><p>3 Remove the screws (2) of gearbox cover.</p><p>Tighten the two screws (1) to separate the cover on the track</p><p>gear box cove</p><p>4 Remove the cover on the gear box cover (3).</p><p>5 Install two screws to a new gearbox cover.</p><p>6 Install the new cover on the track gearbox.</p><p>Note! Before replacing the cover (2), clean the mounting surface</p><p>thoroughly, then coat sealing surface (1) with seal compound.</p><p>7 Install the drain plug (1) and tighten to the specified torque.</p><p>8 Fill the oil through the oil level throttle, until the oil overflow</p><p>the oil level checking throttle.</p><p>9 Install oil level checking plug and tighten to the specified</p><p>torque.</p><p>、</p><p>、</p><p>Fig. 16 Removing, the plug</p><p>Fig.18 Applying, sealing compound</p><p>Fig.19 Installing, the drain plug</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>161</p><p>Track gearbox removing</p><p>Note</p><p>•Before removing, completely clean the gear box components.</p><p>• Choose a clean work area.</p><p>• Make marks on the assembled components to note the correct</p><p>position in order to facilitate assembly.</p><p>• Be careful not to mix the secondary component parts, namely,</p><p>the planetary gear bearings, gears and thrust washers.</p><p>• Thoroughly clean all internal parts and housings.</p><p>• Check and analyze all failures. Determine the most</p><p>fundamental cause of the malfunction!</p><p>2. Put the oil level throttle and oil drain throttle on the on the</p><p>vertical axis. Remove the plug (32)and empty the gear oil.</p><p>- Tools: L Wrench 14 mm (PF 3 / 4) 8 L of oil span</p><p>Note! Drain the oil into a clean container, thoroughly check for</p><p>contamination.</p><p>Note! Prior to draining the oil, release the plug (1) squeezing the</p><p>air.</p><p>3 Remove the screws (30) and remove the cover (28).</p><p>- Tools: L-shaped wrench 10 mm, 5 mm</p><p>Note! Install a screw (31), and carefully raise the lid</p><p>Fig. 22 Remove the screw and cover</p><p>Fig. 21 Disassembly, plug</p><p>1 door section surface inspection</p><p>2 filling and drain plugs.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>162</p><p>4 Remove No.1 planetary gear transmission equipment (18)</p><p>from No.2 planetary gear (10).</p><p>Remove No.1 planetary gear drive device.</p><p>• Hit the spring pin (26) into the No. 1 pin (25).</p><p>• Remove thrust washer (24), No.1 planetary(22) and needle</p><p>roller bearings (23) gear from No.1 bracket (19).</p><p>• Remove thrust ring (17).</p><p>• Remove the retaining ring (21), and then remove the No.2</p><p>epicyclic gear (20).</p><p>• Remove thrust ring (17).</p><p>- Tools: hug bolts (M10), plastic hammer</p><p>WARNING!</p><p>These parts are very heavy. Pay attention to the</p><p>appropriate safety notice.</p><p>Note! Mark the matching signs for the gear (22), pins (25) and</p><p>bracket (19).</p><p>Note! Do not mix gears, bearings, thrust washers and pin</p><p>components.</p><p>Note! Do not reuse the spring pin (26).</p><p>Note! If there is any cracks on the No. 1 pin surface, and also</p><p>replace No. 1 pin, No. 1 bracket (19), No. 1 planetary gear (22)</p><p>and needle roller bearings(23).</p><p>Fig.25 Removing, the spring pin</p><p>Fig. 23 Removing, No.1 planetary gear</p><p>assembly</p><p>Fig.24 Removing, thrust washers, No. 1</p><p>planetary gears, needle roller bearings</p><p>and thrust ring.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>163</p><p>5 Remove No. 1 epicyclic gear (27) and coupling (9).</p><p>Note! Remove 1 bracket (19) and remove the 2 and 1 star gear</p><p>(20,27).</p><p>WARNING!</p><p>These parts are very heavy. Pay attention to the appropriate</p><p>safety.</p><p>6 Remove No. 2 planetary gears (10) from the main shaft (302).</p><p>Dissemble the No. 2 planetary gear drive devices.</p><p>• Hit the spring pin (16) into No. 2 pin (15).</p><p>• Remove thrust washer (14), 2 planetary gear (12) and needle</p><p>roller bearings (13) from No.2 bracket (11).</p><p>Fig. 26 Removing No.1 epicyclic gear and linkage</p><p>assembly</p><p>Fig. 27 Removing, No. 2 planetary gear</p><p>drive device</p><p>assembly</p><p>Figure 28 Removing, thrust washers, No. 2</p><p>planetary gears, needle bearing and thrust</p><p>ring.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>164</p><p>- Tools: Ring bolts (M10), plastic hammer</p><p>Note! Mark the matching marks for the gear (12), pins (15) and</p><p>bracket (11).</p><p>Note! Do not mix gears, bearings, thrust washers and pin</p><p>components.</p><p>Note! Do not reuse the spring pin (16).</p><p>7 Switch the lug bolts into the ring gear (8), then remove the ring</p><p>gear.</p><p>- Tools: hug bolts (M12), plastic hammer</p><p>8 Remove the screws (6), retainer (5) and shim (4).</p><p>- Tools: 19 mm socket wrench (M12)</p><p>Note! Do not reuse the screws.</p><p>9 Switch the lug bolts into the housing (1), then remove the</p><p>entire housing (1), flat pin (7), angular bearings (2) and seal</p><p>gasket (3).</p><p>- Tools: Lug bolts (M12), plastic hammer</p><p>Fig. 29 Removing, the spring pin</p><p>drive device</p><p>assembly</p><p>Figure 32 Removing, enclosure, pins,</p><p>angle bearings and seals</p><p>drive device</p><p>assembly</p><p>Figure 31 Removing, screw, retainer and</p><p>shims</p><p>drive device</p><p>assembly</p><p>Fig.30 Remove the ring gear</p><p>drive device</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>165</p><p>WARNING!</p><p>These parts are very heavy. Pay attention to the</p><p>appropriate safety notes.</p><p>Note! When it is difficult to remove, lift of the parts vertically,</p><p>and tap it with a plastic hammer.</p><p>10 Remove the seals (3) from the housing (1). Remove the seals</p><p>(3) from motor housing (302 main shaft) on the removal of.</p><p>Note! Be careful not to damage the O-ring and sealing surface.</p><p>11 Remove the angular bearings (2) from the housing (1).</p><p>- Tools: Bearing fixtures, plastic hammer</p><p>Track gear box, assembly</p><p>Preparation</p><p>• Clean all parts with detergent and dry them with compressed</p><p>air.</p><p>• Reprocess the damaged parts and prepare all the components</p><p>prior to assembly and replacement.</p><p>• Coat the sliding parts, bearings and gears with clean gear oil.</p><p>• Replace O-rings and seals.</p><p>• Replace the screw (6). Do not reuse these screws!</p><p>• Use torque wrench to tighten the screws and plug to the</p><p>specified torque.</p><p>Tightening torque</p><p>Fig. 33 Remove the angle bearing</p><p>drive device</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>166</p><p>Table 9 tightening torque, unit: kgf · m</p><p>Part Number Part Name Thread Size Tightening torque</p><p>6 Screw M12 11.5</p><p>30 Screw M12 13.5</p><p>31 Screw M10</p><p>32 Stopper PT 1/2 6.6</p><p>32 Stopper PF 3/4 19</p><p>1.Install the angular bearing (2) to the housing (1).</p><p>- Tools: Plastic hammer, desktop presses.</p><p>Note! Outer ring of angle of bearing should be completely</p><p>aligned, full going to the bearing.</p><p>Note! Press it with a hammer or press-fit.</p><p>2 Install the seal (3) on frame (1) gently with press tool.</p><p>Install the seal (3) on motor base (Main shaft 302).</p><p>Assemble the housing (1) to the motor, calibrate the angle</p><p>bearing sleeve to motor block.</p><p>Note! After the seal is installed, check whether the O-ring is</p><p>located on the motor housing.</p><p>Note! Coat the O-rings with grease (NLGI # 2).</p><p>Note! Be careful not to damage the mating surface of seal.</p><p>3 Adjustment method of washers:</p><p>• Measure the bushing on the fixer (5) as shown in Fig. Size</p><p>"B"</p><p>• Install thickness measurement tool (C) inside the inner bearing</p><p>gasket, tighten the four screws (6) according to tightening</p><p>torque.</p><p>- Tools: special tools ,refer to fixed thickness spacer (part</p><p>number8933-00330).</p><p>Note! Tightening torque: 0.8 kgf · m</p><p>• As shown in figure, measured from the top of the inner ring of</p><p>bearing to size "A" of the motor.</p><p>• Measuring the size "B" of locator (5).</p><p>• Gasket thickness S = B - A + (0 ~ 0.05 mm)</p><p>• Choose washer(4) with suitable thickness, calibrate the holder</p><p>(5) correctly, and then tighten the screws (6) to the specified</p><p>torque.</p><p>Fig. 34 Angular bearing, assembly</p><p>drive device</p><p>assembly</p><p>Fig. 35 Seal, assembly</p><p>drive device</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>167</p><p>- Tools: 19 mm socket wrench (M12), torque wrench, depth</p><p>gauge</p><p>Note! Gasket: 0.1,0.9,1.0 and 1.2 mm</p><p>Note! Torque: 0.8 kgf · m</p><p>Note! Coat the screw (6) with Loctite # 277.</p><p>4 Install level pin (7) to the housing (1), calibrate the gear (8)</p><p>correctly.</p><p>- Tools: Plastic hammer</p><p>Note! Coat the mating surface of ring gear (8)with Loctite #</p><p>5699 .</p><p>Note! Temporary install four screws (30).</p><p>5. No.2 planetary gear drive device</p><p>• Place the No.2 bracket (11) with rack down.</p><p>• Install the thrust washer (14), No.2 planetary gear (12) and</p><p>needle roller bearings(13) to the No.2 bracket.</p><p>• Insert No.2 pins (15).</p><p>• Tap the spring pin (16) into the No. 2 bracket (11) of the pin</p><p>hole, then pin (15), then two pile up points on No. 2 bracket</p><p>(11).</p><p>- Tools: Plastic hammer</p><p>Note! Check whether the No. 2 planetary gears rotates smoothly.</p><p>Note! Align bracket and spring pin hole of No.2 pin.</p><p>Note! Piling technology:</p><p>Figure 36 Adjustment, shim</p><p>assembly</p><p>Fig.37 Install thepin</p><p>A. Use the Loctite liquid</p><p>assembly</p><p>Fig.38.No. 2 planetary gear drive</p><p>A Pile</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>168</p><p>WARNING!</p><p>These parts are very heavy. Pay attention to the</p><p>appropriate safety notes.</p><p>Note! Li pile technology:</p><p>A solution using Loctite</p><p>6 No. 2 planetary gear transmission (10) is properly installed to</p><p>the rack of the motor.</p><p>- Tools: ring bolts (M10)</p><p>7 Insert link (9), then the</p><p>No. 1 epicyclic gear (27) to the motor</p><p>shaft.</p><p>8 .No. 1 planetary gear transmission</p><p>• Insert the thrust ring (17) into No.1 bracket (19).</p><p>• Install the assembled No.1 bracket to No. 2 epicyclic gear (20),</p><p>and install retaining ring (21).</p><p>• Install the thrust washer (24), No.1 planetary gear (22) and</p><p>needle roller bearings(23) to the No. 1 bracket (19).</p><p>• Insert No. 1 pin (25). Tap the spring pin (26) into No. 1</p><p>bracket(17) and the pin hole of pin (25), and then stand two pile</p><p>points in No. 1 bracket (19).</p><p>• Embed the thrust ring (17) in No. 1 bracket (19).</p><p>Fig. 39 Installing, No. 2 planetary gear</p><p>transmission</p><p>assembly</p><p>Fig.40 Inserting, link</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>169</p><p>- Tools: plastic hammer</p><p>Note! Align No. 1 bracket and hole of spring pin.</p><p>Note! Piling technology:</p><p>Note! Check whether the No. 1 planetary gears rotates smoothly.</p><p>WARNING!</p><p>These parts are very heavy. Pay attention to the appropriate</p><p>safety notes.</p><p>9 Insert No. 1 planetary gear (18) into the No.2 planetary gear</p><p>(10).</p><p>- Tools: ring bolts (M10)</p><p>Fig.41 No.1 planetary gear transmission</p><p>A Pile</p><p>assembly</p><p>Fig. 42 Cartridge, No.1 planetary gear transmission</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>170</p><p>10 Insert a ring bolt into the oil level throttle and install the</p><p>cover (28) to the ring gear (8). Install screws (31), screw (30)</p><p>and tighten them to the specified torque.</p><p>- Tools: Ring bolts (PT 1 / 2), L-shaped wrench 10 mm (M12),</p><p>torque wrench, plastic hammer</p><p>Note! Coat the mating surface of ring gear (8)with Loctite #</p><p>5699 .</p><p>Note! Coat the thread of screw (30) with Loctite # 277.</p><p>11 Install the plug (32) to cover (28) and tighten it to the</p><p>specified torque.</p><p>- Tools: torque wrench, L wrench 14 mm (PF 3 / 4)</p><p>Fig.45 Installing, plug</p><p>assembly</p><p>Fig.43 Inserting, link</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>171</p><p>Track gearbox, troubleshooting</p><p>Table 10 Troubleshooting of track gearbox</p><p>Gearbox can’t</p><p>rotate.</p><p>Gearbox is damaged.</p><p>Motor is overloading</p><p>Replace the gearbox.</p><p>Reduce the load.</p><p>Floating seal is</p><p>leaking.</p><p>O-ring is distorted.</p><p>Sliding surface is</p><p>worn.</p><p>Replace the floating</p><p>sealing device.</p><p>Housing is</p><p>leaking.