Maintenance point


Attention

Park the machine as follows before maintenance:

1
Park the machine on flat ground.
2
Lower the bucket onto ground.
z


Attention
3. 3
Set the engine speed to idling speed and run it for 3 minutes.
4.
Turn the start switch to OFF position and take off the key
5.
Push the pilot control lever to LOCK position.
6.
Attach a DO NOT OPERATE tag to right hand control lever if the
machine is not operated.


Table of contents
1.
The Recommended oil.
2.
Main maintenance item and locatoin .
3.
Maintenance Intervals.
4.
Maintenance point of every system.
4.1
Diesel engine system
4.2
Swing and Travel Reductions

1.

25L

412L

2#

-2040-4104F

EP2

-2040-4104F

EP2RO2

-2040-4104F

15W-40 API CG-4

-2020-468F

130015W-40 API CG-4

-104014104F

10W-30 API CG-4

-2035-495F

15W-40 API CG-4

-104014104F

ASTM D975 NO.1

-200-432F

ASTM D975 NO.2

-104014104F

30

100%4258

-3040-22104F

SAE85W-140API GL4-
SAE85W-90API GL4-

-2040-4104F

ISO VG 32

-2020-468F

ISO VG 46

-2040-4104F

ISO VG 68

-104014104F

: 230L
:330L

:
5

1.The Recommended oil

Kinds of oil
plants

lubricate

Engine oil

Fuel

quantity

According to
require

25L

412L

Oil brand/Specification

Circumstance temperature

2# MSO2 lithium based grease

-2040-4104F

Mobile EP2

-2040-4104F

Shell EP2 or RO2

-2040-4104F

Mobile 1# 5W-40API CG-4

-2020-468F

Mobile 130015W-40API CG-4

-104014104F

Shell 10W-30API CG-4

-2035-495F

Shell 15W-40API CG-4

-104014104F

ASTM D975 NO.1

-200-432F

ASTM D975 NO.2

-104014104F

Coolant

30

SHELL antifreeze(100 primary) and water

42:58

-3040-22104F

Gear oil

According to
require

SAE85W-140API GL4-Swing reduction

SAE85W-90API GL4-Travel reduction

-2040-4104F

ISO VG 32

-2020-468F

ISO VG 46

-2040-4104F

ISO VG 68

-104014104F

Hydraulic oil

Tank: 230L
System :330L

Note: " " used by the manufacturer after the machine is newly produced


Table of contents
1.
The Recommended oil.
2.
Main maintenance item and locatoin .
3.
Maintenance Intervals.
4.
Maintenance point of every system.
4.1
Diesel engine system
4.2
Swing and Travel Reductions

2.
Main maintenance item and location

Open the right doormay be check and maintenance on the ground

Fuel fine-filter

Fuel prefilter

Engine oil filter

Check hydraulic oil level

daily check

Upgrade pump
of fuel

Oil-water separator
filter

8
The water drain
balve of fuel tank:
everyday or every 8
hour

Pilot
filter

The view of after

open the right
door
8

2.
Main maintenance item and location

Open the back-left doormay be check and maintenance on the ground

Ignition switch

The view of after open

the back-left door

2.
Main maintenance item and location

Open the front-left doormay be check and maintenance on the ground

maintenance air filter

Inside filter
outside filter
50500
Clean every 50 hours,replace
every 500 hours

outside filter of
air-condition

The view of after open the

front-left door

10

2.
Main maintenance item and location

Oil drain valve of engine oil

Oil drain valve of engine

oil Driver can keep
clealily when let engine
oil out

Great capacity
engine oil pan
922D24L
225C18L

922D adopt 25L great

capacity engine oil pan
225C18L

11

2.
Main maintenance item and location

Add lubrication to track tension device

12


Table of contents
1.
The Recommended oil.
2.
Main maintenance item and locatoin .
3.
Maintenance Intervals.
4.
Maintenance point of every system.
4.1
Diesel engine system
4.2
Swing and Travel Reductions

13


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

14

3.1 8
Every 8 Hours or Every Day Service
3.1.1
Check the oil level of the Engine.
3.1.2
Check coolant level.
3.1.3
Check hydraulic oil level.
3.1.4
Drain any water and trash from the fuel tank.
3.1.5
Clean the fuel pre-filter, fuel filter and trash.
3.1.6
Check the refrigerant for leakage.
15

3.1.1
Check the oil level of the Engine

OK

Attention: In order to avoid scalds , do not

inspect when engine oil is high temperature.

