产品维修手册

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Preface
This Manual of Testing Tools introduces common testing tools and testing method of the loader,

excavator, road roller and land leveler, and also specifies those relevant issues needing attention

during testing. This Manual can help maintenance personnel judge the failure of various machine types

more easily, and lay solid technical foundation for work carried out by maintenance personnel. Please

make sure read this manual carefully to make it play its full role.

We are consistently committed to improve and modify our product to make it more advanced and

reliable. We reserve the right of making such changes, however, we would not promise to introduce

such changes to the product already delivered. The design modification, testing and application

instructions will be subject to changes without prior notice. For any questions about this manual, please

consult out company.

If you find any deficiencies during application of this Manual, please feedback the information to us

timely, in which way we can improve the Manual quality continuously and meet your demand better.

Caution

Prior to data testing, the operator shall read this Manual carefully. Do not test the machine without

reading and understanding this Manual.

The operating instruction and precaution specified in this Manual is only applicable to specified

purpose of the machine. If this machine is to be used in unspecified but non-forbidden operation, please

ensure that such operation will not cause injury to you or other persons.

Under no circumstances shall the operation and conducts forbidden by this manual be conducted.

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Contents
I. Summary of Testing Tool kits .................................................................................................. 8
II. Details of Testing Tool Kits ................................................................................................... 10

1. Details of basic testing tool kit 6389900095 for loader and pavement construction machinery 10

2. Details of special testing tool kit 6430001459 for FAW DEUTZ (DALIAN) engine ...................... 20

3. Details of special testing tool kit 6800000294 for TierⅣ& StageⅢ DEUTZ engine ....................... 21

4. Details of special testing tool kit 6389900098 for Volvo D13 engine ............................................. 22

5. Testing tools for F series Yanmar engines on mini excavator ........................................................ 24

6. Techtool testing tools for F series medium and large excavators .................................................. 25

7. Testing tools for Weichai Stage III engine ......................................................................................... 26

8. Testing tools for Yuchai Stage III engine ........................................................................................... 27

9. Details of special testing tool kit 26380002921 for mini excavator ................................................ 28

Auxiliary kit to measure pilot secondary pressure of LG660 and LG660E ................................... 35

10. Details of testing tool kit 6430001352 for hydraulic system of medium and large

excavators 36

Auxiliary kit to measure secondary pressure of medium and large excavator products: ........... 38

11. Details of testing tool kit 6430001162 for electrical system of medium and large

excavators 40

12. Vacuum pump 11212867 ............................................................................................................. 43

13. Pin withdrawer 11212870 ............................................................................................................. 44

14. NXQ series accumulator used gas charging tool 4120006589 .............................................. 45

15.Yunnei engineT3 testing tool（Xinfeng system） ......................................................................... 46

16.Lingong independent electric control detection tool (lingong Techtool)........................................... 47

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17. YITUO YTO COMMON RAIL SYSTEM FAULT DIAGNOSIS INSTRUMENT ..................... 48

III. Selection of Special Testing Tools ............................................................................ 49

1. Selection of special testing tools for loader ....................................................................................... 49

2. Selection of special testing tools for road roller, land leveler and loader-digger ......................... 51

3. Selection of special testing tools for excavators ............................................................................... 53

IV. Application Instructions of Testing Tools ....................................................................... 55

1. Common testing items of loader .............................................................................................................. 55

1.1 Engine oil pressure testing ....................................................................................................... 55

1.2 Testing of pilot primary pressure .................................................................................................. 57

1.3 Testing of pilot secondary pressure .................................................................................... 59

1.4 Pressure testing of loader working hydraulic system ....................................................... 61

1.5 Steering system pressure testing........................................................................................ 63

1.6 Shift pressure testing of transmission system ............................................................................ 65

1.7 Tyre pressure testing ............................................................................................................ 67

1.8 Engine speed testing ............................................................................................................ 69

1.9 Battery testing ........................................................................................................................ 70

1.10 Product temperature testing................................................................................................. 72

1.11 Application instructions of multimeter ................................................................................. 73

2. Common testing items of road roller .................................................................................................. 75

2.1 Pressure testing of closed vibratory hydraulic road roller ............................................... 75

2.2 Boost pressure testing of closed vibratory hydraulic road roller..................................... 78

2.3 Pressure testing of open vibratory hydraulic road roller .................................................. 80

2.4 Boost pressure testing of road roller travelling system .................................................... 82

2.5 Pressure testing of road roller steering system ................................................................ 84

3. Common testing items of land leveler ................................................................................................ 86

3.1 Pressure testing of land leveler working system .............................................................. 86

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3.2 Pressure testing of land leveler steering system .............................................................. 88

3.3 Pressure testing of land leveler braking system ............................................................... 90

4. Common testing items of loader-digger ............................................................................................. 92

4.1 Pressure testing of P1 pump..................................................................................................... 92

4.2 P2 pump pressure testing..................................................................................................... 94

4.3 P3 pump pressure testing..................................................................................................... 96

4.4 Pressure testing of bypass back pressure valve............................................................... 98

5. Common testing items of mini excavator ......................................................................................... 100

5.1 Pressure testing of LG660 series P1/P2 pump ............................................................... 100

5.2 Pressure testing of LG660 series P3 pump ..................................................................... 102

5.3 Pressure testing of LG660 series pilot pump .................................................................. 104

5.4 Port P pressure testing of LG680E working pump ......................................................... 106

5.5 Testing of LG680E pilot primary pressure ....................................................................... 108

5.6 Testing of pilot secondary pressure .................................................................................. 110

5.7 Working hydraulic pressure testing ................................................................................... 112

6. Common testing items of medium and large excavators .................................................................. 114

6.1 Excavator VECU testing .............................................................................................................. 114

6.2 Excavator EECU testing .............................................................................................................. 117

6.3 Application instructions of vacuum pump......................................................................... 120

6.4 Pilot primary pressure testing of excavator...................................................................... 122

6.5 Pilot secondary pressure testing of excavators .............................................................. 124

6.6 Pressure testing of excavator P1/P2 pump ..................................................................... 128

6.7 negative flow pressure testing of excavator .................................................................... 130

6.8 Electric power control pressure testing of excavator ............................................................. 132

6.9 Pressure testing of LG6235E P1/P2 pump .............................................................................. 134

6.10 Pilot primary pressure testing of LG6235E ............................................................................. 136

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6.11 Pilot secondary pressure testing of LG6235E ......................................................................... 138

6.12 Positive flow pressure testing of LG6235E ............................................................................. 140

6.13 Positive flow pressure testing of E6225F/E6250F .................................................................. 142

6.14 Electric power control pressure testing of LG6235E .............................................................. 144

7. Engine system testing............................................................................................................................. 146

7.1 Testing of FAW DEUTZ (DALIAN) engine BF6M1013/BF6M2012............................................ 146

7.2 Testing of VOLVO D13 engine ................................................................................................. 148

7.3 Testing of TierⅣDEUTZ engine .............................................................................................. 150

7.4 Testing tools for F series Yanmar engines on mini excavator ................................................. 152

7.5 Techtool testing tools for F series medium and large excavators........................................... 154

7.6 Testing tools for Weichai Stage III engine............................................................................... 156

7.7 Testing tools for Yuchai Stage III engine ................................................................................. 157
8. Application method of pin withdrawer tool ........................................................................................... 159

8.1 Connector removal tool 88890038 ........................................................................................ 159

8.2 Connector removal tool ......................................................................................................... 160

8.3 Removal tool of connector (non-circular terminal hole)........................................................ 162

8.4 Removal tool of TYCO connector (non-circular terminal hole) .............................................. 163

8.5 removal tool of Deutsch connector........................................................................................ 164

8.6 insertion and extraction tool 88890001 of Bosch connector ................................................. 165

8.7 insertion and extraction tool 9812475 of non-circular connector ......................................... 166

8.8 insertion and extraction tool 88890036 of non-circular connector MQS .............................. 167

8.9 insertion and extraction tool 9808644 of non-circular connector ......................................... 168

8.10 Insertion and extraction tool 88890028 of non-circular connector BMK .............................. 169

8.11 Insertion and extraction tool 88890029 of connector (flat terminal) .................................... 170

8.12 Insertion and extraction tool 9808649 of connector (flat terminal) ...................................... 171
9. Application method of NXQ series accumulator used gas charging tool............................................... 172

9.1 Multi-function gas charging tool FPU-1 4120006589 ............................................................ 172

9.2 pacification of accumulator applicable to multi-function charging tools .............................. 174

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Appendix 1: Schedule of hydraulic system pressure value for SDLG loaders (MPa) ................ 178
Appendix 2: Schedule of tyre pressure value for SDLG loaders (MPa) ..................................... 180
Appendix 3: Lingong Techtool Installation Instructions ............................................................. 181

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I. Summary of Testing Tool kits

Versatilit
S/N Code Name of testing tool kits Overview
y

Basic testing tools for loader and Test the engine, hydraulic
1 6389900095 Yes
pavement construction machinery and electrical system

Testing tool kit for FAW DEUTZ Test the data of FAW
2 4110001007020 No
(DALIAN) engine DALIAN engine

Data acquisition instrument Test the data of Tier Ⅳ

3 6800000294 No
engine
02937571

Special testing tool kit for Test the data of volvoD13

4 6389900098 No
VolvoD13 engine engine

Testing tools for F series Yanmar Test the data of Yanmar

5 4110006286 No
engines on mini excavator engine

11223906 Test the data of F series

Techtool testing tools for F series
6 11217521 medium and large Yes
medium and large excavators
excavators
11222182

Testing tools for Weichai Stage III Test the data of Weichai
7 6430001340 No
engine engine

Testing tools for Yuchai Stage III Test the data of Yuchai
8 6430001350 No
engine engine

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Test the electrical and

Special testing tool kit for mini
9 26380002921 hydraulic system of mini Yes
excavator
excavator

Testing tool kit for hydraulic Test the hydraulic system

10 6430001138 system of medium and large of medium and large Yes

excavators excavators

Testing tool kit for hydraulic Test the hydraulic system

11 6430001352 system of medium and large of medium and large Yes

excavators excavators

Testing tool kit for electrical Test the electrical system of

12 6430001162 system of medium and large medium and large Yes

excavators excavators

Prevent or reduce the

13 11212867 Vacuum pump Yes
leakage of hydraulic oil

Remove connectors of
14 11212870 Pin withdrawer Yes
electrical system

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II. Details of Testing Tool Kits

1. Details of basic testing tool kit 6389900095

for loader and pavement construction

machinery

S/N Item Content Pictures

Code 6389900097
Name Testing tool kits
Quantity 1
1.1
It is used to collect all testing tools for
Remarks the loader and pavement construction
machinery
Code 4190001285
Name GE06L1/8NPTCFX
Quantity 2
1.2
It supports the use of 1.3, and can test
Remarks the oil pressure of Yuchai, Weichai and
Shangchai engines
Code 4120003068
Name Test connector VKA3/06LCF
Quantity 2

1.3 It supports the use of 1.2, and can test

Remarks
the oil pressure of Yuchai, Weichai

Code 4190000208
Name Three-way joint EL08LOMDA3C
Quantity 3

1.4
It supports the use of 1.5, and can test
Remarks
pilot secondary pressure

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Code 4120001854

Name Test connector VKA3/08LA3C

Quantity 3

1.5

It supports the use of 1.4, and can test

Remarks
pilot secondary pressure

Code 4120001100
Name Three-way joint EL10LOMDA3C

Quantity 3

1.6 It supports the use of 1.7 to test the oil

Remarks discharge pressure of pilot pump It is

applicable to SDLG pilot loaders

Code 4120001751
Name Connector VKA3/10LA3C
Quantity 3

1.7 It supports the use of 1.6 to test the oil

Remarks
discharge pressure of pilot pump

It is applicable to SDLG pilot loaders

Code 4120002945
Name Test connector EMA3/14*1.5ISO
Quantity 2

Pressure measurement connector with

1.8 O-ring sealing, which is used to test the

Remarks
loader steering and working system

pressure

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Code 4190000269
Name Three-way joint EL15LOMDA3C
Quantity 2

It supports the use of 1.10 to test the

1.9 pressure of bypass back pressure valve

Remarks
for loader-digger as well as RP9300 and

RT8180 steering pressure

Code 4030000418
Name Test connector VKA3/15LA3C
Quantity 2

It supports the use of 1.9 to test the

1.10
pressure of bypass back pressure valve
Remarks
for loader-digger as well as RP9300 and