</p><p>Cover is damaged.</p><p>Cracks or pin hole</p><p>leaks.</p><p>Replace the cover.</p><p>Replace the housing.</p><p>Mating surface</p><p>is leaking.</p><p>Mating surface is</p><p>damaged.</p><p>Liquid washer is not</p><p>used correctly.</p><p>Replace or repair.</p><p>Remove and reuse it.</p><p>Screw is loose. Tighten it to</p><p>specified torque.</p><p>Plug is loose.</p><p>Tighten it to</p><p>specified torque.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>172</p><p>1.2 Rotary gearbox + rotary pinion gear shaft</p><p>Rotary gear box, instruction</p><p>Rotary gearbox is composed by drive shaft as the group,</p><p>comprising first planetary gear transmission, secondary</p><p>planetary gear transmission and No.1, 2 epicyclic gear, frame</p><p>supporting the drive shaft and ring gear containing planetary</p><p>gear.</p><p>Model Code</p><p>Abnormal</p><p>operating sound</p><p>Gear is damaged. Replace the floating</p><p>sealing device.</p><p>Abnormal</p><p>operating</p><p>temperature</p><p>Bearing or gear is</p><p>damaged.</p><p>Gear oil is not</p><p>enough.</p><p>Replace the gearbox.</p><p>Refill the oil to the</p><p>specified level.</p><p>Gear oil is mixed</p><p>with gear oil.</p><p>Replace the sealing</p><p>ring of motor.</p><p>Fig.1 Model Code</p><p>1 Series number.</p><p>2 Gear ratio code</p><p>3 Size code (Theoretical output torque)</p><p>ex. 100 = 1000 kgf · m</p><p>4 Type mode</p><p>(ex. S = rotary gear box)</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>173</p><p>Rotary gear boxes, cross sections</p><p>1. No.2 planetary gear transmission</p><p>2. No.2 bracket</p><p>3 No. 2 planetary gear</p><p>4 No. 2 pin components</p><p>5 No. 2 pin</p><p>6 bushing</p><p>8 washers</p><p>9 spring pin</p><p>10 drive shaft</p><p>11 lining ring</p><p>12 cover</p><p>13 O-ring</p><p>14 seals</p><p>15 screw</p><p>16 bearing</p><p>Fig.3 Rotary gear boxes, cross sections</p><p>17 bearing</p><p>18 retaining ring</p><p>19 housing</p><p>20 ring gear</p><p>21 pin</p><p>22 screw</p><p>23 metal plate</p><p>24 screw</p><p>25 thrust ring</p><p>26 No. 2 epicyclic gear</p><p>27 thrust washer</p><p>28 No. 1 planetary gear drive</p><p>29 No. 1 bracket</p><p>30 No. 1 planetary gear</p><p>31 No. 1 pin</p><p>32 bearing</p><p>33 washers</p><p>34 washers</p><p>35 retaining ring</p><p>36 spring pin</p><p>37 No. 1 epicyclic gear</p><p>38 retaining ring</p><p>39 level gauge</p><p>40 pipes</p><p>41 nameplate</p><p>42 screw</p><p>43 drain valve</p><p>44 pipes</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>174</p><p>Function</p><p>2—order planetary gear assembly converts speed / low output</p><p>torque of the hydraulic motor into low speed / high torque, and</p><p>then transfer to the inner gear of rotary ring through pinion gear</p><p>to rotate upper structure.</p><p>Operating</p><p>Power supplying to the output shaft of hydraulic motor gear is</p><p>transferred to No. 2 epicyclic gear (26) though No. 1 epicyclic</p><p>gear (37), No. 1 planetary gear (30), No.1 pin (31) and the rack</p><p>of No.1 bracket (29). In the same way, the power is transferred</p><p>to the output shaft (10) through the No.2 planetary gear</p><p>(3), No.2 pin (5) and No. 2 bracket (2).</p><p>At this point, reduction ratio of gear is as follows:</p><p>• First reduction ratio</p><p>i1 = (Zr / ZS1) + 1</p><p>i1 = 1 reduction ratio</p><p>ZS1 =First star gear gear</p><p>Zr = number of ring gear teeth</p><p>•Second reduction ratio</p><p>i2 = (Zr / ZS2) + 1</p><p>i2 = Second reduction ratio</p><p>ZS2 = No.2 epicyclic gear</p><p>Therefore, the total reduction ratio of reduction gear is as</p><p>follows:</p><p>i = i1 × i2</p><p>= (Zr / ZS1 + 1) × (Zr / ZS2 + 1)</p><p>i = The total reduction ratio</p><p>Fig. 4 Rotary gear</p><p>A Torque process</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>175</p><p>Turn gearbox, lubricating</p><p>Notes about lubrication</p><p>• Before operating the rotary function, check the oil level.</p><p>• Check whether the motor and gearbox assemblies leaks.</p><p>• Check whether the mounting screws are tightened.</p><p>• Check whether there is abnormal sound or vibration during</p><p>rotation process.</p><p>• Check the abnormal temperature after operating a short time.</p><p>• Check the performance rotary device according to the</p><p>operating specifications.</p><p>WARNING!</p><p>The temperature of tank is very high when running. Never touch</p><p>and prevent burns. Use a surface thermometer to check the</p><p>temperature.</p><p>During continuous operation, the temperature of housing must</p><p>be below the ambient temperature + 60 ° C.</p><p>Gear oil, specifications</p><p>• Use the gear oil that equivalent to SAE 90 or 140API or</p><p>GL4/GL5 gear oil.</p><p>Gear oil, replacing</p><p>• The first (initial) oil replacement: 500 hours</p><p>• The next replacement: 1000 hours</p><p>• After repair (initial): 500 hours</p><p>Note! Regardless of the number of operating hours, gear oil</p><p>should be replaced at least once a year.</p><p>Note! Do not mix the oil with different types and levels or</p><p>brands.</p><p>Gear oil level</p><p>• Remove the level gauge, wipe it with a clean cloth clean,</p><p>re-insert, remove, and then check the oil is located in the</p><p>diagonal area as shown in picture.</p><p>Fig.5 Checking, oil level</p><p>A Level</p><p>* Level gauge also plays the role of ventilation of the gear</p><p>box.</p><p>A Torque process</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>176</p><p>Gear oil, replacing</p><p>Note! Drain the gear oil when the oil can be decomposed into</p><p>any impurities.</p><p>• Open the cover</p><p>(D) on the drain valve (C), and connect drain</p><p>hose (E) to the drain valve (C), then drain the oil into a suitable</p><p>container.</p><p>• After emptying completely, remove the drain hose (E), and</p><p>then close the drain valve cover (D).</p><p>• Remove the oil level gauge (A), fill the gear box with a can</p><p>that can exhaust the air of pipes.</p><p>Maintenance standard of rotary gear box</p><p>All parts are machined precisely, be careful to operate.</p><p>Store the components of planet bracket together, and do not mix</p><p>bushing, gears, pins and thrust washers.</p><p>Seals</p><p>Replace the seals and O-ring, although they did not seem to be</p><p>damaged.</p><p>Replacement standard of parts</p><p>• Replace all damaged parts or the parts not within the allowable</p><p>scope.</p><p>• Replace part assembly, namely, gears, bushings and thrust</p><p>washers.</p><p>Fig.7 Replacing, gear oil</p><p>A Torque process</p><p>assembly</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>177</p><p>Table 11 standard replacement parts</p><p>Item Part Name Status Standard values Allow the value</p><p>37</p><p>26</p><p>30</p><p>3</p><p>20</p><p>No. 1 epicyclic gear</p><p>No. 2 epicyclic gear</p><p>No.1 planetary gear</p><p>No.2 planetary gear</p><p>Ring gear</p><p>Erosion on the gear</p><p>teeth.</p><p>-Diameter</p><p>Clearance: φ 1mm</p><p>(0.039 in)</p><p>-Area ratio:＜5%</p><p>30</p><p>31</p><p>32</p><p>No.1 planetary gear</p><p>No.1 pin</p><p>Needle Bearings</p><p>Cracks on sliding</p><p>surface of the needle</p><p>roller bearings.</p><p>Some worn parts</p><p>3</p><p>4</p><p>No.2 planetary gear</p><p>No.2 Pin assembly</p><p>Wear on the outer</p><p>diameter of bushing</p><p>25 Thrust ring Wear on the contact</p><p>surface of shaft.</p><p>Diameter</p><p>clearance:</p><p>0.13~0.254 mm</p><p>- Diameter</p><p>Clearance: ＜</p><p>φ0.45 mm</p><p>38</p><p>35</p><p>18</p><p>Retaining ring</p><p>Retaining ring</p><p>Retaining ring</p><p>Abnormal wear of the</p><p>surface area.</p><p>Tank depth: ＜</p><p>0.5mm</p><p>8</p><p>33</p><p>34</p><p>27</p><p>Thrust washer</p><p>Thrust washer</p><p>Thrust washer</p><p>Thrust washer</p><p>Abnormal wear of the</p><p>surface area.</p><p>17</p><p>16</p><p>Spherical Bearings</p><p>Spherical Bearings</p><p>Pitting / lobes on roller</p><p>bearing.</p><p>Manual rotation is not</p><p>smooth.</p><p>14 Seal Always replace it.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>178</p><p>General Tools</p><p>Table 12 General Tools</p><p>No. Explain Size Quantity</p><p>1 Wrench 17 × 19 mm</p><p>24 × 27 mm</p><p>1</p><p>1</p><p>2 Socket wrench - 1</p><p>3 General wrench 10 mm</p><p>14 mm</p><p>1</p><p>1</p><p>4 Torque Wrench 3923 ~ 17652 Nm</p><p>11768 ~ 47072 Nm</p><p>1</p><p>1</p><p>5 Fixed ring clamp φ 35</p><p>φ 42</p><p>φ90</p><p>1</p><p>6 Bearing puller - -</p><p>7 Plastic hammer - 1</p><p>8 Ring bolts M8</p><p>M12</p><p>M16</p><p>M18</p><p>2</p><p>2</p><p>2</p><p>2</p><p>9 (-) Screwdriver 150 mm 1</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>179</p><p>Special tools</p><p>Table 13 special tools</p><p>No. Explain Part Number Number</p><p>1 Bearing assembly fixtures 8920-00280 1</p><p>2 Bearing assembly fixtures</p><p>8932-00600 1</p><p>3 Oil seal assembly fixtures</p><p>8920-00550 1</p><p>4 Oil seal assembly guide fixtures</p><p>8920-00570 1</p><p>5 Oil seal assembly guide fixtures</p><p>8920-00560 1</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>180</p><p>Rotary gear box, replacement</p><p>1 Park the machine in the maintenance position C, refer to</p><p>maintenance position.</p><p>2 • When the engine is running, the hydraulic pipelines are under</p><p>high pressure. Stop the machine, drain the remaining pressure</p><p>within the hydraulic pipelines and the method is to turn the</p><p>ignition switch to ON, smoothly operate the operation lever 3 to</p><p>4 times.</p><p>• Drain the remaining pressure within the hydraulic pipelines,</p><p>the method is to press air respirator on the hydraulic tank.</p><p>• Installed the vacuum pump on the hydraulic tank to maintain</p><p>vacuum.</p><p>• After disconnecting the hoses, install a plug to prevent leakage</p><p>and pollution of oil.</p><p>3 Remove the cover below.</p><p>4 Open the oil drain valve cap (1), install the oil drain valve (2).</p><p>Drain the gear oil to a suitable container.</p><p>Figure 14 Draining, oil of transmission</p><p>1 oil drain valve cover</p><p>2 oil drain hose</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>181</p><p>5 Remove the anti-cavitation hose (1).</p><p>6 Remove the drain hose (2) of rotary motor.</p><p>7 Remove the feedback line hose (3)of rotary motor.</p><p>8 Remove the vice hose (4) of delay valve.</p><p>9 Remove the assembly screws (1) of rotary gear box, and</p><p>remove the silica gel (2) from two rear holes.</p><p>Fig.16 Removing, assembly screws</p><p>1 screw</p><p>2 silicone</p><p>Fig.15 Removing, hose</p><p>1 Anti-cavitation hose</p><p>2 Drain hose</p><p>3 Feedback line hose</p><p>4 Vice hose of delay valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>182</p><p>10 Install the rear screws (1) to separate rotary gear box from the</p><p>upper structure.</p><p>Note! Because of pins, the gearbox housing is not easy to be</p><p>removed.</p><p>11 Enhance the rotary unit with the sling (1), and put is safely</p><p>into the work plate.</p><p>12 Remove the screws (2), enhance the rotary motor with a sling</p><p>(1), and install it into a new rotary gear box.</p><p>Note! Before installing the rotary motor, completely remove the</p><p>seal compound on the surface of the assembly.</p><p>Note! Coat the seal compound on the surface of the new rotary</p><p>gear box. And then install the rotary motor.</p><p>13 Transfer the drain hose (1) and pins (2) to the new rotary gear</p><p>boxes.</p><p>Fig.17 Installing, posterior screw</p><p>1. Posterior screw</p><p>Fig.18 Removing, rotary unit</p><p>1 sling</p><p>2 screws</p><p>Fig.19 Transfer, oil drain hose and pins</p><p>1 oil drain hose</p><p>2 pin</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>183</p><p>14 Enhance the rotary units with the lifting device and install it</p><p>on the machine.</p><p>Note! Before installing the rotary unit, completely remove the</p><p>residual seal compound on the mounting surface of the upper</p><p>structure.</p><p>Note! Coat the sealing surface of the upper structure with the</p><p>seal compound, and then install the rotary unit.</p><p>Note! Coat the assembly screw (1) with Loctite # 277, and</p><p>tighten them according to the specified torque.</p><p>15 Fill the posterior hole with silica gel (2), cover it with</p><p>alignment pins.</p><p>16 Install the feedback line hose (3) of the rotary motor.</p><p>17 Install the vice delay hose (4) of valve.</p><p>18.Install drain hose (2 ) of rotary motor.</p><p>19.Install anti-cavitation hose (3).</p><p>20 Remove vacuum pump installed on the hydraulic tank.</p><p>21 Fill the gearbox oil from the oil filling pipe.