3.1.2
Check coolant level
50

Attention: After the engine coolant temperature drops down to 50 ,

slowly screw out the water radiator cap to release pressure in order to
avoid scalded by high temperature vapor or splashing coolant.

3.1.3
Check hydraulic oil level

Park the machine as follow before check

OK

3.1.4
Drain any water and trash from the fuel tank

3.1.5
Clean the fuel pre-filter, fuel filter and trash

3.1.6
Check the refrigerant for leakage

Under normal working

condition, refrigerant
can be viewed through
the sight glass. An even
and stable refrigerant
flow indicates that the
refrigerant capacity is
normal. If bubbles are
found in the refrigerant,
then replenish
refrigerant because that
indicates a refrigerant
leakage in the system.


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

22

3.2 50
Every 50 Hours or Every Week Service
3.2.1
Lubricate the boom pin.
3.2.2
Lubricate the bottom pin of boom cylinder .
3.2.3
Lubricate the arm, bucket and linkage pin.
3.2.4
Check and adjust the track.
3.2.5
Clean the air filter.
23

3.2.1
Lubricate the boom pin

boom pin

3.2.2
Lubricate the bottom pin of boom cylinder

The bottom pin of

boom cylinder

3.2.3
Lubricate the arm, bucket and linkage pin

Lubricate Point

3.2.4
Check and adjust the track
(1)As the figure shows, swing the upper structure for 90 and lower
the bucket to the ground before raising the track. Keep the angle of
boom and arm within 90 to 110, and keep the bucket bottom
contacted the ground.

3.2.4
Check and adjust the track

(2)Measure the distance from the

bottom of track frame and the
back of track shoe.
CLG922LC270 to 350mm

Measure the distance

3.2.4
Check and adjust the track
(3)To tension the track, firstly turn the grease fitting
to the convenient position, and then connect the
grease gun. Add grease till the tension within the
recommended limit.
(4)To loosen the track, turn the valve
counterclockwise and slowly. When valve is
loosened for 1 to 1.5 circles, the grease will flow out
from grease outlet. If the grease does not flow out
smoothly, lift the track above ground, slowly rotate
the track.

3.2.5
Clean the air filter

A lot of dust

Pat with your

hands

Caution:If the air has

the dust, will creates
the cylinder wear

Blowing from the

inside out with
compressed air


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

31

3.3 100
Every 100 Hours or Two Week Service
3.3.1
Lubricate the boom and arm pivot pin.
3.3.2
Lubricate the piston pin and bottom pin of arm cylinder.
3.3.3
Lubricate the bottom pin of bucket cylinder.
3.3.4
Lubricate the piston pin of boom cylinder .
3.3.5
Check and adjust belt tension of fan.
3.3.6
Check and adjust belt tension of compressor.
32

3.3.1
Lubricate the boom and arm pivot pin

Lubricate point

3.3.2
Lubricate the piston pin and bottom pin of arm cylinder

The piston pin

The bottom pin

3.3.3
Lubricate the bottom pin of bucket cylinder

The piston pin

The bottom pin

3.3.4
Lubricate the piston pin of boom cylinder

the piston pin of

boom cylinder

3.3.5
Check and adjust belt tension of fan
z

Slack fan belt could cause inappropriate

battery charging, engine heating and
quick and abnormal wear. But over
tightened fan belt also will cause bearing
and belt damaged.
9.5-12.7mm (the maximum deformation
by hand )

3.3.6
Check and adjust belt tension of compressor
z
z

Slack fan belt could cause air condition

refrigeration capacity fall
5-10mm (the maximum deformation by
hand )


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

39

3.4 250
Every 250 Hours or Every Month Service
3.4.1
Check the swing reduction gear oil.
3.4.2
Check the travel reduction gear oil.
3.4.3
Check the tightening torque of bolts and nuts.
3.4.4
Replace the engine oil.
3.4.5
Replace the engine oil filter.
3.4.6
Replace the primary fuel filter.
3.4.7
Replace the fuel filter.
3.4.8
Clean the fresh air filter and recirculating air filter of the cab.