RT8180 steering pressure

Code 4030000416
Name Test connector VKA3/18LA3C
Quantity 2

It supports the use of 1.12 to measure

P1,
1.11 P2 and P3 pump prese of loader-digger
Remarks
as well as LG978, LG979, LG989 and

road roller steering system pressure

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Code 4120001850
Name Three-way joint EL18LOMDA3C
Quantity 2

It supports the use of 1.11 to measure

P1, P2 and P3 pump pressure of

1.12
Remarks loader-digger as well as LG978,

LG979, LG989 and road roller steering

system pressure

Code 4120003612
Pressure measurement connector
Name
SMK20-9/16UNF-PE

Quantity 2
1.13 It is used to test the travelling and

Remarks vibration pressure and boost pressure

of full hydraulic road roller

Code 4120002381
Name Test connector SMK20-G1/4-PC
Quantity 2
1.14
ED seal joint, which supports the use
Remarks
of pressure gauge

Code 6410006223
Name Test connector of shift pressure
Quantity 1

1.15
It is used to test the shift pressure of
Remarks
Shantui transmission

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Code 6410006224
Name Test connector of shift pressure
Quantity 1

It is used to test the shift pressure of

1.16
Remarks Hangzhou Gearbox and ZF

transmissions

Code 6410006225

Name Test connector of shift pressure

Quantity 1
1.17
It is used to test the shift pressure of
Remarks
SDLG transmission

Code 6900004485
Name Three-way connector
Quantity 2

It supports the use of 1.2 and 1.3, and

1.18
Remarks is used to measure the oil return

pressure of SDLG torque converter

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Code 6430000942
Pressure gauge CPG063-00010-01-S-
Name
B04
Quantity 2

Pressure gauge of 1Mpa range, which

1.19 is used to measure the oil return

Remarks pressure of torque converter, oil

pressure of engine and pressure of

bypass back pressure valve

Code 6430000943
Pressure gauge CPG063-00025-01-S-
Name
B04
Quantity 2

1.20 Pressure gauge of 2.5Mpa range,

Remarks which is used to measure the shift

pressure of transmission

Code 4030000370
Name Pressure gauge 213.53.063/400G1/4
Quantity 1

Pressure gauge of 40Mpa range, which

1.21
is used to measure the steering and
Remarks
working pressure of loader, road roller,

land leveler and loader-digger

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Code 6410003106
Name Vibration-resisting pressure gauge
Quantity 1

1.22 Pressure gauge of 6MPa range,

which is used to measure the pilot
Remarks
pressure of loader and the boost
pressure of full hydraulic road roller

Code 6430000412

Name Vibration-resisting pressure gauge

Quantity 1

Pressure gauge of 60Mpa range,

1.23

Remarks which is used to measure the

vibration pressure of road roller

Code 4030000368
Name Test hose SMS20/M1/4-3000A
Quantity 1
1.24 Test hose, supporting the use of
pressure
Remarks
gauge

Code 6430000203
Name Battery tester
Quantity 1
1.25
It is used to measure the voltage
Remarks
and discharging of battery

Code 6430001372
Name Tyre pressure gauge
Quantity 1

1.26
Remarks

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Code 6430000206
Name Multimeter
Quantity 1

It is used to detect electrical system

1.28
Remarks failure of loader, road roller, land leveler

and loader-digger

Code 6430000301
Name Infrared thermo detector
Quantity 1

Non-contact infrared ray to measure

temperature, which can be used to

1.29 Remarks
measure the temperature of hydraulic

oil tank and coolant

Code 6430000556
Name Onosokki tachometer
Quantity 1

1.30
It is used to measure the speed of
Remarks
SDLG product engines

Code 4120001838
Name Three-way joint EL28LOMDA3C
Quantity 1

It supports the use of 1.32 to test the

1.31
Remarks vibration pressure of mechanical drive

road roller

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Code 4030000415

Name Test connector VKA3/28LA3C

Quantity 1

1.32 It supports the use of 1.31 to test the

Remarks vibration pressure of mechanical drive

road roller

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Auxiliary kit to measure the depth of tread

pattern and adjust the throttle valve of engine:

Code 6430000806

Name Tread depth gauge

1.33 Quantity 1

It is used to measure the depth of

Remarks
tread pattern

Code 6430000018

Name Feeler gauge

1.34 Quantity 1

It is used to measure the valve

Remarks
clearance of engine

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2. Details of special testing tool kit 6430001459

for FAW DEUTZ (DALIAN) engine

Code 6430001459

Name Diagnostic apparatus SK100

2.1 Quantity 1

It is used to test the data of FAW

Remarks
DEUTZ (DALIAN) engine

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3. Details of special testing tool kit 6800000294

for TierⅣ& StageⅢ DEUTZ engine

Code 6800000294

Data acquisition instrument

Name
02937571(deutz)
3.1

Quantity 1

It is used to test various data and judge

Remarks the failure of stage Ⅲ B & TierⅣ
engine

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4. Details of special testing tool kit 6389900098

for Volvo D13 engine

Code 11223906（replace11217519）

EECU communication unit between

Name
4.1 computer and excavator

Quantity 1

Remarks Connect the harness of 4.2 and 4.3

Code 11222182（replace 11217520）

Connecting harness between computer

Name
USB and communication unit

Quantity 1

4.2

Connect the computer and 4.1

Remarks
communication unit

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Code 11217521

Connecting harness between

Name communication unit and excavator
EECU

Quantity 1

4.3

Connecting 4.1 communication unit and

Remarks
adaptor 4.4

Code 11217659

Name Adaptor

4.4 Quantity 1

Connect excavator EECU and harness

Remarks
4.3

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5. Testing tools for F series Yanmar engines on

mini excavator

Code 4110006286

Name Testing tools

5.1
Quantity

Remarks

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6. Techtool testing tools for F series medium

and large excavators

Code 11222182

Connecting harness between computer

Name
6.1 USB and communication unit

Quantity 1

Remarks

Code 11223906（replace11217519）(VOLVO)

EECU communication unit between

6.2 Name
computer and excavator

Quantity 1

Code 11217521

Connecting harness between

Name
6.3 communication unit and excavator EECU

Quantity 1

Remarks

NOTE: This tool should be used for Volvo control

system excavators.

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7. Testing tools for Weichai Stage III engine

Code 6430001340

Name Smart Star 612600900287

7.1
Quantity 1

Remarks

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8. Testing tools for Yuchai Stage III engine

Code 6430015102

Yuchai inspection tool conversion harness

Name
8.1 YCGJGZ0113

Quantity

Remarks

Code 6430015101

Yuchai inspection tool YCGJGZ0112

Replace by 6410021832
Name diagnostic instrument hardware (including
8.2 YUCHAI special test tool
adapter cable)
YCGJGZ0115
Quantity

Remarks

Code 6430015100

Yuchai inspection tool YCGJGZ0005 Aladdin

Name
8.3 conversion head

Quantity

Remarks

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9. Details of special testing tool kit

26380002921 for mini excavator

S/N Item Content Pictures

Code 6410004211

Name Testing tool kits

9.1 Quantity 1

It is used to collect all basic testing tools

Remarks
for mini excavator

Code 4120001100

Name Three-way joint EL10LOMDA3C

Quantity 1

It supports the use of 9.3 to test the

9.2
inlet oil pressure of pilot valve and pilot

Remarks oil pipe pressure for LG680E and

LG690E

multi-way valves

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Code 6430000375

Name Pilot test connector VKA3/10LA3C

Quantity 1

9.3 It supports the use of 9.2 to test the inlet

oil pressure of pilot valve and pilot oil

Remarks
pipe pressure for LG680E/LG690E multi-

way valves

Code 4120002381

Name Test connector SMK20-G1/4-PC

9.4 Quantity 1

It is used to test the oil discharge

Remarks
pressure of pilot pump

Code 4030000366

Name Test connector VKA3/12LA3C

Quantity 1

9.5
It supports the use of 9.6 to test the oil

Remarks discharge pressure of LG660/LG660E

pilot pump

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Code 4190000143

Name Three-way joint EL12LOMDA3C

Quantity 1
9.6
It supports the use of 9.5 to test the oil

Remarks discharge pressure of LG660/LG660E

pilot pump

Code 4190000269

Name Three-way joint EL15LOMDA3C

Quantity 1
9.7
It supports the use of 9.8 to test

Remarks LG660/LG660EP3 pump discharge

pressure

Code 4030000418

Name Test connector VKA3/15LA3C

Quantity 1

9.8 It supports the use of 9.7 to test

LG660/LG660EP3 pump discharge

Remarks
pressure and the pressure of movable

arm cylinder

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Code 6430000376

Main pipeline test connector

Name
VKA3/18LA3C

9.9 Quantity 1

It supports the use of 9.10 to test the

Remarks pressure of LG660/LG660E excavator

arm and bucket cylinder

Code 4120001850

Name Three-way joint EL18LOMDA3C

Quantity 1
9.10
It supports the use of 9.9 to test the

Remarks pressure of LG660/LG660E excavator

arm and bucket cylinder

Code 6430000377

9.11 Main pipeline test connector

Name
VKA3/20SA3C

Quantity 1

It supports the use of 9.12 to test the

Remarks pressure of LG680E/LG690E excavator

movable arm, arm and bucket cylinder

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Code 4120001367

Name Three-way joint EL20SOMDA3C

Quantity 1
9.12
It supports the use of 9.11 to test the

Remarks pressure of LG680E/LG690E excavator

movable arm, arm and bucket cylinder

Code 6430000412

Name Vibration-resisting pressure gauge

Quantity 1
9.13
Pressure gauge of 60Mpa range,

Remarks which is used to measure the system

pressure

Code 6410003106

Name Vibration-resisting pressure gauge

Quantity 1

9.14

Pressure gauge of 6MPa range, which is

Remarks
used to measure the pilot pressure

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Code 4030000368

Name Test hose SMS20/M1/4-3000A

9.15 Quantity 2

Test hose, supporting the use of each

Remarks
pressure gauge

Code 6430000206

Name Multimeter

9.16 Quantity 1

It is used to test the electrical system

Remarks
failure of mini excavator

Code 6430000453

Name Dial indicator

9.17
Quantity 1

Remarks It is used to repair Yanmar engine

Code 6430000484

Name Extension bar

Quantity 1
9.18

Remarks It is used to repair Yanmar engine

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Code 6410004210

Name Plunger adaptor

9.19
Quantity 1

Remarks It is used to repair Yanmar engine

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Auxiliary kit to measure pilot secondary pressure of

LG660 and LG660E

Code 4190000208

Name Three-way joint EL08LOMDA3C

Quantity 1
9.20
It supports the use of 9.21, and can test

Remarks pilot secondary pressure of LG660 and

LG660E

Code 4120001854

Name Test connector VKA3/08LA3C

Quantity 1
9.21
It supports the use of 9.20, and can test

Remarks pilot secondary pressure of

LG660/LG660E

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10. Details of testing tool kit 6430001352 for

hydraulic system of medium and large

excavators

Code 6410005742

Name Testing tool kits

10.1 Quantity 1

It is used to collect hydraulic testing tools

Remarks
of large excavators

Code 6410003106

Name Vibration-resisting pressure gauge

10.2 Quantity 1

Pressure gauge of 6MPa range, which is

Remarks
used to measure the pilot pressure

Code 6430000412

Name Vibration-resisting pressure gauge

Quantity 1

10.3 Pressure gauge of 60Mpa range,

which is used to measure the system

Remarks
pressure and can be ordered

separately

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Code 4030000368

Name Test hose SMS20/M1/4-3000A

Quantity 2

Test hose, supporting the use of each

Remarks
pressure gauge，M16X2
10.4
Code 11214317

Name Test hose

Quantity 1

Test hose, supporting the use of each

Remarks
pressure gauge，M16X1.5

Code 11210133

Name O-ring

10.5 Quantity 2

It is used to test negative flow pressure

Remarks
of medium and large excavator products

Code 11212871

Name Test connector

10.6 Quantity 1

It is used to test negative flow pressure of

Remarks
medium and large excavator products

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Code 11211026

Name Three-way joint

10.7 Quantity 1

It is used to test negative flow pressure of

Remarks
medium and large excavator products

Auxiliary kit to measure secondary pressure of medium

and large excavator products:

Code 26120002751

Name Pressure measurement connector

10.8 Quantity 1

It is used to test pilot pressure of

Remarks
LG6135E/LG6150E

Code 26120002741

Name Pressure measurement connector

10.9 Quantity 1

It is used test pilot pressure of

Remarks
LG6210E/LG6225E/LG6300E/LG6360E

Code 4030000367

10.10 Name Test connector SMK20-M14×1.5-PC

Quantity 1

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It is used to test LG6235E system pressure

Remarks and pilot pressure of medium and large

excavator products

Code 4120001100

Name Three-way joint EL10LOMDA3C

10.11 Quantity 1

It is used to test LG6235E pilot primary,

Remarks
secondary and positive flow pressure

Code 4120001751

Name Connector VKA3/10LA3C

10.12 Quantity 1

It is used to test LG6235E pilot primary,

Remarks
secondary and positive flow pressure

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11. Details of testing tool kit 6430001162 for

electrical system of medium and large

excavators

Code 6410005743

Testing tool kit for excavator electrical

Name
system
11.1
Quantity 1

It is used to collect testing tools for medium

Remarks
and large excavator electrical system

Code 11214285

Name Data cable

Quantity 1

11.2

It supports the use of 11.2 & 11.4 to test

Remarks
VECU data

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Code 11212874

Multi-pinhole breaker testing kit for engine

Name
controller
11.3
Quantity 1

It supports the use of 11.2 & 11.4 to test

Remarks
VECU data

Code 11212872

Name Data cable

11.4 Quantity 1

It supports the use of 11.2 & 11.3 to test

Remarks
VECU data

Code 11212873

Name Spare harness

Quantity 2

11.5

It supports the use of 11.3 & 11.4 to test

Remarks
EECU data

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Code 11212887

Name SERDIA testing tool(DDE)

Quantity 1

It is used to test engine data and failure

11.6
information of medium and large

Remarks excavators

Note: This tool should be used for Stage 2

DDE engine.