</p><p>Fig. 20 Installing, rotary unit</p><p>1 screw</p><p>2 silicone</p><p>Fig.21 Installing, hose</p><p>1. Anti-cavitation hose</p><p>2. Drain hose</p><p>3 Feedback line hose</p><p>4 Vice hose of delay valve</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>184</p><p>22 Before the operation, drain the air in the hydraulic circuit of</p><p>the rotary motor.</p><p>23 After the maintenance work is completed, start the engine,</p><p>check for leakage.</p><p>Rotary gearbox, disassembling</p><p>Note</p><p>• Before removing, clean the gear box components completely.</p><p>• Choose a clean work area.</p><p>• Mark the components that are assembled together with the</p><p>correct position in order to facilitate assembly.</p><p>• Be careful not to mix the secondary components of parts,</p><p>namely, planetary gear bearings, gears and thrust washers.</p><p>• Thoroughly clean all internal parts and housings.</p><p>• Check and analyze all failures.</p><p>- Determine the root cause!</p><p>Disassembly</p><p>1 Open the drain valve (C) on the discharge valve cover (D), and</p><p>connect drain hose (E) to the drain valve (C), then drain the oil</p><p>into a suitable container.</p><p>2 After emptying completely, remove the drain hose (E), and</p><p>then close the drain valve cover (D).</p><p>3 Remove the screws (24).</p><p>4. Lift the motor from gear box.</p><p>Note! Make the mating marks (A) on the hydraulic motor</p><p>housing (301), board (23),</p><p>gear ring (20) and housing (19).</p><p>Ensure that with the mark (A) is permanent and clearly visible.</p><p>5 Remove the screw (22).</p><p>6 Remove plate (23).</p><p>Fig.22 Removing, the hydraulic</p><p>motor</p><p>Fig. 23 Removing, screws and plates</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>185</p><p>7 Remove No.1 epicyclic gear (37).</p><p>8 Remove the first planetary gear assembly (28) from the ring</p><p>gear (20).</p><p>Remove the transmission device of the first planetary gear as the</p><p>following order:</p><p>- Remove retaining ring (35), then the thrust washer (34),</p><p>planetary gear (30), needle bearing (32) and thrust washer (33).</p><p>- Remove the thrust washer (27).</p><p>- Remove the spring pin (36) from the bracket (29) to remove</p><p>the pin (31).</p><p>Note! Make the mating marks on the gear (30), pins (31) and</p><p>bracket (29).</p><p>Note! If there is no wear or damage, do not remove the pin (31).</p><p>Note! Do not reuse the spring pin (36).</p><p>9 Remove the ring gear (20) and connected pin (21).</p><p>10.Remove No.1 epicyclic gear (26) and thrust ring (25).</p><p>11 .Remove transmission device(1) of No.1 planetary gear from</p><p>the shaft (10).</p><p>Remove the transmission device of the first planetary gear as the</p><p>following order:</p><p>- Tap the spring pin (9) into the pin (5).</p><p>- Remove the spring pin (5) from the bushing (6) from the</p><p>bracket(2).</p><p>Fig. 24 Removing, No.1 epicyclic</p><p>gear</p><p>Fig.27 Removing No.2 epicyclic gear</p><p>Fig.25 Removing, retaining ring</p><p>Fig.26 Removing, the spring pin</p><p>Fig. 28 Removing No.2 planetary gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>186</p><p>- Remove the planetary gear (3) and thrust washer (8).</p><p>Note! Make the mating marks on the gear (3), pins (5) and</p><p>bracket (2).</p><p>Note! Do not mix gears, thrust washers, bushings, and</p><p>marketing components.</p><p>Note! Do not reuse the spring pin (9).</p><p>To remove the spring pin (9), tap it into the pin (5) gently.</p><p>Remove pin (5), then remove the spring pin.</p><p>12 Remove the retaining ring (18).</p><p>13 Remove the screws (15).</p><p>14 Remove the cover (12).</p><p>15 Remove the oil seal (14).</p><p>Note! Do not reuse seals</p><p>16.Fix the reduction gear as shown in the picture.</p><p>Press the shafts (10) from the boxes(19)out with press tool.</p><p>Fig. 31 Removing, shaft</p><p>Fig. 29 Removing, retaining ring</p><p>Fig. 30 Removing, cover and oil seal</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>187</p><p>17 Remove the spherical bearing (16) and collar (11) from the</p><p>shaft(10)with press tool.</p><p>Note! If it is difficult to remove the spherical bearing (16) as</p><p>shown in the figure, use a bearing remover.</p><p>Note! Be careful not to damage the collar (11) with too much</p><p>force.</p><p>18 Remove the O-ring (13) from the collar (11).</p><p>Note! Do not reuse O-ring.</p><p>19 Push the spherical bearing (17) out of the tank (19) with the</p><p>press tool.</p><p>Note! Spherical bearing (17) can also be removed by work</p><p>bench press tool.</p><p>Rotary gear box assembly</p><p>Note</p><p>• When installing the gear box assembly to the upper structure,</p><p>align it with bonding pin on the mounting plate, to ensure that</p><p>oil drain port/ oil filler in the correct position.</p><p>Fig. 33 Removing, O-ring</p><p>Fig. 32 Removing, spherical bearings</p><p>Fig. 34 Removing,, spherical</p><p>bearings</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>188</p><p>• Install the hydraulic motor to the gearbox components, so that</p><p>the position of oil level gauge and the pipeline is as shown.</p><p>• Use torque wrench to tighten the mounting screws to the</p><p>specified torque.</p><p>• Clean all parts with detergent and dry them with compressed</p><p>air.</p><p>• Reprocess all the damaged parts prior to assembly and prepare</p><p>all replaced parts.</p><p>• Coat the sliding parts, bearings and gears.</p><p>• Replace O-rings and oil seals.</p><p>• Use torque wrench to tighten the screws and plug to the</p><p>specified torque.</p><p>Tightening torque</p><p>Table 21 Tightening torque, unit: Nm</p><p>Item Instruction Thread Size Tightening torque</p><p>24 Screw M12 118</p><p>22 Screw M16 265</p><p>15 Screw M10 64</p><p>44 Tubing PT 1/2 49±4.9</p><p>43 Stopper PT 1/2 44</p><p>40 Tubing PT 3/4 71</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>189</p><p>Assembly</p><p>1 Install the O-ring (13) to the collar (11), and then install it to</p><p>the shaft (10).</p><p>Note! Coat the O-ring (13) with grease (NLGI 2).</p><p>2 Press the spherical bearing (16) down to the shaft (10) with</p><p>press tool.</p><p>Note! Heat the spherical bearings to 110 ° C before installing.</p><p>Fig. 48 Installing, collar</p><p>Fig. 49 Installing, spherical bearings</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>190</p><p>3 Press the oil seal (14) into the cover (12) with press tool.</p><p>Note! Coat the outer diameter of the oil seal with Loctite # 680.</p><p>Be careful not to touch the oil seal lip chips.</p><p>4 Install the shaft components (10) into the tank(19) with a ring</p><p>bolt (M8 × 1.25).</p><p>WARNING!</p><p>The parts are heavy. When operating these components, should</p><p>take appropriate safety precautions.</p><p>5 Install the oil seal protection (A) to the shaft gear (10).</p><p>6 Install the cover assembly (12) to the tank(19), and install</p><p>screws (15).</p><p>Note! Coat the mating surface of tank (12) Loctite glue (Loctite</p><p># 5699).</p><p>Coat the oil seal lip with grease (NLGI2).</p><p>Coat the thread of screw (15) with Loctite 277.</p><p>Fig. 50 Installing, seals</p><p>Fig. 53 Installing, cover</p><p>Fig. 52 Installing, shaft</p><p>Fig. 51 Coating, Loctite agent</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>191</p><p>7.Fix the tank (19) as shown in the figure.</p><p>8 Press the spherical bearing (17) to the tank(19) with press tool.</p><p>Note! Install the both internal and external bearing sleeve with</p><p>press tool.</p><p>9 Install spherical bearings (17), and install the retaining ring (18)</p><p>on the shaft (10).</p><p>Note! After assembling bearings and retaining ring, check</p><p>whether the tank (19) is rotated smoothly.</p><p>10 No. 2 planetary gear transmission device</p><p>- Insert the thrust washer (8) and the second planetary gear (3)</p><p>into the bracket (2).</p><p>- Insert the pin (5) and bushing (6).</p><p>- Tap the spring pin (9) into the pin hole of the bracket (2). After</p><p>this, add the piles on both side of the spring pin (9).</p><p>Fig. 55 Installing, locating ring</p><p>Fig. 56 Installing, No.2 planetary</p><p>gear</p><p>Fig. 54 Installing, spherical bearings</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>192</p><p>Note! Align the pin assembly (4) and spring pin hole of</p><p>bracket(2).</p><p>Install the thrust washers (8) attached with a small amount of</p><p>grease to the gear (3).</p><p>Install spring pin (9), with cutting edge towards the end of pin</p><p>(5).</p><p>Ensure that the gear (3) rotates smoothly.</p><p>11First planetary gear rotating device</p><p>- Install the pin (31) to the bracket (29) with press tool, and</p><p>install the spring pin(36). After this, add the piles on both side of</p><p>the spring pin (9)..</p><p>- Put the thrust washer (27) on the surface of bracket (29).</p><p>- Install the pin (31) on the thrust washer (33), including the</p><p>bearing (32), gear (30), thrust washers (34) and retaining ring</p><p>(35).</p><p>A Pile</p><p>Note! Check the planetary gear (30) is rotated smoothly.</p><p>12 Ring gear and planetary gear assembly</p><p>- Insert joining pins (21) to the chassis (19) of the four positions.</p><p>- Install the ring gear (20) to the chassis (19).</p><p>- Insert the first planetary gear</p><p>unit 2 (1) to the ring gear (20).</p><p>- Insert the thrust ring (25) into the second planetary gear (1),</p><p>then install the epicyclic gear (26).</p><p>Fig. 57 Installing, pin</p><p>Fig. 58 Installing, No. planetary gear</p><p>Fig. 59 Checking, planetary gear</p><p>A pile</p><p>Fig. 60 Installing, No. 2 planetary</p><p>gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>193</p><p>WARNING!</p><p>The parts are heavy. When operating these components, should</p><p>take appropriate safety precautions.</p><p>Note!</p><p>- Coat the mating surface of the tank (19) with Loctite 5699</p><p>silicone rubber.</p><p>- Support the tank (19).</p><p>13 Transmission device of No.1 planetary gear and</p><p>No.1epicyclic gear</p><p>- Install the first planetary gear assembly (28) to the ring gear</p><p>(20).</p><p>- Install the retaining ring (38) into the epicyclic gear (37), and</p><p>insert the planetary gear (28).</p><p>Note! Rotate No.1epicyclic gear, and ensure the shaft (10)</p><p>rotates smoothly.</p><p>Fig. 61 Installing, No. 2 planetary</p><p>gear</p><p>Fig. 62 Installing, No.1 planetary</p><p>gear</p><p>Fig. 63 Installing,No.1 planetary gear</p><p>gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>194</p><p>14 Install the plate (23) to the ring gear (20), and then install the</p><p>screws (22).</p><p>Note! Align the mating marks on tank(19), the ring gear (20)</p><p>and plate (23).</p><p>Coat the mating surface of ring gear (20) with Loctite 5699.</p><p>Coat the thread of screw (22) with Loctite 277.</p><p>Align the installation throttle of the drain pipe and plug holes in</p><p>a straight line.</p><p>15 Install the motor to the plate (23), and then install screws</p><p>(24).</p><p>Note! Align the mating mark(A)on the motor and plates (23).</p><p>Coat the mating surface of covering plate (23) with Loctite</p><p>5699.</p><p>Coat the thread of screw (24) with Loctite 277.</p><p>Fig. 64 Installing, the board</p><p>A Plug hole</p><p>gear</p><p>Fig. 65 Installing, the board</p><p>gear</p><p>Fig. 66 Installing, the motor</p><p>gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>195</p><p>16 Tighten the drain valve (43) to the pipe (44), and then tighten</p><p>the pipe (44) to the tank (19).</p><p>17 Install the pipe (40) to the motor, and then insert the level</p><p>gauge (39).</p><p>Note! Make the oil drain throttle of the pipe toward side.</p><p>Coat the thread of pipe and plug with PTFE tape or Loctite 577.</p><p>Fig. 67 Installing, the pipe</p><p>gear</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>196</p><p>Troubleshooting of rotary gearbox</p><p>Table 24. Rotary gearbox, troubleshooting</p><p>Shaft is</p><p>leaking.</p><p>Contacting surface</p><p>of seal is damaged.</p><p>O-ring is is worn. Replace sealing</p><p>gasket.</p><p>Replace or repair the</p><p>output shaft.</p><p>O-ring is distorted.</p><p>Replace the gear oil</p><p>Housing is</p><p>leaking.</p><p>Cover is damaged.</p><p>Cracks or pin hole</p><p>leaks.</p><p>Replace the cover.</p><p>Replace the housing.</p><p>Mating surface</p><p>is leaking.</p><p>Mating surface is</p><p>damaged.</p><p>Liquid washer is not</p><p>used correctly.</p><p>Replace or repair.</p><p>Remove and reuse it.</p><p>Screw is loose. Tighten it to</p><p>specified torque.