40

3.4.1
Check the swing reduction gear oil
Take out dipstick, the oil level should reach the position
between L and H. If the oil level is below L, then open oil fill
cap to replenish gear oil.

OK

Oil dipstick

Port for lubricating oil

oil fill

3.4.2
Check the travel reduction gear oil
(1)Move the machine slowly until oil level plug is located to level mark.
(2)Unscrew air exhaust plug slowly to release pressure after the gear oil cools
down completely.
(3)Unscrew plug to check oil level. The oil should be below the oil level mark.

Oil level mark

Oil drain plug

Refill oil

3.4.3
Check the tightening torque of bolts and nuts
zIf there is any looseness, tighten to the specified torque.
zReplace the bolts and nuts with new one of same quality or
higher quality.
z Use torque wrench to check and tighten bolts and nuts.
zEnsure the threads are clean when mounting or replacing.
z Apply lubricant to bolts and nuts to maintain their frictional
coefficients.
z If the bolts on the counterweight are loose, contact your
dealer or service center.

3.4.3
Check the tightening torque of bolts and nuts

bolt of revolving frame and

swing bearing 800N.m

track shoe bolt 750N.m

Counterweight
bolt 1850N.m
swing reduction
gear bolt 600N.m

bolt of sprocket 305N.m

3.4.4
Replace the engine oil

The oil drain valve

Drain Oil

Attention: In order to avoid scalds , do not replace when

engine oil is high temperature.

3.4.5
Replace the engine oil filter

Engine oil filter

3.4.6
Replace the primary fuel filter

The primary fuel filter

3.4.7
Replace the fuel filter

The fuel filter

3.4.8
Clean the fresh air filter and recirculating air filter of the cab

the fresh air filter


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

50

3.5 5003
Every 500 Hours or Three Months Service
3.5.1
Lubricate the swing bearing.
3.5.2
Lubricate the swing gear.
3.5.3
Clean the surface of radiator group.
3.5.4
Replace the external and internal components of air filter.
3.5.5
Clean the surface of the condenser.
51

3.5.1
Lubricate the swing bearing
Check the lubricant on the gear, lubricant must properly flow on
the surface of gears. If need, refill about 0.5 kg lubricant.

The swing bearing

Lubricate Cover

NOTICE: Do not fill too much grease.

3.5.2
Lubricate the swing gear
Remove cover near the swivel joint at the bottom of the swing
gear compartment. Refilling capacity for the grease is about 4 kg.

Lubricate the swing gear

Lubricate Drain Cover

3.5.3
Clean the surface of radiator group
Use pressure air to clean radiator or oil cooler

If the surface of radiator

group is very dirty, the
water and oil temperature
will overheat.
NO PRESSURE
WASHERS ALLOWED!!

clean

3.5.4
Replace the external and internal components of air filter

External filter

Internal filter

3.5.5

Clean the surface of the condenser

clean


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

57

3.6 10006
Every 1000 Hours or Six Months Service
3.6.1
Replace the fuel lift pump filter.
3.6.2 500
Replace the swing reduction gear oil.(500 hours replace for
the first time )
3.6.3 500
Replace the travel reduction gear oil.(500 hours replace for
the first time )
3.6.4
Replace the pilot oil filter.
3.6.5
Replace the hydraulic oil return filter.
3.6.6
Lubricate the bearing of swing reduction gear.
58

3.6.1
Replace the fuel lift pump filter

The fuel lift pump filter

3.6.2 500
Replace the swing reduction gear oil.(500 hours replace for the first time )

Drain Oil plug

Port for lubricating oil

3.6.3 500
Replace the travel reduction gear oil.(500 hours replace for the first time )

Oil drain plug

Drain oil

Refill oil

3.6.4
Replace the pilot oil filter

pilot oil filter

Replace the pilot oil filter

Cleaning housing internal

3.6.5
Replace the hydraulic oil return filter
(1) Slowly loosen the breather cap counterclockwise to release pressure,
then open the cap carefully
(2) Secure cover with hand to overcome the spring force when removing
the last two bolts. Open the cover.
(3) Remove spring and return filter.
(4) Replace with a new return filter.
(5) Install spring, cover and o-ring.