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12.Vacuum pump 11212867

Code 11212867

Name Vacuum pump

Quantity 1
12.1
It is used to prevent or reduce hydraulic oil

Remarks leakage during removal of medium and

large excavators

43
 Detection Tool

13. Pin withdrawer 11212870

Code 11212870

Name Pin withdrawer

3.1 Quantity 1

It is used to remove electrical system

Remarks
connectors of the excavator

44
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14. NXQ series accumulator used gas

charging tool 4120006589

Code 4120006589

Name Multi-function gas charging tool FPU-1

14.1 Quantity 1

It is used in pressure detection and

Remarks
nitrogen charging of accumulator

45
 Detection Tool

15.Yunnei engineT3 testing tool （ Xinfeng

system）

Code 4110003492001

Yunnei engine T3 testing tool（Xinfeng

Name
15.1 system）

Quantity 1

Remarks Read failure code

46
 Detection Tool

16.Lingong independent electric control

detection tool (lingong Techtool)

Code 4130003269

Name TechTool Service station version

16.1
Quantity 1

Remarks Read fault codes, program flashing, etc.

47
 Detection Tool

17.YITUO YTO COMMON RAIL SYSTEM

FAULT DIAGNOSIS INSTRUMENT

Code 4190016082

YITUO YTO COMMON RAIL SYSTEM FAULT

Name
DIAGNOSIS INSTRUMENT (YTO SMALL GUARD)
16.1
Quantity 1

Remarks Read fault codes, program flashing, etc.

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 Detection Tool

III. Selection of Special Testing

Tools

1. Selection of special testing tools for loader

Basic testing tool

kit for loader and Testing tool kit for FAW Testing tool kit for Testing tools for
Testing tool kit for Testing tools for Yuchai
pavement DEUTZ (DALIAN) data acquisition Weichai Stage III
Volvo D13 engine Stage III engine
Model construction engine instrument engine

machinery

4110001007
6389900095 6800000294 6389900098 6430001350 6430001340
020

L916 ●

L918 ●
●(If equipped)

L920 ●
●(If equipped) ●(If equipped)

L933 ●
●(If equipped) ●(If equipped)

L936 ●
●(If equipped) ●(If equipped)

L946 ● ●

L952 ● ●

L953 ●
●(If equipped) ●(If quipped)

L953F ●
●(If equipped) ●(If quipped)

L955 ●
●(If equipped) ●(If equipped)

L955F ●
●(If equipped) ●(If equipped)

L956 ● ●

L956F ●
●(If equipped) ●(If equipped)

L968F ● ●

L978F ● ●

L979F ● ●

L989F ● ●

49
 Detection Tool

LG933L ●

LG946L ● ●

LG918 ●

LG936L ● ●(If equipped)

LG938L ●
●(If equipped)

LG946L ●

LG956L ●

L938F ● ●

LG959 ● ●

LG968 ●

LG916 ●

L948F ● ●

L948 ● ●

L958F ● ●

L959F ● ●

LG958L ● ● ●

50
 Detection Tool

2. Selection of special testing tools for road

roller, land leveler and loader-digger

Basic testing tool kit

Testing tool kit for
for loader and Testing tools for Testing tools for
FAW DEUTZ
pavement Weichai Stage III Yuchai Stage III
(DALIAN)
Product model construction engine engine
engine
machinery

6389900095 4110001007020 6430001340 6430001350

RD730 ●

RS7120 ● ●

RD7140 ● ●

RS7180 ● ●

RS7200 ● ●

RS7220 ● ●
Road roller

product
RS8140 ● ●

RS8160 ● ●

RS8180 ● ●

RS8200 ● ●

RS8220 ● ●

RS8260 ● ●

G9138 ●

G9165 ● ●

Land leveler G9180 ● ●

G9190 ● ●

G9220 ● ●

51
 Detection Tool

B877 ● ● (If equipped)

B876 ● ●(If equipped)

Loader-digger

B877F ●(If equipped)

B876F ●(If equipped)

52
 Detection Tool

3. Selection of special testing tools for

excavators

Testing tool kit Testing tool kit

Special for hydraulic for electrical
Testing tool Testing tool
testing tool kit system of system of Pin with
Vacuum pump kit for D13 for Yanmar
Product for mini medium and medium and drawer
engine engine
model excavator large excavator large

s excavator s

4110006286
2638000292 6430001352 6430001162 11212870 11212867 6389900098
001

LG660E ● ● ● ●

LG665E ● ● ● ●

LG680E ● ● ● ●

LG690E ● ● ● ●

LG6135E ● ● ● ●

LG6150E ● ● ● ●

LG6210E ● ● ● ●

LG6225E ● ● ● ●

LG6235E ● ● ●

LG6250E ● ● ● ●

LG6300E ● ● ● ●

LG6360E ● ● ● ● ●

LG6400E ● ● ● ● ●

E635F ●

E660F ● ●

E665F ● ●

E680F ● ●

E685F ● ●

53
 Detection Tool

E690F ● ●

E6135F ● ● ● ●

E6150F ● ● ● ●

E6210F ● ● ● ●

E6225F ● ● ● ●

E6250F ● ● ● ●

E6300F ● ● ● ●

E6360F ● ● ● ●

E6400F ● ● ● ●

E6460F ● ● ● ●

54
 Detection Tool

IV. Application Instructions of

Testing Tools

1. Common testing items of loader

1.1 Engine oil pressure testing

Location drawing of oil pressure switch

1.4190001285 2.4120003068 3.4030000368 4.6430000942

GE06L1/8NPTCFX Test connector test hose SMS20/M1/4- Pressure gauge 1Mpa

VKA3/06LCF 3000A

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 Detection Tool

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, pull

up the parking brake, and shut down the engine.

Remove the oil pressure switch of engine, and install detection

connector 1 and test connector 2 at the removal position.

Connect one end of test hose 3 to test connector 2, with the other end connected to

pressure gauge 4.

Start the engine, and respectively record the oil pressure when the engine is at idling

speed and rated speed.

After completion of testing, remove the test connector, install the oil pressure switch of

engine, and wipe clean the leaked engine oil.

Scope of application

This testing content applies to oil pressure testing of Weichai, Yuchai

and Shangchai engine equipped by SDLG products.

Reference pressure

The oil pressure during engine idling is generally 0.1~0.3Mpa, while the oil pressure at

rated speed is usually 0.3~0.6Mpa.

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1.2 Testing of pilot primary pressure

Remove the oil pipe Pilot filter

1.4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and pull

up parking brake. Shut down the engine, operate the working device handle for 3-5 times to

release the residual pressure of hydraulic oil inside the pipe.

Remove the oil inlet pipe of pilot filter at the position shown in the figure, install three-way

connector 1 at the removal position, and connect test connector 2 and removed oil pipe

to the three-way connector.

Connect one end of test hose 3 to connector 2, with the other end connected to pressure

gauge 4.
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Start the engine, operate the pilot handle to limit position, gradually accelerate the throttle,

and observe stable pressure value on the pressure gauge.

To ensure the accuracy of testing data, it is able to place the control handle to other limit

position, and repeat measurement.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe.

Wipe clean the leaked hydraulic oil during removal.

Scope of application

This testing content applies to pilot primary pressure testing of SDLG pilot loader. See Appendix 1 for

reference pressure.

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1.3 Testing of pilot secondary pressure

Remove the oil pipe

1.4190000208 2. 4120001854 3.4030000368 4.6410003106

Three-way joint Test connector Test hose Vibration-resisting

EL08LOMDA3C VKA3/08LA3C SMS20/M1/4-3000A pressure gauge 6Mpa

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and pull up

parking brake. Shut down the engine, operate the working device handle for 3-5 times to

release the residual pressure of hydraulic oil inside the pipe.

Remove the pilot oil pipe at the position shown in the figure, install three-way connector 1 at

the removal position, and connect testing connector 2 and removed pilot oil pipe to the three-

way connector. Connect one end of test hose 3 to test connector 2, with the other end
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connected to pressure gauge 4.

Start the engine, operate the pilot handle to rollback position, and gradually accelerate the

throttle to the maximum after reaching limit position. Observe the stable pressure value of oil

pressure gauge, i.e. the pilot pressure at rollback linkage of tested loader. The oil pipes, from

left to right, are respectively the auxiliary linkage and bucket rollback pilot oil pipe as well as

movable arm lifting pilot oil pipe.

To ensure the accuracy of testing data, it is able to place the control handle to the lifting position

of movable arm, and repeat measurement.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe; and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pilot secondary pressure testing of SDLG pilot loader equipped

with D32A.

As there is difference existing among multi-way valve models for various machines, the

description of other machines will not be repeated, and the content here can be taken as

reference. See Appendix 1 for reference pressure.

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1.4 Pressure testing of loader working hydraulic

system

1.4120002945 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

EMA3/14*1.5IS O 3000A 213.53.063/400G1/4

Testing steps:

Place the loader at maintenance site, operate the pilot handle to place the movable arm

cylinder and rotating bucket cylinder to the limit position of piston rod extension. Pull up the

parking brake. Shut down the engine, operate the pilot handle to tilting and lowering position

to release the pressure, and place the bucket on the ground after pressure relief.

Remove the pressure tap plug on large-cavity steel tube of rotating bucket cylinder at the

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position shown in the figure, and install test connector 1 at the removal position.

Connect one end of test hose 2 to test connector 1, with the other end connected to pressure

gauge 3.

Start the engine, place the control handle of rotating bucket to rollback position, gradually

accelerate the throttle after the bucket reaching limit position, and observe the stable value on

the pressure gauge, i.e. current working pressure of hydraulic system for tested loader.

After completion of testing, repeat the pressure relief step in 1), remove the test connector, and

install the pressure measurement plug.

Wipe clean the leaked hydraulic oil during removal and assembly.

Scope of application

This testing content applies to pressure testing of working hydraulic system of SDLG loader.

See Appendix 1 for reference pressure.

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1.5 Steering system pressure testing

1.4120002945 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

EMA3/14*1.5IS O 3000A 213.53.063/400G1/4

Testing steps:

Place the loader on maintenance site, with bucket laid flat on the ground. Shut down the

engine, operate the steering wheel for 3-5 times to release the residual pressure of hydraulic

oil inside the pipe.

Remove the screw plug at the position shown in the figure, and install test connector 1 at

removal position.

Connect one end of test hose 2 to test connector 1, with the other end connected to pressure

gauge 3.

Start the engine, lift the movable arm to make the bucket leave the ground, steer the front
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 Detection Tool

frame to left limit position, accelerate the throttle gradually, and observe the stable value on

the pressure gauge, i.e. current working pressure of loader steering system.