</p><p>Plug is loose.</p><p>Tighten it to</p><p>specified torque.</p><p>Gearbox can’t</p><p>rotate.</p><p>Gearbox is damaged.</p><p>Machine is</p><p>overloading</p><p>Replace the gearbox.</p><p>Reduce the load.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>197</p><p>2 Hydrostatic drive (Hydraulic motor,</p><p>including the operating system)</p><p>2.1 Hydraulic motor 1, travel motor</p><p>Travel motor,instruction</p><p>• Hydraulic motor: the hydraulic motor is the design based on</p><p>the variable impact and axial piston, including the paring brake</p><p>valve assembly and the parking brake. Rear flange includes</p><p>balancing valves, check valves, cross safety valve and</p><p>displacement conversion valve.</p><p>• Brake device: Brake devices includes valves, each one has its</p><p>specific function as described in notes.</p><p>• Check valve: check valve is on/off according to oil pressure,</p><p>and guide the oil flow to the counter weight and spools. Check</p><p>valve also prevents cavitation of travel motor.</p><p>• Back pressure valves: Back pressure valve is used to start</p><p>smoothly and stop the travel motor. It controls the traveling</p><p>speed according to the oil output of pump by blocking or</p><p>suppressing circuit of the travel motor to prevent machine out of</p><p>control on the slope.</p><p>• Cross safety valve: Relief valve protects motor and circuit</p><p>from the puncture caused by pressure, keeping starting pressure /</p><p>bypass pressure of hydraulic motor constant.</p><p>• High / Low 2 - Speed moving: The angle of the swash plate</p><p>can be adjusted according to the speed switch and displacement</p><p>Abnormal</p><p>operating sound</p><p>Gear is damaged. Replace the floating</p><p>sealing device.</p><p>Abnormal</p><p>operating</p><p>temperature</p><p>Bearing or gear is</p><p>damaged.</p><p>Gear oil is not</p><p>enough.</p><p>Replace the gearbox.</p><p>Refill the oil to the</p><p>specified level.</p><p>Fig. 46 Travel motor, structure</p><p>1 Hydraulic motor</p><p>2 Brake</p><p>3 Parking brake</p><p>4 Displacement conversion valve</p><p>5 Control valve</p><p>6 Main pump</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>198</p><p>conversion valve and set in two positions: High speed / low</p><p>torque or low speed / high torque.</p><p>• Parking brake device: Traveling /parking brake is applied by</p><p>spring and released by hydraulic.</p><p>Once the spool of travel control valve is in neutral, the brake is</p><p>automatically applied.</p><p>Table 11 Throttle connecting</p><p>Throttle sign Throttle size Throttle</p><p>(A), (B) PF1 Oil supply(oil return)</p><p>(P1) ~ (P4) PT1 / 4 Pressure checking</p><p>(P5) PT 1 / 8 Oil supply of displacement</p><p>conversion valve</p><p>(P) PF 1 / 4 Release pressure of the brake</p><p>(D1) ~ (D2) PF 1 / 2 Draining</p><p>Fig.47 Travel motor structure</p><p>1 High-speed</p><p>2 Low-speed</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>199</p><p>Table 12 Direction of rotation</p><p>Import Export X-axis view</p><p>A B Clockwise</p><p>B A Counterclockwise</p><p>Fig.48 Travel motor, cylinder and piston</p><p>2-shaft 3 swash plate 4 cylinder 5 piston 6 piston sets 7 fixed plate</p><p>8 thrust ball 9 valve plate 10 washers 11 roller 12 brake piston 13 brake springs</p><p>14 spring 15Friction plate 16 mating piece 32 oil seal 35 O-ring 39 O-ring 45</p><p>clampring</p><p>49 bearing 50 bearing 51 needle 61 piston</p><p>62 piston set 67steel ball 71 parallel pin 93 spring</p><p>101Release valve piston 102 well 103 holder</p><p>104 plug 105 shims 106 Spring 108 O-ring</p><p>109 O-ring 110 O-ring 111 prop ring 117 prop ring</p><p>119 O-ring 120 seals 201rear flange 223 balance spool</p><p>224 plug 225 locking device226 plug 227 Check Valve</p><p>228 Spring 230 Spring 236 O-ring 237 O-ring</p><p>241 parallel pin243 screws 246 plug 252 plug</p><p>254 plug 257 plug 263 spools 266 Spring</p><p>268 ball 279 filter 280 plug 281 Pistons</p><p>282 plug 283 O-ring 284 O-ring 285 ball</p><p>294 O-ring 295 O-ring 296 O-ring 297 hole port</p><p>298 plug 299 nameplate 302 Main shaft</p><p>327 O-ring 329 O-ring 342 parallel pin</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>200</p><p>Operating, the hydraulic motor</p><p>Pressurized oil is sent from the hydraulic pump through the</p><p>control valve into the throttle on the rear flange (201) and flows</p><p>to the half part of cylinder body (4) through the valve (9).</p><p>Pressurized oil in the cylinder (4) pushes the piston out and</p><p>produces force [F (kgf) = P (kgf/cm</p><p>2</p><p>) × A (cm</p><p>2</p><p>)]. The force acts</p><p>the swash plate (3) on the fixed shaft (2) with certain angle (a °),</p><p>and this force will be divided two sub-force (F2 and F3).</p><p>In the sub-force, the radial force (F3) generates torque (T = F3 ×</p><p>ri), respectively, relative to (Y1) - (Y2).</p><p>The total torque {T = Σ (F3 × ri)} will be sent to the cylinder</p><p>body (4) by the piston (5), resulting in a rotational force to rotate</p><p>the cylinder body bonding to the output drive shaft (2) with</p><p>spline.</p><p>Upper dead point throttle is the starting point of the rotation</p><p>period: piston rotates180 ° and gets out of the cylinder, rotate the</p><p>swash plate to slide to the next dead point, and then get out of</p><p>the cylinder, and release the low pressure oil to the circuit.</p><p>Fig. 49 Hydraulic moto, operating</p><p>TDC--Top dead center</p><p>BDC--Bottom dead center</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>201</p><p>Operating, brake valve</p><p>Operations (Brake release)</p><p>When pressurized oil is supplied to the throttle (A), it opens the</p><p>check valve (227) and flows into inlet throttle (C) of the</p><p>hydraulic motor.</p><p>Meanwhile, the pressurized oil goes into the chamber (b)</p><p>through the channel (a) and through a small hole of the balance</p><p>spool (223). With the pressure of the chamber (b)increasing, the</p><p>spool (223) moves to the left, and connect the throttle (D) and</p><p>exit (B), so that the oil flow from the motor returns to the tank to</p><p>rotate the hydraulic motor. According to movement of spool</p><p>(223), pressurized oil flows to the throttle (P) and throttle (S).</p><p>Oil flow overcomes the spring force by pushing the piston (12)</p><p>to release parking brake by throttle (P). If the supply throttle and</p><p>oil return throttle exchange with each other, the motor will be</p><p>running in the opposite direction.</p><p>Stopping or stopping to rotate(Brake)</p><p>When oil flow from the main control valve is blocked, the</p><p>pressure of the throttle (A) will rapidly decrease. When this</p><p>happens, the oil in the chamber (b) will spill through the channel</p><p>(a) and through the hole in the spool (223),then reaches the</p><p>throttle (A); At the same time, the spring force (228) acts on the</p><p>locking device (225 ), moves the balance coil (223) to right</p><p>(neutral position).</p><p>Returning speed of spool (223) is controlled by the rear pressure</p><p>generated by the throttle of the channel (a). When the spool</p><p>returns to the neutral position completely, channels leading to</p><p>the orifice (A, B) will be blocked to make the oil left in the</p><p>motor to prevent rotation.</p><p>However, the inertia will make the motors rotate continously,</p><p>resulting in the pressure is surging at oil return port (D). (This is</p><p>the condition of dynamic braking).</p><p>Pressurized oil flows through the left release valve piston (101),</p><p>to the hole of the chamber (f), and then to the chamber (g) and</p><p>start to move the piston (281) to the right. When the piston</p><p>reaches the end of stroke, the pressure of chamber(g and f)</p><p>Fig.50 Brake valve releasing</p><p>Fig.51 Brake valve acting</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>202</p><p>begins to rise and react on the valve piston (101). At this point,</p><p>open pressure of release valve is higher than the normal release</p><p>set pressure. This process is used to buffer the pressure spikes</p><p>when the valve is open.</p><p>With the hydraulic oil of throttle (D) overcomes the spring of</p><p>relief valve and the pressurized oil in the chamber(g and f)</p><p>works together, the right release valve is opened, and connect</p><p>the throttle(D and C) to prevent abnormal increase of pressure</p><p>and cavitation phenomena.</p><p>The oil pressure of throttle (D) decreases, the release valve is</p><p>closed; However, if the pressure rises above the setting pressure</p><p>of relief valve, pressure reducing cycle will repeat. Secondary</p><p>control of release valve will stop the hydraulic motor smoothly.</p><p>Over speeding</p><p>When the machine travels on the slope, the machine's weight</p><p>(inertia) tends to rotate the hydraulic motor faster than the oil</p><p>speed provided by hydraulic pump. This phenomenon is called</p><p>over speeding.</p><p>In this case, the hydraulic pressure of the motor drops, and</p><p>move the balance spool to the neutral position to block the</p><p>returning oil from throttle (D) to throttle (B). As the channel is</p><p>closed, it forms a throttle effect to form a counter-pressure on</p><p>the throttle (D) to slow down the hydraulic motor, until the force</p><p>of pump flow is acted on the motor.</p><p>Operating, parking brake</p><p>Travelling</p><p>When the traveling operation lever is operated, the pressurized</p><p>oil from the pump pushes the balancing spool (223), open the</p><p>circuit leading to the brake chamber (a) of brake piston (12).</p><p>When the oil pressure gets to about 6 kgf/cm</p><p>2</p><p>, it starts to push</p><p>brake piston (12) into the rear flange (201) to overcome the</p><p>force of brake spring (13). At the same time, the piston moves</p><p>away from the friction plate (15) and the mating piece (16) to</p><p>Fig.53 Parking brake, travelling</p><p>Fig.52 Brake valve, over speeding</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>203</p><p>separate them, and release the braking force of the control</p><p>cylinder (4).</p><p>Stopping</p><p>When the traveling control lever is in neutral, balanced spool</p><p>will return to its neutral position, and cuts off the circuit leading</p><p>to the brake chamber (a).</p><p>Oil of chamber (a) is drained to the tank through a orifice on the</p><p>brake valve. This orifice is used to adjust to slow down the</p><p>drained oil and prevent the brake spring from acting the brake</p><p>suddenly.</p><p>When the pressure drops to 6 kgf/cm</p><p>2</p><p>, the brake spring (13) will</p><p>push the brake piston (12) to the right to connect the engagement</p><p>piece (16) and the friction plate (15) on the main shaft (302) of</p><p>gear box and the cylinder body (4).</p><p>When the plates are squeezed together, the formed friction force</p><p>would exert a brake torque of 40.6 kgf · m on the output shaft</p><p>(2)of motor..</p><p>Operating, displacement conversion valve</p><p>Low speed</p><p>When the travelling solenoid valve is disconnected (ph), the</p><p>servo-hydraulic flow leading to the throttle (D) is cut off.</p><p>Hydraulic flow of the throttle (A, B) moves spool (263) up to</p><p>overcome the force of the spring (266), and blocked the</p><p>throttle(C).</p><p>Meanwhile, the pressurized hydraulic oil in the</p><p>chamber (P) is drained to the motor box, which can</p><p>allow the force acting on the rotating components to</p><p>move the swash plate (3) to the maximum angle θ1 of</p><p>swash plate, and contact with the surface Y. Piston</p><p>stroke "increases", rotation of cylinder "reduces",</p><p>resulting in "high torque" and "low speed."</p><p>Fig.55 Displacement conversion valve, low speed</p><p>Fig.54 Parking brake, stopping</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>204</p><p>High speed</p><p>When the solenoid valve is connected (ph), servo-hydraulic oil</p><p>will flow to the throttle (D).</p><p>Hydraulic flow (40kgf/cm2) of the throttle (D) overcomes the</p><p>spring (266) force to move the spool (263) down and overcomes</p><p>hydraulic oil pressure the throttle (A, B) to open the throttle (C).</p><p>Pressurized oil flows from the throttle (C) to the chamber (P)</p><p>and push the piston (61) to move swash plate (3) to a minimum</p><p>tilt angle θ2 to touch the x plane. The stroke of piston reduces,</p><p>the rotation of cylinder increases, resulting in high-speed/low</p><p>torque.</p><p>When moving at high speed, the speed switches to low speed</p><p>automatically.