3.6.6
Lubricate the bearing of swing reduction gear

Lubricate point


Table of contents
3.
Maintenance Intervals
3.1 8
Every 8 Hours or Every Day Service
3.2 50
Every 50 Hours or Every Week Service
3.3 100
Every 100 Hours or Two Week Service
3.4 250
Every 250 Hours or Every Month Service
3.5 5003
Every 500 Hours or Three Months Service
3.6 10006
Every 1000 Hours or Six Months Service
3.7 2000
Every 2000 Hours or Every Year Service

65

3.7 2000
Every 2000 Hours or Every Year Service
3.7.1
Replace the hydraulic oil.
3.7.2
Replace the suction oil filter of hydraulic oil tank.
3.7.3
Replace the coolant and clean the internal surface of
radiator.

66

3.7.1
Replace the hydraulic oil
1Swing the revolving frame to 90 to park the machine on
a flat ground.
2Retract the arm cylinder and extend the bucket cylinder
completely to lock the machine.
3Lower the bucket onto ground.
4Shut down the engine and take out the key.
5Push the pilot shutoff lever to LOCK position.

3.7.1
Replace the hydraulic oil
6Clean the top of hydraulic tank to prevent dust coming into
the hydraulic oil system.
7Slowly loosen the breather cap counterclockwise to release
pressure, then open the cap carefully..
8Open the hydraulic tank cover.
9Clean the oil outlet of hydraulic tank and unscrew oil drain
plug to drain oil. Collect the oil with container.

3.7.1
Replace the hydraulic oil
10Remove suction filter and rod group.
11Clean the internal surface of suction filter and hydraulic oil tank.
Take out the screen to wash. If it needs to replace with a new
filter, install the new filter onto the rod.
12Install suction filter and rod group. Ensure the filter is fixed to
correct position.

3.7.1
Replace the hydraulic oil
13Wash the hydraulic oil tank with clean hydraulic oil. Wipe it with
clean and dry towel. Install and tighten the oil drain plug.
14Refill hydraulic oil to the position between low and high mark.
15Install the hydraulic oil cover. Ensure the suction filter and rod
are fixed to correct position.

3.7.1
Replace the hydraulic oil
16Unscrew the air exhaust plug from the top of the pump. Fill oil to
the pump through the plug mouth and then install the air
exhaust plug.
17Start the engine and run it at idle speed. Put a DO NOT
OPERATE tag to the pilot shutoff lever. Make sure the pilot
shutoff lever is at LOCK position.
18Loosen the breather cap to release the air until the oil flows out
of the mouth. Tighten the cap.

3.7.1
Replace the hydraulic oil
19Run the engine at a speed of 1200 rpm. Operate the control
lever slowly for about 15 minutes to exhaust the air in the system.
20Retract the arm cylinder and extend the bucket cylinder
completely to lock the machine.
21Lower the bucket onto ground.

3.7.1
Replace the hydraulic oil
22Shut down the engine and take out the key.
23Push the pilot shutoff lever to the LOCK position.
24Check sight glass of the hydraulic oil tank. Refill hydraulic oil if
necessary.

3.7.2
Replace the suction oil filter of hydraulic oil tank

3.7.3
Replace the coolant and clean the internal surface of radiator
1Slowly screw out the water radiator filler cap to release
pressure after the coolant temperature is below 50 .
2Open the water release valve at the bottom of the radiator,
drain out the coolant of the engine and collect with a container.
3After draining out coolant of the engine, close the water release
valve at the bottom of the water radiator.