After completion of testing, repeat the pressure relief step in 1), remove the test connector,

and install the pressure measurement plug.

Wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of steering system of SDLG loader.

As there is difference existing among steering system pressure measuring position for

various machines, the description of other machines will not be repeated, and the content

here can be taken as reference.

See Appendix 1 for reference pressure.

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 Detection Tool

1.6 Shift pressure testing of transmission system

1.6410006224 2.4030000368 3.6430000943

Test connector of Test hose SMS20/M1/4- pressure gauge CPG063-

00025-01-S-B04
shift pressure 3000A

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and pull up

parking brake. Shut down the engine, operate the gear operating lever for 3-5 times, and

release residual pressure. Note: keep the electric lock energized when release the pressure

of ZF electric cabinet.

Remove the pressure switch on the shift operating valve at position shown in the figure, and

install shift test connector 1 at the removal position.

Connect one end of the test pipe 2 to the shift pressure test connector, with the other end
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 Detection Tool

connected to the pressure gauge.

Start the engine and step on the brake, shift each gear, observe the stable pressure value on

the oil pressure gauge, i.e. the current shift pressure of tested loader.

After testing, repeat the pressure relief step in 1), install pressure switch of shift operating

valve, and wipe clean the leaked transmission oil.

Scope of application

Category of
Code Model of applicable transmission Reference pressure
transmission

A30X series and BX50 series

6410006225 1.1～1. 5MPa
SDLG transmission transmissions

4030000367 VRT200 transmission 1.9～2.3MPa

ZF

ZF transmission transmission:4WG158/4WG180/

ZF：1.6～1.8MPa
Hangzhou Gear 6410006224 WG200
Hangchi:：
1.3～1.7Mpa

transmission Hangzhou Gear:

4WG180/6WG180/YD13/BS428

Shantui transmission
Shantui transmission 6410006223 1.1～1. 5MPa
BD05/BYD4208

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1.7 Tyre pressure testing

1.6430000423 2.6430000205

Connecting rod of Tyre pressure gauge

tyre pressure gauge

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, pull up the

parking brake, and shut down the engine.

Prior to tyre pressure measurement, ensure that the tyre is at cooling state, otherwise the

tyre pressure testing will be affected.

Connect the tyre pressure gauge and connecting rod, remove the dust cap of tyre inflating

valve, and connect the pressure gauge connecting rod to the inflating valve.

After testing, install the dust cap of tyre inflating valve.

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Scope of application

This testing content applies to engineering tyre pressure testing of SDLG pavement

construction machinery.

See Appendix 2 for reference pressure.

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1.8 Engine speed testing

1.6430000556

Onosokki tachometer

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and pull

up parking brake. Shut down the engine.

Attach a piece of reflective tape on the movable disc of test shaft, if the reflect light of

tested piece is strong, the paint of dark color shall be coated.

Start the engine, press and hold the tachometer power for 5s, illuminate the laser light on

the reflective tape, which means displaying the rotating speed on the tachometer screen.

Before tachometer leaves its position, release the power to save the reading.

Scope of application

This testing contents applies to engine speed testing of SDLG products.

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1.9 Battery testing

1.6430000203

Battery tester

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, pull up

the parking brake, and shut down the engine.

Prior to testing, use metal brush to clean the battery terminal, because rusty terminal will

cause wrong testing result. Also check whether the pointer of instrument panel is at zero

position, which can be adjusted via rotating zero adjuster on the rear cover hole.

Clamp the test clip head on the battery terminal, and it is positive pole if the surface

indicator light is on; to ensure testing accuracy, it is required to connect the terminal and

clamp securely.

Observe the surface pointer, and it is good in green area, low in red area and poor in yellow

area. Toggle the load switch until the pointer is stable, but the time shall not exceed 10s.

Note: do not let the battery stay in discharging condition for long time.

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Scope of application

This testing contents applies to battery energy testing of SDLG products.

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1.10 Product temperature testing

1.6430000301

Infrared thermo detector

Testing steps, taking hydraulic oil temperature testing as example:

Place the loader at maintenance position, with the bucket laid flat on the ground, pull up

the parking brake, and shut down the engine.

Align the thermodetector with the hydraulic oil tank, then pull the trigger, and record the

displayed temperature of thermodetector.

The hydraulic oil temperature is the tester displayed temperature plus 5℃.

Scope of application

This testing content applies to the temperature testing of SDLG hydraulic oil (left figure)

and engine coolant (right figure).

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1.11 Application instructions of multimeter

1.6430000206

Multimeter

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and pull

up parking brake. Shut down the engine.

Insert the black probe into the COM hole and red probe into VO or VO Hz hole, place

rotating function switch within DCV range, and select the range of 200V.

Connect the electro probe on both ends of circuit in parallel, and the displayed value of

instrument is the tested voltage value.

Scope of application

This testing content applies to pressure testing of SDLG loader engines.

Note: this multimeter can be used to test the current, resistance and voltage; for specific
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application method, refer to its instructions.

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2. Common testing items of road roller

2.1 Pressure testing of closed vibratory hydraulic

road roller

System pressure port B

Location drawing of vibration pump

System pressure port A

1.4120003612 2.4030000368 3.6430000412

Pressure Test hose Vibration-resisting

measurement SMS20/M1/4-3000A pressure gauge 60Mpa

connector

SMK20-9/16UNF-PE

Testing steps:

Place the road roller on maintenance site, press the parking brake switch, and shut down the

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engine (investigate the site to avoid vehicle trapping, and prevent vibrating on solid ground).

Remove the system pressure port A plug on the vibration pump (or vibration motor).

Install pressure measurement connector 1 on pressure port A, connect one end of test hose

2 to the pressure tap 1, with the other end connected to pressure gauge 3.

Start the engine, gradually accelerate the throttle, select high and low frequency switch,

press the vibration starting switch, and record stable pressure value at Port A.

Repeat above steps to measure the pressure of Port B.

After measurement, install the screw plug of pressure port B, and wipe clean the leaked oil

during testing.

Scope of application

This testing content applies to vibrating pressure testing of SDLG road roller RS7120; for

vibrating pressure testing of other closed vibratory hydraulic road roller

RS6200/RD7140/RS7180/RS7200/RS7220/RS7260, refer to this result.

Reference pressure

Model RS6200 RS7120 RS7180 RS7200 RS7220 RS8200 RS8220

Pressure of

large
12.5Mpa 12.5Mpa 14Mpa 13Mpa 13Mpa 12.5Mpa 12.5Mpa
amplitude

vibration

Pressure of

small
12.5Mpa 11.5Mpa 12Mpa 13.5Mpa 13.5Mpa 12.5Mpa 12.5Mpa
amplitude

vibration

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 Detection Tool

The frequency and amplitude of above test data are within design scope, and the engine is

at max. Throttle condition; due to instrument error and excitation mechanism lubricating and

manufacturing error, the data here can only be used as reference instead of standard; the

testing method is placing steel wheels in situ on two rubber tyres for testing.

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2.2 Boost pressure testing of closed vibratory

hydraulic road roller

Boost pressure testing port

1.4120003612 2.4030000368 3.6410003106

Pressure Test hose SMS20/M1/4- Vibration-resisting

measurement 3000A pressure gauge 6Mpa

connector

SMK20-9/16UNF-PE

Testing steps:

Place the road roller on maintenance site, press the parking brake switch, and shut down the engine.

Remove the testing point plug on red circle position, and install pressure measurement connector 1.

Connect one end of test hose 2 to boost pressure measurement connector 1 of vibration

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 Detection Tool

pump, with the other end connected to pressure gauge 3.

Start the road roller, gradually accelerate the throttle, and the displayed pressure on pressure

gauge is the boost pressure of vibrating system.

Scope of application

This testing content applies to vibrating boost pressure testing of SDLG road roller RS7120; for

vibrating boost pressure testing of other closed vibratory hydraulic road roller

RS6200/RD7140/RS7180/RS7200/RS7220/RS7260, refer to this result.

Note: when vibrating system of full hydraulic road roller fails and requires pressure testing,

measure the boost pressure preferentially, and then measure the vibration pressure if the boost

pressure is normal.

Reference pressure

Model RS6200 RS7120 RD7140 RS7180 RS7200 RS7220 RS7260 RS8200 RS8220

Boost 2.4Mpa 1.95Mpa 2.15Mpa 2.4Mpa 2.4Mpa 2.4Mpa 2.4Mpa 2.4Mpa 2.4Mpa

pressure

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 Detection Tool

2.3 Pressure testing of open vibratory hydraulic

road roller

Pressure port P

Pressure port B Pressure port A

of oil pipe of oil pipe

1. 4120002945 2.4030000368 3.6430000412

Test connector Test hose Vibration-resisting

EMA3/14*1.5ISO SMS20/M1/4-3000A pressure gauge 60Mpa

Testing steps:

Place the road roller on maintenance site, pull up the parking brake, and shut down the

engine (investigate the site to avoid vehicle trapping, and prevent vibrating on solid ground).

Remove the pressure port plug MA at oil outlet A of vibrating valve, and install the test

connector 1. Connect one end of test hose 2 to test connector 1, with the other end connected

to pressure gauge 3.

Start the engine, gradually accelerate the throttle, select high and low frequency switch,

press the vibration starting switch, and record stable pressure value at Port A.

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 Detection Tool

Repeat above steps to measure stable pressure value of Port B.

After testing, remove test connector 1, install the removed oil pipe, and wipe clean the

leaked hydraulic oil during testing.

Scope of application

This testing content applies to the vibrating pressure testing of SDLG road roller RS8140

equipped with Huade vibrating valve; for vibrating pressure testing of other road roller

RS8160/RS8180/RS8200/RS8220 equipped with Huade vibrating valve, refer to this result.

Reference pressure

Vehicle RS8140 RS8160 RS8200

Pressure
6Mpa 10Mpa 11.5Mpa
of large

Pressure
4.5Mpa 7.5Mpa 10.5Mpa
of small

The frequency and amplitude of above test data are within design scope, and the engine is at
max. throttle condition; due to instrument error and excitation mechanism lubricating and
manufacturing error, the data here can only be used as reference instead of standard; the testing
method is placing steel wheels in situ on two rubber tyres for testing.

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 Detection Tool

2.4 Boost pressure testing of road roller travelling

system

1.4120001751 2.4030000368 3.641000316

Connector Test hose Vibration-resisting

VKA3/10LA3C SMS20/M1/4-3000A pressure gauge

6Mpa

Testing steps:

Place the road roller on maintenance site, shut down the engine, and press the parking brake

switch.

Remove the testing point plug on red circle position, and install test connector 1.

Connect one end of test hose 2 to boost pressure tap 1 of travelling pump, with the other

end connected to pressure gauge 3.

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Start the engine, gradually accelerate the throttle, observe the stable pressure value of

pressure gauge, and the displayed pressure is the boost pressure.

Scope of application

This testing content applies to boost pressure testing of SDLG road roller RS7120 travelling

system; for boost pressure of other full hydraulic road roller RS7180/RS7200RS7220/RS7260

travelling system, refer to this result.

Reference pressure

The boost pressure of RS7120 travelling system is 2.4Mpa. The boost pressure of travelling

system for other full hydraulic road rollers is 2Mpa.

Note: when the full hydraulic road roller travelling system fails and requires pressure testing,

measure the boost pressure preferentially; considering the pressure of travelling system, this result

can only be used as reference when the road condition, engine speed, vehicle speed and high and

low speed selection are under the same condition; it is recommended to judge according to

following testing methods:

Test the parking brake, and use grade braking or brake testing switch for testing purpose.

Test the parking brake, during travelling of overall machine, pull up the travelling handle, and the

braking of overall machine is normal, with braking distance of approx. 6m;

Test the vehicle speed: 9km/h and 12.5km/h for 12t; 4.7km/h and 12km/h for 18t-26t;

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2.5 Pressure testing of road roller steering system

1.4030000416 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

VKA3/18LA3C 3000A 213.53.063/400G1/4

Testing steps:

Place the road roller at maintenance site. Shut down the engine, and open the engine hood.

Remove the test plug on three-way joint at steering pump oil outlet as shown in the figure, and

install test connector 1.

Connect one end of test hose 2 to test connector 1, with the other end connected to pressure

gauge 3.

Start the road roller, steer the front frame to right limit position, gradually accelerate the

throttle, and observe the stable value of pressure gauge, i.e. the current set pressure of road

roller steering system.