</p><p>When the load (traction) increases at high-speed, the oil pressure</p><p>of throttle (A, B) will increase.</p><p>If the pressure is about 260 kgf/cm2, it will overcome the total</p><p>force (40 kgf/cm</p><p>2</p><p>) of servo-hydraulic flow in the spring (266)</p><p>and throttle ( D)</p><p>........................................................................................................................................................................... 96</p><p>Measuring ............................................................................................................................................................................ 97</p><p>Rotation speed ......................................................................................................................................................................... 97</p><p>Preparation ........................................................................................................................................................................... 97</p><p>Rotation towards left/right at idle .......................................................................................................................................... 98</p><p>Preparation ........................................................................................................................................................................... 98</p><p>Measuring ............................................................................................................................................................................ 99</p><p>Measuring clearance of bearing ............................................................................................................................................. 99</p><p>Measuring .......................................................................................................................................................................... 100</p><p>Installation conditions ........................................................................................................................................................ 100</p><p>Walking speed ....................................................................................................................................................................... 102</p><p>Preparation ......................................................................................................................................................................... 102</p><p>Measuring .......................................................................................................................................................................... 102</p><p>Performance of moving straight .......................................................................................................................................... 103</p><p>Preparation ......................................................................................................................................................................... 103</p><p>Measuring .......................................................................................................................................................................... 103</p><p>Track running speed ............................................................................................................................................................. 104</p><p>Preparation ......................................................................................................................................................................... 104</p><p>2.3 Emergence measures ......................................................................................................................................... 104</p><p>2.3.1 Jump connection starting ............................................................................................................................................ 104</p><p>Start the engine with the actuating cable ............................................................................................................................ 104</p><p>Ⅲ ENGINE SYSTEM..................................................................................................................................................... 106</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>IV</p><p>1 OVERVIEW OF THE ENGINE ....................................................................................................................................... 106</p><p>BF6M2012C Engine .............................................................................................................................................................. 106</p><p>Engine characteristics curves ............................................................................................................................................... 109</p><p>BF6M2012C engine ........................................................................................................................................................... 109</p><p>Basic examination, engine..................................................................................................................................................... 109</p><p>Purpose of the basic examination ....................................................................................................................................... 109</p><p>Testing of the basic examination ....................................................................................................................................... 110</p><p>Troubleshooting .................................................................................................................................................................... 110</p><p>1.1 Cylinder head ..................................................................................................................................................... 111</p><p>Cylinder cover, indication .................................................................................................................................................... 111</p><p>BF6M2012CEngine ........................................................................................................................................................... 111</p><p>Valve ....................................................................................................................................................................................... 112</p><p>Decisive cylinder cover gasket .............................................................................................................................................. 112</p><p>Measuring projection of piston .......................................................................................................................................... 112</p><p>Installing cylinder cover ....................................................................................................................................................... 113</p><p>Tool.................................................................................................................................................................................... 113</p><p>Tightening sequence .......................................................................................................................................................... 113</p><p>1.2 Pistons ................................................................................................................................................................ 114</p><p>Piston, indication ................................................................................................................................................................... 114</p><p>BF6M2012C Engine .......................................................................................................................................................... 114</p><p>Piston rings, indication ......................................................................................................................................................... 115</p><p>Piston cooling ......................................................................................................................................................................... 115</p><p>(ph) to move the spool (263) up and block the</p><p>throttle (C .) Meanwhile, the oil in the chamber (P) is</p><p>drained to the motor housing, and rotate the swash plate</p><p>(3) to the maximum tilt angle θ1, contact with the surface</p><p>Y, and the motor is running at low speed.</p><p>Fig.57 Displacement conversion valve, auto speed conversion</p><p>Fig.56 Displacement conversion valve, high speed</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>205</p><p>Travel motor, operation precautions</p><p>Installing</p><p>• Check that the mating surface is clean.</p><p>• Check that the motor is positioned in the frame correctly</p><p>• If the gear that will be installed to the frame is very tight,</p><p>install the components into frame evenly with the mounting</p><p>screws.</p><p>•Tighten the screws to the specified torque with a approach of</p><p>crossing in stages.</p><p>• When installing sprocket teeth, follow the same precautions.</p><p>Table 14</p><p>Screw Quantity Dimension Torque7, kgf / m</p><p>A 30 M16(P2.0) 27±3</p><p>B 22 M16(P2.0) 27±3</p><p>Note! Screws must be strength10.9 (Tensioning strength: 100</p><p>kgf/mm</p><p>2</p><p>) or higher.</p><p>Pipeline system</p><p>• Before connecting the pipelines to the motor, check and</p><p>confirm there is no impurities in the throttle or the pipe.</p><p>• Before starting, clear the air in the lines and motors.</p><p>• Before starting, fill the motor housing with the specified</p><p>hydraulic oil.</p><p>Note! Hydraulic oil capacity: 1.7 lit.</p><p>• Check the discharge pressure is in the chassis specifications.</p><p>Note! Pressure of housing: 2 ~ 7 kgf / cm</p><p>2</p><p>• Check whether the direction of rotation is right by operating</p><p>the handle.</p><p>Lubricating</p><p>Important! Operating the travelling function, fill the</p><p>transmission to the correct oil level with the specified gear oil.</p><p>Travel motor, maintenance standards</p><p>Maintenance and replacement standards of parts</p><p>The following standard about components maintenance</p><p>capability can be decided according to the measurement before</p><p>Fig.58 Installation location</p><p>A Screw, from gear box to the frame</p><p>B Screw, from sprocket gear to gear box</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>206</p><p>disassembly. However, they are general standards, and when the</p><p>parts presents excessive external damage or discoloration, the</p><p>primary thing is to determine the extent of replacement based on</p><p>the average residual life span of parts and components.</p><p>Gasket</p><p>Replace the oil seals and O-ring, although they did not seem</p><p>damaged.</p><p>Replacement standards of parts</p><p>Replace all damaged parts or those not within the range of</p><p>values.</p><p>Table 15.Replacement standard of components</p><p>No. Name Condition Standard</p><p>value</p><p>Allowed</p><p>value</p><p>2 Shaft The surface wear of contact framework seal(32).</p><p>Wear of spline.</p><p>3 Swash plate The sliding surface of piston sleeve (6) is damaged.</p><p>The sliding surface of piston sleeve (62) is damaged.</p><p>4 Cylinder</p><p>body</p><p>Wear of spline.</p><p>Piston bore is worn or has scratches.</p><p>The sliding surface of contact valve (9) is damaged or</p><p>worn unevenly.</p><p>Linear</p><p>space</p><p>28 ~</p><p>45μm</p><p>Linear</p><p>space</p><p>50μm</p><p>5 Piston Axial gap exists between the piston (5) and piston</p><p>sleeve (6).</p><p>Excessive or uneven wear of the piston sleeve.</p><p>Gap</p><p>0.05mm</p><p>Gap</p><p>0.05mm 6 Piston</p><p>sleeve</p><p>7 Fixed plate The uneven wear of outer edge.</p><p>8 Thrust ball The spherical sliding part of the fixed plate (7) is worn</p><p>unevenly.</p><p>Sliding surface has scratches or tints of uneven wear.</p><p>9 Valve</p><p>pieces</p><p>15 Friction</p><p>pieces</p><p>Wear of micro-groove pattern.</p><p>Sliding surface has scratches.</p><p>Edge is damaged.</p><p>Plate is bent.