Drain the Coolant

Fill Coolant

3.7.3
Replace the coolant and clean the internal surface of radiator
4Check all water lines and clamps of cooling system for damage,
replace if necessary. Check water radiator for leakage, damage
and piled-up trashes, clean and repair if necessary.
5Replenish cleanser which is mixed with water and sodium carbonate
into the cooling system of the engine, its proportion is 0.5 kilograms of
sodium carbonate with 23 liters of water. The level should reach normal
level of the engine and keep stable within 10 minutes.

Drain the Coolant

Fill Coolant

3.7.3
Replace the coolant and clean the internal surface of radiator
6Keep the water radiator filler cap open, start the engine, when the
coolant temperature is over 80 , run the engine for 5 minutes again.
7Stop the engine, drain out cleanser.
8Replenish clean water into cooling system of the engine till it reaches
normal level and is kept stasble within 10 minutes. keep the water
radiator filler cap open, start the engine, when the coolant temperature
is over 80 , run the engine for 5 minutes again.

Drain the Coolant

Fill Coolant

3.7.3
Replace the coolant and clean the internal surface of radiator
9Stop the engine, drain out water in the cooling system. If the drained
water is still dirty, clean the system again till the drained water gets
clean.
10Replace with a new coolant filter, close all drain valve, then replenish
new coolant

Drain the Coolant

Fill Coolant


Table of contents
1.
The Recommended oil.
2.
Main maintenance item and locatoin .
3.
Maintenance Intervals.
4.
Maintenance point of every system.
4.1
Diesel engine system
4.2
Swing and Travel Reductions

79

4.1 Diesel engine system

Quantit
y

Component

1 Engine oil
2The engine oil filter

Check

50

25L

Replace

Replace

6 The external
components of air filter

Clean

Replace

7 The internal
components of air filter

Replace

8 Check coolant level

9 Check and adjust belt tension of

fan

10 Replace the coolant

Clean the internal surface of radiator

30L

11 Clean the surface of radiator

group

The first service time

250

500

1000

2000

Drain

5 Replace fuel filter

100

Replace

3 Drain any water and trash from

the fuel tank.
4 Fuel pre-filter.

Interval(hours)

2000
Every 2000 Hours or Every Year Service

Shorten the time of maintenance

80

4.1 Diesel engine system

Check coolant leveleveryday or 8 hours
When the engine is cooling, the water in radiator must be full.

Check and adjust fan tension (from B series diesel engine operation and
maintenance mannual)
Key point: loose fan drive belt may cause lack of battery charging, engine
heating and abnormal and rapid wear of belt. While the belt is too tight,
may cause the damage of bearing and drive belt
81

4.1 Diesel engine system

Antirust :
When change coolant water, add about 0.58L0.15 gallon
antirust, while using antifreeze, antirust is not available any more.
Antifreeze:
If the temperature is forecast down to below 0 (32 degrees
Fahrenheit), please add a mixture of antifreeze and softened
water into the coolant system. If antifreeze you have bought
including ratio instruction, please follow the instructions and
make the mixtures according to the local minimum temperature.
The following table lists the proportion of SHELL stock
temperature for ratio of antifreeze and mixture for the reference.
82

4.1 Diesel engine system

Antifreeze ratio table:
the proportion of SHELL antifreeze and water
The ratio of antifreeze

The ratio of water

Condensing point

30%

70%

-15

34%

66%

-20

39%

61%

-25

41.8%

58.2%

-30

45%

55%

-35

83

4.1 Diesel engine system

Clean the outer part of radiator---per 500 hours
1 Open side entrance and engine hood .
2 Use the compressed air or water to clean or wash the radiator and oil coolant .

Cleaning mouths are

on and under the
shroud , you can use
the compressed air or
water to clean or wash
the inner part of core

84

4.2
Swing and Travel Reduction

components
1
Swing
Reductions
2
Travel
Reductions

quantity

Oil level
check

replace

3.4L

Oil level
check

replace

5.5L2

Intervals(Hours)
8

50

100

250

500

1000

2000

The first service time
85