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After completion of testing, repeat the pressure relief step in 1), remove the test connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to steering system pressure testing of SDLG road roller RS8140

/RS8160RS8180/RS8200/RS8220/RS6200.For pressure testing of RS7120/RS7180/RS7200

/RS7220/RS7260, select the pressure measurement connector of steering pump; for pressure

testing of RP9300, select the pressure tap of steering gear; for pressure testing of RT8180, select

the steering cylinder, three-way connector 4190000269 and test connector 4030000418.

Reference pressure

The pressure value of RS7120 and RP9300 steering system is 14Mpa, and the steering

pressure of other road rollers is 16Mpa.

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3. Common testing items of land leveler

3.1 Pressure testing of land leveler working system

Location drawing of multi-way valve

1.4030000416 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

VKA3/18LA3C 3000A 213.53.063/400G1/4

Testing steps:

Place the land leveler at maintenance position, with the shovel laid flat on the ground, pull up

the parking brake, and shut down the engine.

Remove left coaming of the multi-way valve, screw off the screw plug on pressure tap of

multi-way valve, install the pressure measurement connector 1, and connect one end of the

test hose 2 to the pressure tap 1 of the multi-way valve, with the other end connected to the

pressure gauge 3.

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 Detection Tool

Start the engine, operate any handle (except for steering handle) on left of the steering wheel

to the limit position, accelerate the throttle to max. Speed of engine gradually, and record the

stable value of pressure gauge.

Connect the test hose to the right end of multi-way valve, and control the right working device handle

of steering wheel, so as to detect the pressure of right multi-way valve.

After completion of test, repeat the pressure relief step in 1), remove the test hose, and install the

left coaming of multi-way valve.

Scope of application

This testing content applies to working system pressure testing of SDLG land leveler

G9165/G9180/G9190/G9200/G9220.

Reference pressure

The system pressure value is 21Mpa.

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3.2 Pressure testing of land leveler steering system

1.4030000418 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

VKA3/15LA3C 3000A 213.53.063/400G1/4

Testing steps:

Place the land leveler at maintenance position, with the shovel laid flat on the ground, and

shut down the engine.

Remove the side cover plate of pressure port for the steering system shown in the figure,

remove the screw plug of reserved pressure tap on the steering system, install the pressure

measurement connector 1, and connect one end of the test hose 2 to the pressure

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measurement connector, with the other end connected to the pressure gauge 3.

Start the engine, rotate the steering wheel to the right limit position, accelerate the throttle to

max. speed of engine, and observe the pressure value of the pressure gauge, i.e. current set

pressure of land leveler steering system.

After completion of detection, repeat the pressure relief step in 1), remove the test hose, and

install the cover plate above the pressure port.

Scope of application

This testing content applies to steering system pressure testing of SDLG land leveler

G9138/G9165/G9180/G9190/G9200/G9220.

Reference pressure

The pressure value of steering system for land leveler G9138/G9165/G9180/G9190/G9200/G9220

is 14Mpa.

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3.3 Pressure testing of land leveler braking system

1. 4120002945 2.4030000368 3.4030000370

Test connector Test hose SMS20/M1/4- Pressure gauge

EMA3/14*1.5IS O 3000A 213.53.063/400G1/4

Testing steps:

Place the land leveler at maintenance position, with the shovel laid flat on the ground, pull up

the parking brake, and shut down the engine.

Remove the pressure tap plug of brake valve block, install the test connector 1, and connect

one end of test hose 2 to the pressure measurement connector 1, with the other end connected

to pressure gauge 3.

Start the engine, gradually accelerate the throttle to the max. engine speed, step on the foot

brake valve, and the displayed data of pressure gauge is just the current pressure of braking
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system.

After completion of testing, repeat the pressure relief step in 1), remove the test hose, and

install the screw cap of pressure measurement connector.

Scope of application

This testing content applies to braking system pressure testing of SDLG leveler

G9138/G9165/G9180/G9190/G9200/G9220.

Reference pressure

The pressure value of braking system for land leveler G9138/G9165/G9180/G9190/G9200/G9220

is 10.3Mpa.

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4. Common testing items of loader-digger

4.1 Pressure testing of P1 pump

Remove the oil pipe

Location drawing of P1 pump

1.4120001850 2.4030000416 3.4030000368 4

Three-way joint Test connector Test hose Pressure gauge

EL18LOMDA3C VKA3/18LA3C SMS20/M1/4-3000A 213.53.063/400G1/4

Testing steps:

Place the loader-digger at maintenance position, with the bucket laid flat on the ground, and

pull up parking brake. Shut down the engine, operate the working device handle for 3-5

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times to release the residual pressure of hydraulic oil inside the pipe.

Remove the oil inlet pipe of pump P1 at the position shown in the figure, install three-way

connector 1 at the removal position, and connect testing connector 2 and removed oil pipe to

the three-way connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure

gauge 4.

Start the engine, operate the rotating bucket at loading end or movable arm cylinder to the

bottom, gradually accelerate the throttle, overflow continuously, and observe the stable

pressure value of pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe; and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to P1 pump pressure testing of SDLG loader-digger B876/B877

series, and be subject to actual situation if the testing position changes.

Reference pressure
The P1 pump pressure of B876/B877 series is 22.5Mpa.

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4.2 P2 pump pressure testing

1.4120001850 2.4030000416 3.4030000368 4.4030000370

Three-way joint Test connector Test hose SMS20/M1/4- Pressure gauge

EL18LOMDA3C VKA3/18LA3C 3000A 213.53.063/400G1/4

Place the loader-digger at maintenance position, with the bucket laid flat on the ground, and pull up

parking brake. Shut down the engine, operate the working device handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipe.

Remove the oil pipe at the position shown in the figure, install three-way connector 1 at the removal

position, and connect testing connector 2 and removed oil pipe to the three-way connector.

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Connect one end of test hose 3 to test connector 2, with the other end connected to pressure gauge

Start the engine, operate the working device handle, and operate the stick cylinder to the bottom,

gradually accelerate the throttle, overflow continuously, and observe the stable pressure value of

pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

and install the removed oil pipe; and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to P2 pump pressure testing of SDLG loader-digger B876/B877 series,

and be subject to actual situation if the testing position changes.

Reference pressure

P2 pump pressure of B876/B877 series is 22.5Mpa.

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4.3 P3 pump pressure testing

Remove the oil pipe

1.4120001850 2.4030000416 3.4030000368 4.4030000370

Three-way joint Test connector Test hose SMS20/M1/4- Pressure gauge

EL18LOMDA3C VKA3/18LA3C 3000A 213.53.063/400G1/4

Testing steps:

Place the loader-digger on maintenance site, with bucket laid flat on the ground. Shut down the

engine, operate the steering wheel and outrigger cylinder for 3-5 times to release the residual

pressure of hydraulic oil inside the pipe.

Remove the oil pipe at the pressure-gradient control valve port P, install three-way connector

at the removal position, and connect testing connector 2 and removed oil pipe to the three-way

connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure

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gauge 4.

Start the engine, operate the outrigger slewing cylinder to the bottom without rotating the

steering wheel, gradually accelerate the throttle, and the observed stable pressure value is

the pressure of steering pump (Pump P3).

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe; and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to P3 pump pressure testing of SDLG loader-digger B876/B877

series, and be subject to actual situation if the testing position changes.

Reference pressure

The P3 pump pressure of B876/B877 series is 24Mpa.

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4.4 Pressure testing of bypass back pressure valve

Remove the oil pipe

1.4190000269 2.4030000418 3.4030000368 4.6430000942

Three-way joint Test connector Test hose SMS20/M1/4- Pressure gauge 1Mpa

EL15LOMDA3C VKA3/15LA3C 3000A

Testing steps:

Place the loader-digger at maintenance position, with the bucket laid flat on the ground, and pull

up parking brake. Shut down the engine, operate the steering wheel and working device handle

for 3-5 times to release the residual pressure of hydraulic oil inside the pipe.

Remove oil return pipe of outrigger valve (red hose).

Install three-way connector 1 on the removal position, and connect the test connector 2 and

removed hose to the three-way connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure

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gauge 4.

Start the engine, operate the working device handle, gradually accelerate the throttle, and

observe stable pressure value on the pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe; and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of bypass back pressure valve for SDLG

loader-digger B876/B877 series.

Reference pressure

For bypass back pressure valve of B876/B877 series, its pressure at engine idling speed and

rated speed is respectively P=2.5bar and P=4.5bar.

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5. Common testing items of mini excavator

5.1 Pressure testing of LG660 series P1/P2 pump

Pressure port

Pressure port of P2 pump of P1 pump

Location drawing of P1/P2

3.4030000368 2.6430000412

Test hose MS20/M1/4- Vibration-resisting

3000A pressure gauge 60Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, lift the

safety locking lever, and shut down the engine. Respectively operate each pilot control handle

for 3-5 times to release the residual pressure of hydraulic oil inside the pipe.

Connect one end of test hose 1 to test connector of excavator P1/P2 pump, with the other end

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connected to pressure gauge 2.

Start the engine, lay down the safety locking lever, and the testing method of different actuator

elements is as follows:

--Cylinder: slowly operate the pilot control handle to full stroke, let the piston reach the stroke

end of cylinder, and make the oil overflow.

-- Travelling: insert an object like iron rod between the crawler and frame, and lock the crawler

on the frame.

Corresponding action of P1 pump: bucket/right travelling/movable arm;

corresponding action of P2 pump: left travelling/arm;

After testing, repeat the pressure relief steps in 1), and wipe clean the leaked hydraulic oil

during removal.

Scope of application

This testing content applies to pressure testing of P1//P2 pump system for SDLG excavator

LG660E/E660F.

Reference pressure

The system pressure of LG660E/E660F series P1/P2 pump is 21Mpa.

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5.2 Pressure testing of LG660 series P3 pump

Remove the oil pipe

1.4190000269 2.4030000418 3.4030000368 4.6430000412

Three-way joint Test connector Test hose SMS20/M1/4- Vibration-resisting

EL15LOMDA3C VKA3/15LA3C 3000A pressure gauge

60Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut down the

engine, respectively operate each pilot control handle for 3-5 times, release the residual pressure of

hydraulic oil inside the pipe, and lift the safety locking lever.

Remove the oil outlet pipe of P3 pump, install three-way connector 1 at the removal position, and

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connect testing connector 2 and removed oil pipe to the three-way connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure gauge

4.Start the engine, lay down the safety locking lever, and the detection method of different actuator

elements is as follows:

--Cylinder: slowly operate the pilot control handle to full stroke, let the piston reach the

stroke end of cylinder, and make the oil overflow.

--Slewing: to make slewing mechanism unmovable, lean on the bucket on a fixed object, or place the

bucket into a groove.

Corresponding action of P3 pump: dozer blade/slewing

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of pump system for SDLG

excavator LG660E/E660FEP3.

Reference pressure

The system pressure of LG660E/E660F series P3 pump is 21Mpa.

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5.3 Pressure testing of LG660 series pilot pump

Remove the oil pipe

1.4190000143 2.4030000366 3.4030000368 4.6410003106

Three-way joint Test connector Test hose SMS20/M1/4- Vibration-resisting

EL12LOMDA3C VKA3/12LA3C 3000A pressure gauge

6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut down

the engine, respectively operate each pilot control handle for 3-5 times, release the residual

pressure of hydraulic oil inside the pipe, and lift the safety locking lever.

Remove the oil outlet pipe of pilot pump, install three-way connector 1 at the removal

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position, and connect testing connector 2 and removed oil pipe to the three-way connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure

gauge 4.

Start the engine, gradually accelerate the throttle, and observe the stable pressure value of testing

meter.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of pilot pump for SDLG excavator LG660E/E660F

series.

Reference pressure

The pressure of LG660E/E660F series pilot pump is 2.9Mpa.

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5.4 Port P pressure testing of LG680E working

pump

Remove the oil pipe

3.4030000368 4.6430000412

Test hose SMS20/M1/4- Vibration-resisting

3000A pressure gauge

60Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut down the

engine, respectively operate each pilot control handle for 3-5 times, and release the residual

pressure of hydraulic oil inside the pipe.

Connect one end of test hose 1 to test connector, with the other end connected to pressure gauge 2.

Start the engine, control the working device handle, and record the value of pressure gauge.
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To ensure the accuracy of testing data, it is able to place the control handle to other limit position,

and repeat measurement.

After testing, repeat pressure relief steps in 1), and remove the test hose.