</p><p>Braking</p><p>torque</p><p>＜40.6</p><p>kgf · m</p><p>Braking</p><p>torque</p><p>＜40.6</p><p>kgf • m</p><p>16 Mating</p><p>pieces</p><p>49,50 Bearing Pitting / lobes appear on the bearing sleeve or ball or</p><p>roller.</p><p>Manual rotation is not smooth.</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>207</p><p>101 Piston of</p><p>release</p><p>valve</p><p>Sliding surface is damaged.</p><p>102 Well Surface of base is damaged.</p><p>The gap relative to the piston (101) is too large.</p><p>201 Rear flange Balance spool (223) or hole is damaged.</p><p>The gap between hole and the spool is too large.</p><p>Piston (281) or hole is damaged.</p><p>The gap from hole to the spool is too large.</p><p>Surface of check valve (227) or base is damaged or worn.</p><p>Sealing surface of valve / angle is abnormal.</p><p>Linear</p><p>space</p><p>10 ~</p><p>20μm</p><p>Linear</p><p>space</p><p>25μm</p><p>223,26</p><p>3</p><p>Spool Sliding surface or hole is damaged.</p><p>281 Piston Sliding surface is damaged.</p><p>Table16.General tool</p><p>No. Explain Size Quantity</p><p>1 General wrench 5 mm、10 mm、8 mm、14 mm 1</p><p>1</p><p>2 1/2″ drive，3/4″ drive 1</p><p>3 Torque Wrench About 280 n·m</p><p>About 850 n·m</p><p>1</p><p>1</p><p>4 Socket wrench 32、41 mm 1</p><p>5 L-shape Socket wrench 5、6、8、10、14、19 mm 2</p><p>6 Hammer Calibrated 12# 1</p><p>7 Plastic hammer L = 300 mm 1</p><p>8 Screwdriver L = 150 mm 1</p><p>9 Clamp plier Extending</p><p>Retracting</p><p>1</p><p>10 Crane Lifting capacity≥300kg</p><p>11 Ring bolts M16</p><p>PF 1 / 2</p><p>12 Desk press Working capacity≥300kg</p><p>13 Compressed air</p><p>Hose and nozzle</p><p>Spraying force 3 ~ 5 kgf / cm</p><p>2</p><p>14 Oil draining span W450 × D300 × H120</p><p>15 Heating container Temperature increasing capacity: ≥100°C</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>208</p><p>Volume:≥500 × 500 × 500（mm）</p><p>16 Leather gloves</p><p>17 Sealing tap</p><p>18 Micro-depth gauge Measurement range: 30 mm</p><p>Min scale:0.01mm</p><p>19 Gap gauge Measurement range: 0.04 ~ 0.3 mm</p><p>20 Grinding machine Cast cutting</p><p>21 Air chisel BRH - 8（Compressed air 6 kgf / cm</p><p>2）</p><p>Table17.Special tool</p><p>No. Instruction Quantity No, Quantity</p><p>1 Fixer(Ⅰ)</p><p>Serial number:8932 - 00160</p><p>1 4Elevator</p><p>Serial number:8932 - 00210</p><p>1</p><p>2 Fixer(Ⅱ)</p><p>Serial number:8932 - 00150</p><p>2</p><p>3 Fixer(Ⅲ)</p><p>Serial</p><p>number: 8933 - 00320</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>209</p><p>Pressure relief valve of travel motor, replacing</p><p>1. Park the machine parked in the maintenance position F, refer</p><p>to maintenance position.</p><p>2 When the engine is running, hydraulic pipe is under high</p><p>pressure. Stop the machine and drain the residual hydraulic</p><p>pressure within the pipeline, the method is turn the ignition</p><p>switch (ON), and operate the operation lever smoothly 3 to 4</p><p>times.</p><p>Note! Drain the residual hydraulic pressure within the pipeline,</p><p>the method is to press air respirator on the hydraulic tank.</p><p>3 Remove the screw (1) and motor cover (2).</p><p>4 Remove pressure relief valve (1)of track motor.</p><p>5 Install the new pressure relief valve</p><p>6 Check pressure relief valve (1)of track motor, if necessary,</p><p>adjust it.</p><p>7 Install the motor cover.</p><p>Travel motor, disasembly</p><p>Note</p><p>• Before removing, clean the gear box components completely.</p><p>• Choose a clean work area.</p><p>• Mark the components that are assembled together with the</p><p>correct position in order to facilitate assembly.</p><p>• Be careful not to mix the secondary components of parts,</p><p>namely, planetary gear bearings, gears and thrust washers.</p><p>• Thoroughly clean all internal parts and housings.</p><p>• Check and analyze all failures.</p><p>1 Before the demolition, install the motor on a rotary bench.</p><p>Drain the hydraulic oil and gear oil.</p><p>Note! Oil pan size: 4 lit, 8 lit...</p><p>Fig.59 Removing, motor cover</p><p>Fig.60 Removing, valve</p><p>Fig.61 Travel motor</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>210</p><p>2 Remove the pressure relief valve from the rear flange (201).</p><p>Remove O-ring (108), (109), (110) and prop ring (111), (117)</p><p>from pressure relief valve.</p><p>Note! Do not reuse O-ring after removing.</p><p>3 Remove the screw (243).</p><p>4 Remove the flange (201) from the main shaft (302).</p><p>Note! Be careful not to remove the shaft (2).</p><p>Fig.63 Screws, removing</p><p>Fig. 62 Release valve, removing</p><p>Fig. 64 Rear flange, removing</p><p>Service</p><p>1.3 Valves mechanery .............................................................................................................................................. 116</p><p>Valves, indication .................................................................................................................................................................. 116</p><p>Valve , adjusting .................................................................................................................................................................... 116</p><p>Assembly ................................................................................................................................................................................ 119</p><p>1.5 Engine Assembly ................................................................................................................................................ 120</p><p>Engine Assembly ................................................................................................................................................................... 120</p><p>2 LUBRICATION SYSTEM ............................................................................................................................................... 121</p><p>Lubrication system, indication ............................................................................................................................................. 121</p><p>Oil flow process chart ........................................................................................................................................................ 121</p><p>Diagram, oil circuit ............................................................................................................................................................ 122</p><p>Lubrication system, working principle................................................................................................................................ 122</p><p>Oil pipeline ........................................................................................................................................................................ 122</p><p>Lubricating oil pump ......................................................................................................................................................... 123</p><p>Oil cooling tank ................................................................................................................................................................. 124</p><p>3 FUEL SYSTEM ............................................................................................................................................................. 125</p><p>3.1 Overview ............................................................................................................................................................. 125</p><p>Fuel system, indication .......................................................................................................................................................... 125</p><p>Fuel flow system diagram .................................................................................................................................................. 125</p><p>Fuel injection system, indication .......................................................................................................................................... 127</p><p>Oil supply pump ................................................................................................................................................................ 127</p><p>3.2 Fuel pump; filter; oil mesh ................................................................................................................................ 128</p><p>Fuel system, leakage .............................................................................................................................................................. 128</p><p>Oil supply pump, replacing .................................................................................................................................................. 128</p><p>Fuel filter, replacing .............................................................................................................................................................. 129</p><p>Additional extra oil filter, replacing .................................................................................................................................... 130</p><p>3.3 Fuel Tank ........................................................................................................................................................... 131</p><p>Description of the fuel tank .................................................................................................................................................. 131</p><p>3.4 Injectors; oil supply pipelines ............................................................................................................................ 132</p><p>Injector, indication ................................................................................................................................................................ 132</p><p>Injector, replacing one .......................................................................................................................................................... 133</p><p>Fuel rail pressure, checking .................................................................................................................................................. 133</p><p>Test conditions ................................................................................................................................................................... 133</p><p>Engine starting conditions .................................................................................................................................................. 134</p><p>The engine is running, but without load. ............................................................................................................................ 135</p><p>In the case that the load of engine is too high .................................................................................................................... 135</p><p>4 AIR INTAKE SYSTEM; EXHAUST SYSTEM ................................................................................................................... 136</p><p>4.1 Overview ............................................................................................................................................................. 136</p><p>Air intake system, instruction .............................................................................................................................................. 136</p><p>Exhaust System, instruction ................................................................................................................................................. 137</p><p>Seal clamp, installation ...................................................................................................................................................... 137</p><p>4.2 Air cleaner with the connecting pipe; air preheater ......................................................................................... 138</p><p>Preheating coil, replacing ..................................................................................................................................................... 138</p><p>4.3 Inflatable cooler and connecting pipe ............................................................................................................... 138</p><p>Boost air cooler, indication ................................................................................................................................................... 