Scope of application

This testing content applies to Port P pressure testing of working pump for SDLG excavator LG680E.

For Port P pressure testing of LG665E/LG685/LG690E/E665F/E680F/E685F/E690F load

sensing system, the above can be used as reference.

Reference pressure

The pressure testing result of LG665E/E665F Port P, LG680E/E680F Port P and

LG690E/E685F/E690F Port P is respectively 22.5Mpa, 27Mpa and 28Mpa.

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5.5 Testing of LG680E pilot primary pressure

Remove the oil pipe

1.4190000143 2.4030000366 3.4030000368 4.6410003106

Three-way joint Test connector Test hose SMS20/M1/4- Vibration-resisting

EL12LOMDA3C VKA3/12LA3C 3000A pressure gauge

6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut

down the engine, respectively operate each pilot control handle for 3-5 times, and release

the residual pressure of hydraulic oil inside the pipe.

Remove the oil outlet pipe of pilot oil source valve block as shown in the figure, install

three-way connector 1 at the removal position, connect the test connector 2 and removed

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hose to the three-way connector, and connect one end of test hose 3 to the test connector,

with the other end connected to the pressure gauge.

Start the engine, control the working device handle, gradually accelerate the throttle, and

record the value of pressure gauge.

After testing, repeat pressure relief steps in 1), and remove the test hose.

Scope of application

This testing content applies to pilot primary pressure testing of SDLG excavator LG680E.

For pilot primary pressure testing of LG665E/LG690E/E665F/E680F/E685F/E690F load

sensing system, the above can be used as reference.

Reference pressure

The pilot primary pressure of LG665E/LG680E/LG690E/E665F/E680F/E685F/E690F

load sensing system is 3.5Mpa.

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5.6 Testing of pilot secondary pressure

Remove the oil pipe

1.4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut

down the engine, respectively operate each pilot control handle for 3-5 times, and release the

residual pressure of hydraulic oil inside the pipe.

Remove the pilot oil pipe of multi-way valve, install three-way connector 1 at the removal

position, and connect testing connector 2 and removed oil pipe to the three-way connector.

Connect one end of test hose 3 to test connector 2, with the other end connected to pressure

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gauge 4.

Start the engine, control corresponding working device handle, and record the value of

pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed hose, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pilot secondary pressure testing of SDLG mini excavator

LG665/LG665E/E665F, which can be taken as reference for the pilot secondary pressure testing of

other mini excavator LG660E/LG680E/G690E/E660F/E680F/E685F/E690F series.

Reference pressure

The pilot secondary pressure of LG665E/LG680E/LG690E/E660F/E680F/E685F/E690F is 3.5Mpa.

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5.7 Working hydraulic pressure testing

1.4120001367 2.46430000377 3.4030000368 4.6430000412

Three-way joint Test connector of Test hose SMS20/M1/4- Vibration-resisting

EL20SOMDA3C main pipeline 3000A pressure gauge 60Mpa

VKA3/20SA3C

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut

down the engine, respectively operate each pilot control handle for 3-5 times, and release

the residual pressure of hydraulic oil inside the pipe.

Remove the oil inlet pipe for large cavity of movable arm, install the three-way connector, and

connect the oil inlet pipe for large cavity of movable arm and test connector to the three-

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way connector.

Connect one end of test hose 3 to test connector 2 of main pipeline, with the other end

connected to pressure gauge 4.

Start the engine, operate the lifting handle of movable arm, gradually accelerate the throttle

after the movable arm reaches the limit position, and observe stable pressure value on the

oil pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, and install the removed oil pipe. Wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to the pressure testing of LG680E/LG690E movable arm cylinder,

rod cylinder and bucket cylinder. For pressure testing of LG660E/LG665E/E660F/E665F

movable arm and bucket cylinder, select test connector 4030000418 and three-way connector

4190000269. For pressure testing of LG660E/LG665E/E660F/E665F rod cylinder, select test

connector 6430000376 and three-way connector 4120001850.

Reference pressure

22Mpa for LG660E/E660F, 22.5Mpa for LG665E/E665F, 27Mpa for LG680E/E680F, and

28Mpa for LG690E/E685F/E690F.

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6. Common testing items of medium and large

excavators

6.1 Excavator VECU testing

1.11214285 2.11212872 3.11212874 4.6430000206

Data cable
Data cable Multi-pinhole breaker Mustimeter

testing kit for engine

controller

Zone VA Zone VB
Location drawing of VECU

Figure 1 Place the excavator at maintenance

Figure 2 Unplug VECU connector
site

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Figure 3 Connect VA and VB data cable

Figure 4 Connect the removed connectors in

connectors
Figure 2 and 3 with VECU testing data cable

Figure 5 There are 2 terminals on the data Figure 6 Connect the data cable (No.

cable, when 1-62 connector is connected to 11212872)

the breaker, No. 1-62 on the breaker indicate

corresponding VB1-VB62 pins in Zone VB;

when connect terminal 63-86 to the breaker, 1-

8 on the breaker indicate VB63-VB70 pins,

while 9-24 on the breaker indicate VA1-VA16

pins of VECU.

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Figure 7 Testing kit of multi-pin breaker for Figure 8 Use mustimeter to test each terminal

data cable insertion inside the multi-pin breaker

Scope of application

This testing content applies to the signal testing of each VECU terminal for SDLG E

series medium and large excavators (except for LG6235E).

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6.2 Excavator EECU testing

1.11212887 2. Supporting software

SERDIA testing tool

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, lift the

safety locking lever, and shut down the engine.

Connect one end of data cable to the ECU testing port of engine, with the other end

connected to the computer (need installing SERDIA supporting software).

For specific diagnosis method, see instructions of SERDIA testing tools.

Scope of application

This testing content applies to testing of FAW DEUTZ (DALIAN) engine EECU equipped by SDLG

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E series medium and large excavators.

1.11212873 2.11212872 3.11212874 4.6430000206

Spare harness Data cable Multi-pinhole breaker Mustimeter

testing kit for engine

controller

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut

down the engine, and turn off the battery switch.

Unplug EECU connector, connect spare harness 1, and connect the previously removed

connector to the spare harness.

Connect one end of spare harness 1 to data cable 2.

Connect data cable 2 to the testing kit 3 of multi-pin breaker.

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Turn on the battery switch, start the engine, and use mustimeter 4 to test the signal of each

terminal inside the multi-pin breaker testing kit 3.

Scope of application

This testing content applies to testing of FAW DEUTZ (DALIAN) engine EECU equipped by

SDLG E series medium and large excavators.

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6.3 Application instructions of vacuum pump

1.11212867 2. Supporting tools

Vacuum pump

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, shut

down the engine, and lift the safety locking lever.

Clean the surface of hydraulic oil tank, especially around the air respirator, press the air

respirator to release the internal pressure of oil tank, and use hexagonal socket T30 inside

the tool kit to remove the screw and air respirator from the hydraulic oil tank.

Install the adaptor and connector, and also connect the hose (install other adaptors for

non-medium and large excavators).

Insert the power of vacuum pump to the power adapter, insert the plug of power adapter on the

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cigarette lighter seat inside the cab, tighten the adjusting screw, and turn on the switch (12V

excavator requires no power adapter).

Run for 2-3 min (the pressure shall not decrease to less than -0.3Mpa, otherwise the

hydraulic oil tank will be damaged).

Cut off the power, then maintain and inspect the hydraulic system, unplug the power plug and

loosen the adjusting screw after maintenance, so as to let external air enter the hydraulic oil

tank.

Remove the adapter, and immediately install the air respirator.

Scope of application

This testing content applies to vacuuming the hydraulic oil tank of SDLG excavators (except

for LG6235E).

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6.4 Pilot primary pressure testing of excavator

1.11214317 2.6410003106

Piezometer tube Pressure gauge

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipeline.

Remove the screw cap of pressure measurement connector on the pilot oil block, connect

one end of piezometer tube 1 to the pressure measurement connector, with the other end

connected to the pressure gauge, and turn on the power switch of pressure gauge.

Start the engine, operate the pilot handle to limit position, gradually accelerate the throttle, and
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observe stable pressure value on the pressure gauge, i.e. the pilot pressure.

After completion of testing, repeat the pressure relief step in 1), remove the piezometer

tube, and install the screw cap of pressure measurement connector.

Scope of application

This testing content applies to pilot primary pressure testing of SDLG excavator

LG6135E/LG6150E, which can be used as reference for pressure testing of other medium and

large excavators of E series as well as E6225F/E6250F/E6360F/E6400F/E6460F.

Reference pressure

The pilot primary pressure of SDLG medium and large excavators is 3.5~4Mpa.

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6.5 Pilot secondary pressure testing of excavators

Pilot oil pipe

1.26120002741 2.4030000367 3.4030000368 4.6410003106

Pressure measurement Test connector Test hose SMS20/M1/4- Vibration-resisting

connector SMK20-M14×1.5-PC 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release

the residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Install the vacuum pump, and refer to application instructions of vacuum pump in 6.3 for

installation methods.

Remove the pilot oil pipe of multi-way valve, install three-way connector at removal position,
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connect the test connector and pilot oil pipe to the three-way connector, and turn on the

power switch of pressure gauge.

Start the engine, lay down the safety locking lever, and the detection method of different

actuator elements is as follows:

--Cylinder: slowly operate the pilot control handle to full stroke, let the piston reach the stroke

end of cylinder, and make the oil overflow;

--Slewing: to make slewing mechanism unmovable, lean on the bucket on a fixed object, or place

the bucket into a groove;

-- Travelling: insert an object like iron rod between the crawler and frame, and lock the

crawler on the frame.

Observe the stable value on the pressure gauge, i.e. the current pressure of pilot system of

tested excavator.

After completion of testing, repeat the pressure relief step in 1), remove the pressure

measurement connector, install the pilot oil pipe, and wipe clean the leaked hydraulic oil during

removal.

Scope of application

This testing content applies to pilot secondary pressure testing of SDLG medium and large

excavator

LG6210E/LG6225E/LG6250E/LG6300E/LG6360E/LG6400E/E6210F/E6225F/E6250F/E6300

F/E6360F/E6400F/E6460F.

The measurement of LG6135E/LG6150E/E6135F/E6150F pilot secondary pressure adopts

three-way connector 26120002751.

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Reference pressure

The pilot secondary pressure of SDLG medium and large excavators is 3.5~4Mpa.

Taking LG6210E as example, see following figure for information about pilot oil port at

multi-way valve.

al1 Pilot oil inlet of left slewing bl1 Pilot oil inlet of right slewing

al2 Spare port bl2 Spare port

al3 Pilot oil port of arm rollback bl3 Pilot oil port of arm extension

al4 Pilot oil inlet of left travelling & bl4 Pilot oil inlet of left travelling

reversing & backward

ar1 Pilot oil inlet of movable arm br1 Pilot oil inlet of bucket

lowering unloading

ar2 Pilot oil inlet of bucket excavation br2 Pilot oil inlet of bucket

unloading

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ar3 Pilot oil inlet of right travelling & br3 Pilot oil inlet of right travelling

reversing & backward

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6.6 Pressure testing of excavator P1/P2 pump

1.11214317 2.6410003106

Piezometer tube Pressure gauge

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Connect the piezometer tube 1 and pressure gauge 2 to pressure measurement connector,

and turn on the power switch of gauge pressure.

Start the engine, lay down the safety locking lever, operate the pilot handle to limit position,

gradually accelerate the throttle, and observe stable pressure value on the pressure gauge.

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Testing method of different actuator elements:

--Cylinder: slowly operate the pilot control handle to full stroke, let the piston reach the stroke

end of cylinder, and make the oil overflow.

--Slewing: to make slewing mechanism unmovable, lean on the bucket on a fixed object, or place

the bucket into a groove.

-- Travelling: insert an object like iron rod between the crawler and frame, and lock the

crawler on the frame.

Measure the increased pressure: during cylinder action, press the pressurization switch on the

right pilot control handle.

Corresponding action of left pump: movable arm/bucket/right travelling; corresponding action of

right pump: slewing/spare/arm/left travelling.

After completion of testing, repeat the pressure relief step in 1), remove the piezometer

tube, and install the screw cap of pressure measurement connector.

Scope of application

This testing content applies to P1/P2 pump pressure testing of SDLG medium and

large excavators (except for E6225F/E6250F).

Reference pressure

The P1/P2 pump pressure of SDLG medium and large excavators is 32.4Mpa, and the pressure

during boosting is 34.3Mpa.

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6.7 negative flow pressure testing of excavator

Pilot oil pipe

1.11211026 2.11210133 3.11212871 4.11214317 5.6410003106

Three-way O seal ring Test connector Piezometer tube Pressure gauge

connector

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and shut down

the engine. Loosen the breather valve on the oil tank to release the internal pressure of oil tank;

respectively operate each pilot control handle for 3-5 times to release the residual pressure of

hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the oil pipe at position shown in the figure, install two O seal rings 2 respectively on both

ends of three-way connector 1, install three-way connector 1 to the negative flow port of hydraulic

pump, and also install connector 3 and removed oil pipe on the three-way connector.

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Connect one end of piezometer tube to test connector 3, with the other end connected to pressure

gauge 5.

Turn on the power switch of pressure gauge, and start the engine.

Testing method: --when there is no action, gradually shift the gear from minimum throttle to

maximum throttle, and readout the reading.

--When there is action, slowly place the pilot control handle to full stroke, and readout the reading.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to testing of negative flow pressure FL for SDLG medium and large

excavators, which can be used as reference for negative flow pressure FR.

Reference pressure

When there is no action, the negative flow pressure is 3.5Mpa.

When there is action, slowly place the pilot control handle to full stroke, and the corresponding

negative flow pressure will decrease from 3.5Mpa to 0.6Mpa.

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6.8 Electric power control pressure testing of

excavator

1.11214317 2.6410003106

Piezometer tube Pressure gauge

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and shut down

the engine. Loosen the breather valve on the oil tank to release the internal pressure of oil tank;

respectively operate each pilot control handle for 3-5 times to release the residual pressure of

hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the screw cap of pressure measurement connector at the position shown in the figure,

test one end of pressure measurement hose 1 to the pressure measure connector, with the other

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end connected to pressure gauge 2.

Start the engine, gradually accelerate the throttle gear, and observe the value of pressure gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to electric power control pressure testing of SDLG medium and large

excavators.

Reference pressure

The electric power control pressure of medium and large excavators will increase from 0Mpa to

4Mpa along with the acceleration of throttle gear.

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6.9 Pressure testing of LG6235E P1/P2 pump

Pressure port of P1 Pressure port

pump of P2 pump

1.4030000367 2.4030000368 3.6430000412

Test connector SMK20- Test hose SMS20/M1/4- Vibration-resisting

M14×1.5-PC 3000A pressure gauge 60Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove P1 pump pressure switch of excavator, install test connector 1 to the pressure port,

and connect one end of the piezometer tube to the test connector, with the other end

connected to pressure gauge 3.

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Start the engine, lay down the safety locking lever, operate the pilot handle to limit position,

gradually accelerate the throttle, and observe stable pressure value on the pressure gauge. Testing

method of different actuator elements:

--Cylinder: slowly operate the pilot control handle to full stroke, let the piston reach the stroke

end of cylinder, and make the oil overflow.

--Slewing: to make slewing mechanism unmovable, lean on the bucket on a fixed object, or place

the bucket into a groove.

-- Travelling: insert an object like iron rod between the crawler and frame, and lock the crawler

on the frame.

Corresponding action of P1 pump: slewing/arm/right travelling; corresponding action of P2 pump:

movable arm/bucket/left travelling.

After completion of testing, repeat the pressure relief step in 1), remove the test connector, and

wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of P1//P2 pump for SDLG excavator LG6235E. The

testing of E6225F/E6250F P1/P2 pump pressure can refer to this testing item.

Reference pressure: the pressure of LG6235E P1/P2 pump is 35Mpa. The pressure of

E6225F/E6250F P1/P2 pump is 33～3535Mpa.

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6.10 Pilot primary pressure testing of LG6235E

1. 4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and shut

down the engine. Loosen the breather valve on the oil tank to release the internal pressure

of oil tank, respectively operate each pilot control handle for 3-5 times to release the residual

pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the pilot oil pipe at the position shown in the figure, install three-way connector 1 at

the removal position, and connect test connector 2 and removed oil pipe to the three-way

connector.

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Connect one end of piezometer tube to the connector 2, with the other end connected to

pressure gauge 4.

Start the engine, operate the pilot handle to full stroke, gradually accelerate the throttle, and

observe stable pressure value on the pressure gauge, i.e. the pilot pressure.

To ensure the accuracy of testing data, it is able to place the control handle to other position, and

repeat measurement.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, install the removed oil pipe, and wipe clean the leaked hydraulic oil during removal.

Scope of application

This testing content applies to pilot pressure testing of SDLG excavator LG6235E.

Reference pressure

The tested LG6235E pilot pressure is 3.5~4Mpa.

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6.11 Pilot secondary pressure testing of LG6235E

1. 4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and shut

down the engine. Loosen the breather valve on the oil tank to release the internal pressure of

oil tank, respectively operate each pilot control handle for 3-5 times to release the residual

pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the pilot oil pipe at the position shown in the figure, install three-way connector at the

removal position, and connect test connector 2 and removed oil pipe to the three-way connector.

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Connect one end of piezometer tube to the connector 2, with the other end connected to

pressure gauge 4.

Start the engine, operate the pilot handle to full stroke, gradually accelerate the throttle, and

observe stable pressure value on the pressure gauge, i.e. the pilot pressure.

To ensure the accuracy of testing data, it is able to place the control handle to other position,

and repeat measurement.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil during removal.

Scope of application

This testing content applies to pilot pressure testing of SDLG excavator LG6235E.

Reference pressure

The tested LG6235E pilot pressure is 3.5~4Mpa.

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6.12 Positive flow pressure testing of LG6235E

Remove the oil pipe

1.4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release

the residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the oil pipe at the position shown in the figure, install three-way connector 1 at

positive flow port of hydraulic pump, and connect test connector 2 and removed oil pipe to

the three-way connector 1. Connect one end of pressure measurement hose 3 to test

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connector 2, with the other end connected to pressure gauge 4.

Start the engine. Testing method: --When there is no action, gradually shift the gear from minimum

throttle to maximum throttle, and readout the reading.

--When there is action, slowly place the pilot control handle to full stroke, and readout the reading.

After completion of testing, repeat the pressure relief step in 1), remove the three-way connector,

install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to positive flow X1 pressure testing of SDLG excavator LG6235E.

Reference pressure

When there is no action, the positive flow X1 pressure is 0Mpa.

When there is action, slowly place the pilot control handle to full stroke, and the corresponding

positive flow X1 pressure will increase from 0Mpa to 3.5Mpa.

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6.13 Positive flow pressure testing of

E6225F/E6250F

Remove the oil pipe

1.4120001100 2.4120001751 3.4030000368 4.6410003106

Three-way joint Connector Test hose SMS20/M1/4- Vibration-resisting

EL10LOMDA3C VKA3/10LA3C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the oil pipe at the position shown in the figure, install three-way connector 1 at

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positive flow port of hydraulic pump, and connect test connector 2 and removed oil pipe to the

three-way connector 1. Connect one end of pressure measurement hose 3 to test connector 2,

with the other end connected to pressure gauge 4.

Start the engine. Testing method: --When there is no action, gradually shift the gear from

minimum throttle to maximum throttle, and readout the reading.

--When there is action, slowly place the pilot control handle to full stroke, and readout the

reading.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to positive flow X1 pressure testing of SDLG excavator

E6225F/E6250F.

Reference pressure

When there is no action, the positive flow X1 pressure is 0Mpa.

When there is action, slowly place the pilot control handle to full stroke, and the corresponding

positive flow X1 pressure will increase from 0Mpa to 3.5Mpa.

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6.14 Electric power control pressure testing of

LG6235E

Remove the oil pipe

1.4030000367 2.4030000368 3.6410003106

Test connector SMK20- Test hose SMS20/M1/4- Vibration-resisting

M14×1.5-P C 3000A pressure gauge 6Mpa

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine. Loosen the breather valve on the oil tank to release the internal

pressure of oil tank; respectively operate each pilot control handle for 3-5 times to release the

residual pressure of hydraulic oil inside the pipeline, and lift the safety locking lever.

Remove the screw plug at the position as shown in the figure, and install test connector 1 on the

screw plug.

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Connect one end of pressure measurement hose 2 to test connector 1, with the other end

connected to pressure gauge 3.

Start the engine, gradually accelerate the throttle gear, and observe the value of pressure

gauge.

After completion of testing, repeat the pressure relief step in 1), remove the three-way

connector, install the removed oil pipe, and wipe clean the leaked hydraulic oil.

Scope of application

This testing content applies to pressure testing of electric power control Y3 for SDLG excavator

LG6235E.

Reference pressure

The pressure of electric power control Y3 of LG6235E will increase from 0Mpa to 3.5Mpa along

with the acceleration of throttle gear.

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7. Engine system testing

7.1 Testing of FAW DEUTZ (DALIAN) engine

BF6M1013/BF6M2012

1.4110001007020

Diagnostic apparatus ES-

620

Testing steps:

Place the overall machine on the maintenance site, with bucket laid flat on the ground, shut

down the engine, and press the button of parking brake.

Remove the inner trim panel behind the cab seat, and connect the line of

diagnostic apparatus to the fault diagnosis port of engine.

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See instructions of ES-620 diagnostic apparatus for specific diagnosis method.

Application scope of starting

This testing content applies to BF6M1013/BF6M2012 engine system testing, which can test the

BF6M1013/BF6M2012 engine equipped by loader, road roller and land leveler.

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7.2 Testing of VOLVO D13 engine

1.11223906 2. 11222182 3.11217521 4.11217659

EECU Connecting harness Connecting harness Adapter

communication unit between computer between communication

between computer and USB and unit and excavator

excavator communication unit EECU

Testing steps:

Place the loader on the maintenance site, with bucket laid flat on the ground, shut down the

engine, and press the button of parking brake.

Remove the inner trim panel behind the cab seat, and remove the screw cap of engine

failure diagnosis interface.

Successively connect the diagnosis interface to adapter 4/connecting harness 3 between

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communication unit and excavator EECU/computer and excavator

Connecting harness 2 between EECU communication unit 1/computer USB

and communication unit.

Start the engine, and see this instructions of testing tools for specific diagnosis method.

Application scope of starting

This testing content applies to testing of VOLVO D13 engine E-ECU equipped by SDLG

LG979, L979, L989, LG989, LG6360E and LG6400E.

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7.3 Testing of TierⅣDEUTZ engine

1.6800000294

Data acquisition

instrument 02937571

Testing steps:

Place the loader on the maintenance site, with bucket laid flat on the ground, shut down the

engine, and press the button of parking brake.

Remove screw cap of right engine EECU in the cab, and connect one end

of data acquisition instrument harness to the engine failure diagnosis interface.

Connect the other end of data acquisition instrument to the computer (require to pre-install

the supporting software).

See instructions of SerDia2010 for specific diagnosis method.

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Application scope of starting

This testing content applies to testing of Tier Ⅳ engine EECU equipped by SDLG LG938L
/LG948L machines.

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7.4 Testing tools for F series Yanmar engines on

mini excavator

1.4110006286001 2. 4110006286002

I/F BOX (diagnosis box + procedure + account) 检查线束 129927-91070

1RF002-25100

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and shut down

the engine.

Remove the inspection port cover of right control box in the cab, and connect the connecting harness

1 between computer USB and communication unit to the failure diagnosis interface, with the other

end of harness 1 connected to communication unit 2.

Connect one end of connecting harness 3 between communication unit and excavator EECU to the

communication unit 2, with the other end connected to the computer (require to pre-install the
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supporting software).

Rotate the starting key, switch on the overall power supply, the computer equipped with

communication unit and engine indicator light will turn green, which indicates that the connection is

normal, and testing can be conducted.

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7.5 Techtool testing tools for F series medium and

large excavators

1.11222182 2.11223906 3.11217521

Connecting harness EECU Connecting harness

between computer USB communication unit between communication

and communication unit between computer and unit and excavator

excavator EECU

Testing steps:

Place the excavator at maintenance position, with the bucket laid flat on the ground, and

shut down the engine.

Remove the inspection port cover of right control box in the cab, and connect the connecting

harness 1 between computer USB and communication unit to the failure diagnosis interface,
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with the other end of harness 1 connected to communication unit 2.

Connect one end of connecting harness 3 between communication unit and excavator

EECU to the communication unit 2, with the other end connected to the computer (require to

pre-install the supporting software).