138</p><p>Boost air cooler connections (hoses, rigid tube), replacing ................................................................................................ 139</p><p>5 COOLING SYSTEM ......................................................................................................................................................</p><p>140</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>V</p><p>5.1 Overview ............................................................................................................................................................. 140</p><p>Cooling System,instruction ................................................................................................................................................... 140</p><p>Cooling system, operating..................................................................................................................................................... 141</p><p>Coolant .............................................................................................................................................................................. 141</p><p>Draining the cooling system .............................................................................................................................................. 143</p><p>5.2 Radiator, including assembly and connection .................................................................................................. 143</p><p>Coolant, replacing ................................................................................................................................................................. 143</p><p>Draining the coolant........................................................................................................................................................... 143</p><p>Filling the coolant in the cooling system ........................................................................................................................... 144</p><p>5.3 Coolant pumps; thermostat ............................................................................................................................... 144</p><p>Thermostat, replacing ........................................................................................................................................................... 144</p><p>Thermostat, checking ............................................................................................................................................................ 145</p><p>5.4 Fan; fan cover; fan coupler .............................................................................................................................. 146</p><p>Fan belt and / or generator belt, compressor belt, replace all belts .................................................................................. 146</p><p>6 ENGINE CONTROL ...................................................................................................................................................... 148</p><p>6.1 Overview ............................................................................................................................................................. 148</p><p>Normal conditions (auto position)........................................................................................................................................ 148</p><p>Emergency ......................................................................................................................................................................... 148</p><p>6.2 Speed control ...................................................................................................................................................... 149</p><p>Engine speed control switch description ............................................................................................................................. 149</p><p>Engine speed control switch, checking ................................................................................................................................ 150</p><p>Checking ............................................................................................................................................................................ 150</p><p>Ⅳ POWER TRANSMISSION ....................................................................................................................................... 151</p><p>1 GEAR BOX .................................................................................................................................................................. 151</p><p>1.1 Track gearbox .................................................................................................................................................... 151</p><p>Track gearbox, instruction ................................................................................................................................................... 151</p><p>Notes of track gearbox operation ......................................................................................................................................... 154</p><p>Installation ......................................................................................................................................................................... 154</p><p>Tightening torque ............................................................................................................................................................... 155</p><p>Replacement procedure of gear oil .................................................................................................................................... 155</p><p>Operation Checking ........................................................................................................................................................... 156</p><p>Track gearbox, maintenance standards .............................................................................................................................. 156</p><p>Seal washer ........................................................................................................................................................................ 156</p><p>Components, replacement standard ................................................................................................................................... 156</p><p>Common tools .................................................................................................................................................................... 157</p><p>Special tools ....................................................................................................................................................................... 158</p><p>Gasket thickness measurement fixtures .............................................................................................................................. 158</p><p>Track gear box, removing .................................................................................................................................................... 158</p><p>Track gear box, installing ..................................................................................................................................................... 159</p><p>Track gear box, replacing the lid ......................................................................................................................................... 160</p><p>Track gearbox removing ...................................................................................................................................................... 161</p><p>Track gear box, assembly ..................................................................................................................................................... 165</p><p>Preparation ......................................................................................................................................................................... 165</p><p>Tightening torque ............................................................................................................................................................... 165</p><p>Track gearbox, troubleshooting ........................................................................................................................................... 171</p><p>1.2 Rotary</p><p>gearbox + rotary pinion gear shaft ........................................................................................................ 172</p><p>Rotary gear box, instruction ................................................................................................................................................ 172</p><p>Model Code ....................................................................................................................................................................... 172</p><p>Rotary gear boxes, cross sections ...................................................................................................................................... 173</p><p>Function ............................................................................................................................................................................. 174</p><p>Operating ........................................................................................................................................................................... 174</p><p>Turn gearbox, lubricating .................................................................................................................................................... 175</p><p>Notes about lubrication ...................................................................................................................................................... 175</p><p>Maintenance standard of rotary gear box ........................................................................................................................... 176</p><p>Seals ................................................................................................................................................................................... 176</p><p>Replacement standard of parts ........................................................................................................................................... 176</p><p>General Tools..................................................................................................................................................................... 178</p><p>Special tools ....................................................................................................................................................................... 179</p><p>Rotary gearbox, disassembling ............................................................................................................................................ 184</p><p>Note ................................................................................................................................................................................... 184</p><p>Disassembly ....................................................................................................................................................................... 184</p><p>Rotary gear box assembly..................................................................................................................................................... 187</p><p>Note ................................................................................................................................................................................... 187</p><p>Tightening torque ............................................................................................................................................................... 188</p><p>Assembly ........................................................................................................................................................................... 189</p><p>Troubleshooting of rotary gearbox ...................................................................................................................................... 196</p><p>2 HYDROSTATIC DRIVE (HYDRAULIC MOTOR, INCLUDING THE OPERATING SYSTEM) .............................................. 