Rotate the starting key, switch on the overall power supply, the computer equipped with

communication unit and engine indicator light will turn green, which indicates that the

connection is normal, and testing can be conducted.

Scope of application

This testing content applies to engine system, electrical system and hydraulic system testing of

SDLG E6135F, E6150F, E6210F, E6225F, E6250F, E6300F, E6360F, E6400F, E6460F and

E7150F excavators.

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7.6 Testing tools for Weichai Stage III engine

1.6430001340

Smart Star 612600900287

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and shut

down the engine.

Remove the right storage box cover in the cab, and connect the diagnosis tool 1 to the

failure diagnosis interface, with the other end connected to the computer.

Rotate the starting key, switch on the overall power supply, and carry out test.

For details about diagnosis method and failure code, see the diagnosis instructions.

Scope of application

This testing content applies to stage III engine testing of Weichai WP series and WD series.

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7.7 Testing tools for Yuchai Stage III engine

6430015102, Yuchai inspection tool

conversion harness YCGJGZ0113,

6430015101, Yuchai inspection tool

YCGJGZ0112 diagnostic instrument hardware

(including adapter cable),

6430015100, Yuchai inspection tool

YCGJGZ0005 Aladdin conversion head

Replace by 6410021832 YUCHAI special test

tool YCGJGZ0115

Testing steps:

Place the loader at maintenance position, with the bucket laid flat on the ground, and shut

down the engine.

Remove the left front testing tool cover in the cab, and connect the diagnosis tool 1 to the

failure diagnosis interface, with the other end connected to the computer.

Rotate the starting key, switch on the overall power supply, and carry out test.

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For details about diagnosis method and failure code, see the diagnosis instructions.

Scope of application

This testing content applies to testing of Yuchai YC4D engine series and Yuchai YC6J series

Stage III engine.

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8. Application method of pin withdrawer tool

8.1 Connector removal tool 88890038

It is mainly used to remove the buckle inside the connectors

Figure 1 Removal tool 88890038

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8.2 Connector removal tool

Connector
11666161 9812480 9808646 9812483 9812481 9812482
tool

Terminal
φ1.2 φ1.5-1.6 φ2.3 φ2.5 φ3.5 φ4.0
diameter

Terminal
Round Round Round Round Round Round
appearance

Figure 4 Removal tool 9812480

Figure 3 Removal tool 11666161

Figure 6 Removal tool 9812483

Figure 5 Removal tool 9808646

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Figure 8 Removal tool 9812482

Figure 7 Removal tool 9812481

Operating instruction of tools:

Remove the buckle inside the connector.

Select corresponding tool according to the diameter of terminal inside the connector.

Insert the round hole end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.3 Removal tool of connector (non-circular

terminal hole)

Connector tool 9808650 9808645

Terminal diameter φ1.2 φ2.5

Terminal appearance Non-circular Non-circular

Figure 9 Removal tool 9808650

Figure 10 Removal tool 9808645

Operating instruction of tools:

Remove the buckle inside the connector.

Select corresponding tool according to the diameter of terminal inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.4 Removal tool of TYCO connector (non-circular

terminal hole)

Figure 11 Removal tool 9809774 Terminal

diameter: φ1.5

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.5 removal tool of Deutsch connector

Connector tool 11709649 11709666 11709655

Connector Deutsch 12-core Deutsch 16-core Deutsch 18-core

Figure 13 Removal tool 11709666

Figure 12 Removal tool 11709649

Figure 14 Removal tool 11709655

Operating instruction of tools:

Remove the buckle inside the connector.

Select corresponding tool according to the diameter of terminal inside the connector.

Insert the pin end of tool into the leading-out terminal hole.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.
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8.6 insertion and extraction tool 88890001 of Bosch

connector

Figure 15 Removal tool 88890001

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal

of connector.

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8.7 insertion and extraction tool 9812475 of non-

circular connector

Figure 16 Removal tool 9812475

Terminal: 2.8

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.8 insertion and extraction tool 88890036 of non-

circular connector MQS

Figure 17 Removal tool 88890036

Terminal: 0.63

Operating instruction of tools:

Remove the buckle inside the connector.

As shown by arrow in Figure 17, use pin end of tool to press out the buckle on one terminal

of connector.

During tool pressing, unplug and insert the wire corresponding to the leading-out terminal

of connector.

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8.9 insertion and extraction tool 9808644 of non-

circular connector

Figure 18 Removal tool 9808644

Terminal: 5.8

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool pressing, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.10 Insertion and extraction tool 88890028 of non-

circular connector BMK

Figure 19 Removal tool 88890028 Terminal:

BMK0.64

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out

terminal of connector.

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8.11 Insertion and extraction tool 88890029 of

connector (flat terminal)

Figure 20 Insertion and extraction tool

88890029

Terminal: 2.8/5.8

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal of

connector.

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8.12 Insertion and extraction tool 9808649 of

connector (flat terminal)

Figure 21 Insertion and extraction tool 9808649

Terminal: special clamp terminal

Operating instruction of tools:

Remove the buckle inside the connector.

Insert the pin end of tool into the hole on terminal end of connector.

During tool insertion, unplug and insert the wire corresponding to the leading-out terminal

of connector.

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9. Application method of NXQ series

accumulator used gas charging tool

9.1 Multi-function gas charging tool FPU-1

4120006589

Charging valve of Pressure gauge Charging hose Charging connector

accumulator

Testing steps:

During application, screw the charging head of charging tool on the charging valve of

accumulator, and connect it to the nitrogen gas cylinder via charging hose. If it is only for

testing or measuring the nitrogen pressure, it is not required to connect the charging hose.

Rotate the central spindle anti-clockwise to open the charging valve of accumulator, so as to

adjust the pressure.

Prior to testing of accumulator pressure adjustment, please cut off the connection between

the accumulator and system to drain the liquid.

During charging, the pressure in the nitrogen cylinder must be sufficiently high to meet

charging requirement, otherwise the nitrogen supercharging equipment shall be provided.

It is required to comply with relevant safety regulations, and the nitrogen with purity more than

99.8% shall be adopted.

The M28*1.5 internal thread on the valve body is used to charge the diaphragm

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accumulator; when charge the diaphragm or piston accumulator, it is only required to

connect corresponding charging connector on the valve body.

Screw the charging connector on the charging valve of accumulator, meanwhile ensure the

relief valve is closed, and rotate the hexagon socket head cap screw of central spindle

anti-clockwise to open the air valve.

Finally open the relief valve, and drain the nitrogen inside the charging tool.

Note: it is strictly forbidden to charge the oxygen or air into the accumulator, which may cause

explosion.

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9.2 pacification of accumulator applicable to multi-

function charging tools

Screw specification
S/N Code Name Supplier Used part
on nitrogen end

YUETHAI HYDRAULICS Assembly of

Accumulator
1 4120004415 TECHNOLOGY 7/8-14UNF stable
30100300
(SHANGHAI) CO., LTD module

YUETHAI HYDRAULICS
Accumulator Assembly of
2 4120004416 TECHNOLOGY 7/8-14UNF
30100310 stable module
(SHANGHAI) CO., LTD

Piston Hedeke Hydraulic

Assembly of
3 4120006007 accumulator Technology (Shanghai) M28*1.5
stable module
SK400-4 Co., Ltd.

Piston Hedeke Hydraulic

Assembly of
4 4120006008 accumulator Technology (Shanghai) M28*1.5
stable module
SK400-6 Co., Ltd.

Piston Hedeke Hydraulic

5 4120006346 accumulator Technology (Shanghai) M28*1.5 Brake

SK280-1.5 Co., Ltd.

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Piston Hedeke Hydraulic

6 4120006347 accumulator Technology (Shanghai) M28*1.5 Brake

SK280-1 Co., Ltd.

Accumulator
Jinan High-tech Electrical
7 4120002705 PED1-1.0L- M14*1.5 Brake
Complete Sets Co., Ltd
31.5

Accumulator

NXQ-A- Jinan High-tech Electrical

8 4120005112 M14*1.5 Brake
1.0/31.5-L Complete Sets Co., Ltd

-Y-B

Accumulator

NXQ-A- Jinan High-tech Electrical

9 4120005111 M14*1.5 Brake
1.6/31.5-L Complete Sets Co., Ltd

-Y-B

Accumulator

412000465 NXQ-A- Jinan High-tech Electrical

10 M14*1.5 Brake
9 1.6/31.5-L Complete Sets Co., Ltd

-Y

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Accumulator
Jinan High-tech Electrical
11 4120004505 NXQ-A- M14*1.5 Brake
Complete Sets Co., Ltd
4/31.5-L- Y

Accumulat
412000442 Jinan High-tech Electrical
12 or NXQ1- M14*1.5 Brake
2 Complete Sets Co., Ltd
L2.5/31.5

Accumulator
Jinan High-tech Electrical
13 4120003326 NXQ-A-1/20- M14*1.5 Brake
Complete Sets Co., Ltd
L-Y

Accumulator
412000272 Jinan High-tech Electrical
14 NXQ-A- M14*1.5 Brake
9 Complete Sets Co., Ltd
1.6/20-L- Y

Accumula

tor Jinan High-tech Electrical

15 4120000708 M14*1.5 Brake
NXQ1- Complete Sets Co., Ltd

L2.5/20

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YUETHAI HYDRAULICS Hydraulic

Accumulator
16 4120002830 TECHNOLOGY M28*1.5 control
ELM0.75
(SHANGHAI) CO., LTD assembly

Accumulator Jinan High-tech Electrical Hydraulic

17 4120002274 GXQ-D- Complete Sets Co., M28*1.5 control

0.75L-100 Ltd93 assembly

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Appendix 1: Schedule of hydraulic

system pressure value for SDLG
loaders (MPa)
Overload Overload

valve valve
Pressure of
Pilot pressure of pressure of Steering
Vehicle model main safety
pressure large cavity small cavity pressure
valve
for rotating for rotating

bucket bucket

Domestic configuration

L916 / 18～18.5 20～20.5 12～12.5 16

L920 / 17.5～18 20 12.5 12

L933 / 16～16.5 18.5 12.5 14

L936 3.5 16～16.5 18.5 12 14

L946 / 15～15.5 18 12 14

L952 / 15～15.5 18 12 14

L953 / 17.7～18.2 20.5 12 16

L953F / 17.7～18.2 20.5 12 16

L955 / 18.2～18.7 20～20.5 12～12.5 16

L955F / 18.2～18.7 20～20.5 12～12.5 16

L956 3.5 17～17.5 20 12 16

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L956F 4.31 19.2～19.7 20.5～21.5 11.5～12.5 16

L968F 4.31 20.7～21.2 22.5～23.5 11.5～12.5 16

L978F 3.5 21 23 15 20.7

L989F 3.5 28.5 30 30 21

Export configuration

LG916 / 18 20 12 16

LG918 3.5 17.5～18 20 12.5 12

LG933L 3.5 16～16.5 18～18.5 12～12.5 14

LG936L 3.5 16～16.5 18.5 12 14

LG938L 3.5 16～16.5 18～18.5 12～12.5 12

LG946L 3.5 15～15.5 18～18.5 12～12.5 14

L953F 3.5 17.7～18.2 20～20.5 12～12.5 16

LG956L 3.5 17～17.5 20 12 16

LG958L 3.5 17～17.5 20 12 16

L958F 4.31 18.7～19.2 20.5～21.5 11.5～12.5 16

LG968 3.5 18～18.5 20～20.5 12～12.5 14

L968F 4.31 20.7～21.2 22.5～23.5 11.5～12.5 16

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Appendix 2: Schedule of tyre

pressure value for SDLG loaders
(MPa)
Vehicle model Pressure of front tyre Pressure of rear tyre

LG916/LG918 0.32±0.01MPa 0.28±0.01MPa

LG933L 0.32±0.01MPa 0.28±0.01MPa

LG936L 0.32±0.01MPa 0.28±0.01MPa

LG938L 0.32±0.01MPa 0.28±0.01MPa

LG946L 0.35±0.01MPa 0.28±0.01MPa

L953F 0.39±0.01MPa 0.33±0.01MPa

LG958L 0.39±0.01MPa 0.33±0.01MPa

L958F 0.39±0.01MPa 0.33±0.01MPa

LG968 0.39±0.01MPa 0.33±0.01MPa

LG968F 0.39±0.01MPa 0.33±0.01MPa

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Appendix 3: Lingong Techtool

Installation Instructions

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