197</p><p>Service Manual──LG6210E&6225E Hydraulic Excavator</p><p>VI</p><p>2.1 Hydraulic motor 1, travel motor ........................................................................................................................ 197</p><p>Travel motor,instruction ...................................................................................................................................................... 197</p><p>Operating, the hydraulic motor .......................................................................................................................................... 200</p><p>Operating, brake valve ....................................................................................................................................................... 201</p><p>Operating, parking brake ................................................................................................................................................... 202</p><p>Operating, displacement conversion valve ......................................................................................................................... 203</p><p>Travel motor, operation precautions ................................................................................................................................... 205</p><p>Installing ............................................................................................................................................................................ 205</p><p>Pipeline system .................................................................................................................................................................. 205</p><p>Lubricating ......................................................................................................................................................................... 205</p><p>Travel motor, maintenance standards ................................................................................................................................. 205</p><p>Maintenance and replacement standards of parts ............................................................................................................... 205</p><p>Gasket ................................................................................................................................................................................ 206</p><p>Replacement standards of parts .......................................................................................................................................... 206</p><p>Pressure relief valve of travel motor, replacing .................................................................................................................. 209</p><p>Travel motor, disasembly ..................................................................................................................................................... 209</p><p>Note ................................................................................................................................................................................... 209</p><p>Travel motor, assembly ........................................................................................................................................................ 217</p><p>Note ................................................................................................................................................................................... 217</p><p>Brake, assembly ................................................................................................................................................................. 218</p><p>Troubleshooting of track motor ........................................................................................................................................... 226</p><p>2.2 Hydraulic motor 2, rotary motor ....................................................................................................................... 229</p><p>Rotary motor instruction ......................................................................................................................................................</p><p>229</p><p>Rotation system, components... ......................................................................................................................................... 230</p><p>Rotary motor, structure ...................................................................................................................................................... 230</p><p>Rotary motor working principle .......................................................................................................................................... 232</p><p>Hydraulic motor ................................................................................................................................................................. 233</p><p>Anti-cavitation valve .......................................................................................................................................................... 234</p><p>Valve (Model: KRD22EK10C) ......................................................................................................................................... 234</p><p>Rebound damping valve .................................................................................................................................................... 236</p><p>Rotation brake .................................................................................................................................................................... 238</p><p>Maintenance standards of rotary motor ............................................................................................................................. 239</p><p>Lubrication and exhaust of rotary motor ............................................................................................................................ 239</p><p>Note about lubrication ....................................................................................................................................................... 239</p><p>Maintenance and replacement standard of parts ................................................................................................................ 239</p><p>Gasket ................................................................................................................................................................................ 239</p><p>Replacement standards of parts .......................................................................................................................................... 240</p><p>Cross safety valve, pressure adjustment ............................................................................................................................. 241</p><p>General Tools..................................................................................................................................................................... 242</p><p>Special tool ........................................................................................................................................................................ 242</p><p>Rotary motor, replace ........................................................................................................................................................... 242</p><p>Pressure relief valve of travel motor, replacing .................................................................................................................. 242</p><p>Rotary motor has been removed, replacing the seals ......................................................................................................... 244</p><p>Rotary motor, replacing the brake piston seals .................................................................................................................. 245</p><p>Pressure reducing valve of rotary motor, replacing ........................................................................................................... 247</p><p>Rotary motor, disassembly ................................................................................................................................................... 248</p><p>Rotating motor assembly ......................................................................................................................................................... 251</p><p>Tightening torque. ................................................................................................................................................................... 251</p><p>Rotary motor troubleshooting ................................................................................................................................................. 256</p><p>Determine the possible causes ................................................................................................................................................. 256</p><p>Be careful of dirt ................................................................................................................................................................... 256</p><p>Operating components .......................................................................................................................................................... 256</p><p>Motor troubleshooting .......................................................................................................................................................... 256</p><p>Check the oil in the tank ....................................................................................................................................................... 256</p><p>Abnormal noise ..................................................................................................................................................................... 256</p><p>Pressure measurement of all the components ..................................................................................................................... 256</p><p>Measuring the displacement of motor ................................................................................................................................. 256</p><p>Motor can’t rotate ................................................................................................................................................................. 257</p><p>Rotation of motor is reverse. ................................................................................................................................................ 257</p><p>Rotation speed is not up to the set value. ............................................................................................................................. 258</p><p>Torque is not enough. ........................................................................................................................................................... 258</p><p>Hydraulic motor slides too much. ........................................................................................................................................ 258</p><p>Hydraulic is leak from the seals. .......................................................................................................................................... 259</p><p>Hydraulic is leak from the mating surface. ......................................................................................................................... 259</p><p>2.3 Hydraulic pump includes couplers, running including the operation system. .................................................... 260</p><p>Flexible coupling..................................................................................................................................................................... 260</p><p>Flexible coupling, removing ................................................................................................................................................. 261</p><p>Flexible coupling, installation ............................................................................................................................................... 261</p><p>2.4.Rotary joints; pipeline ........................................................................................................................................</p>