acy 2h维修使用说明书英文版(32336)
DESCRIPTION
7u76TRANSCRIPT
ACY-2H MANUAL
Foreword This manual provides users with a generalized overview and theory of
operation of various components and systems on the ACY-2 scooptram. It
also covers all routine service by service hour maintenance interval .By
using this manual you will be able to understand how complex systems
work, how to troubleshoot problems in operation, and how to remove
safely and effectively and how to replace worn or damaged components.
This manual content maybe different from the products improved in
future because of product’s improvement and enhancement. Since many
reasons restrain, we cannot inform every user about it, please every user
understand.
To give you better service, if you find any question, you can feedback
to us with it and its improvement advice when you use this manual. We
will be gratitude very much!
If there is any mistake or shortcoming, please criticize and conduct. . Anchises corporate in Beijing 2007.3
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Catalog
Chapter one summary....................................................................................6
1.1 Entire Vehicle Mainly Configuration..................................................................................6
1.1.1 Engine........................................................................................................................6
1.1.2 Hydraulic Torque Converter ..........................................................................6
1.1.3 Kinetic Change Gear Case ..............................................................................6
1.1.4 Axle ............................................................................................................................6
1.1.5 Brake System.........................................................................................................7
1.1.6 Hydraulic System ................................................................................................7
1.2 Entire Vehicle Mainly Capacity Parameter........................................................................7
1.2.1 Entire Dimension.................................................................................................7
1.2.2 Vehicle Weight And Axle Load.....................................................................8
1.2.3 Running Capacity ................................................................................................8
1.2.4 Hydraulic System ................................................................................................8
1.2.5 Oil Tank....................................................................................................................8
1.2.6 Electric System .....................................................................................................9
1.2.7 Operator’s Arrangement...................................................................................9
1.2.8 Steering.....................................................................................................................9
Chapter two Scooptram Operating.........................................9
2.1 Safety Regulation ..................................................................................................................9
2.2 Pre-Startup Check And Maintenance ...............................................................................10
2.3 Pre-Startup Check Term....................................................................................................11
2.4 Poststart Check And Maintainment..................................................................................11
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2.5 Engine Startup.....................................................................................................................11
2.6 Engine Choke.......................................................................................................................12
2.7 Poststart Operating.............................................................................................................12
2.8 Engine Malfunction Diagnosement And Eliminatement .................................................13
2.9 Scooptram Operating..........................................................................................................15
2.10 Scooptram Shutup.............................................................................................................15
Chapter three every mainly part structure and
maintenance....................................................................................................................16
3.1 Transmission System...........................................................................................................16
3.1.1 Axle...........................................................................................................................17
3.1.2 Transmission Shaft............................................................................................18
3.1.3 Tire, Rim ................................................................................................................19
3.2 Hydraulic Systems...............................................................................................................20
3.2.1 Hydraulic System Component ....................................................................20
3.2.2Fluid That The System Uses..........................................................................22
3.2.3 Fuel Tank Of The Hydraulic Pressure .....................................................23
3.2.4The Changing Of Hydraulic Oil ..................................................................24
3.2.5the System Exhausts ..........................................................................................24
3.2.6Systematic Accident Analysis Of The Hydraulic Pressure And
Safeguarding ....................................................................................................................25
3.3Electric system......................................................................................................................27
3.3.1Power system ........................................................................................................27
3.3.2Start system............................................................................................................27
3.3.3Lighting system....................................................................................................27
3.3.4Signal system ........................................................................................................27
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3.3.5Instrument system...............................................................................................27
3.3.6Electric circuit.......................................................................................................28
3.3.7Precautions of using of the regulator of the current alternating
generator ............................................................................................................................28
3.3.8The trouble preventing .....................................................................................29
3.3.9Accident analysis and Remedial method.................................................29
Chapter four Maintenance and maintenance of the
scraper....................................................................................................................................31
4.1 Generally safeguard the step and method of maintaining the work regularly:.............31
4.1.1Wash the machine ...............................................................................................31
4.1.2 Put lubricating oil ..............................................................................................31
4.1.3Antirust and protect............................................................................................31
4.1.4Change the part ....................................................................................................31
4.1.5The circuit maintaining ....................................................................................32
4.1.6check the oil level ...............................................................................................32
4.1.7Change the oil .......................................................................................................32
4.1.8Check the seal and its surface .......................................................................32
4.1.9Check and lock the component ....................................................................32
4.2 General unscheduled maintenance and project maintained ...........................................32
4.3 Safeguard and maintain tabulating regularly ..................................................................33
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Chapter one summary The ACY-2 Scooptram consists of a Power Frame and a Load Frame connected by
an articulating joint that permits 40-degree turns, in combination with an oscillating joint that permits the units to tilt relative to each other to accommodate uneven surfaces. The Power Frame includes the diesel engine and a power shift transmission.
The boom, the bucket, and the front axle are mounted on the load frame. The bucket may be either of a standard design or an eject-o-dump design consisting of a push plate assembly controlled by the operator. The entire vehicle is designed for maximum durability and easy maintenance.
1.1 Entire Vehicle Mainly Configuration
1.1.1 Engine
Production Factory DEUTZ corporate in Germany Model BF4M1013C Type 2-stage combustion water cooling diesel
Power Rating 63kw
Maximum Torque 275Nm
1.1.2 Hydraulic Torque Converter
Production Factory DANA corporate in American Model C272-300 Type with hydraulic pump
1.1.3 Kinetic Change Gear Case
Production Factory DANA corporate in American Model R32366 Type KINETIC CHANGE GEAR Number 6(forward 3 backward 3)
1.1.4 Axle
Production Factory Xuzhoumeichi-Beijing Anchises
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Model NO-SPIN against sliding differential planetary transmission axle
1.1.5 Brake System
Component Working Brake Stopping Brake
Note Spring-Applied, Hydraulically Released;
Fully Enclosed, Force Cooled Multiple Wet
Discs at Each Wheel End Parking and
Emergency shutdown.
1.1.6 Hydraulic System
Component Working Steering Brake
Chang Gear Supply Oil
Note Mainly Sections From Abroad
1.2 Entire Vehicle Mainly Capacity Parameter
1.2.1 Entire Dimension
Load Rating 4000kg
Entire Dimension Figure See Figure 1
Entire Long (Bucket Lay Down) 6820mm
Entire Width 1770mm
Entire Height 2100mm
Bucket Volume (Nominal Heaped) 2m3
Bucket boom Raise Time 5.6s
Bucket dump Time 6.4s
Maximum Raised Height 4218mm
Maximum dump HEIGHT 1743mm
Dump Distance 900mm
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Dump ANGLE 40°
Axle Distance 2525mm
Tread 1373mm
Minimum gap away field ≥250mm
away angle 15°
1.2.2 Vehicle Weight And Axle Load
Empty 12500kg
Front Axle Load (empty) 5625kg
Rear Axle Load (empty) 6875kg
Full Loaded 16500kg
1.2.3 Running Capacity
Processing Speed
1st Gear Forward/Reverse 0~4.76km/h
2nd Gear Forward/Reverse 0~9.4km/h
3rd Gear Forward/Reverse 0~18.4km/h
Gradeability 34%(1st Gear 1.2km/h)
1.2.4 Hydraulic System
Working System See Figure 2 Pressure rating14mp
Steering System See Figure 2 Pressure rating 14mp
Braking System See Figure 3 Pressure rating 12.5mp
Chang Gear Supply Oil System See Figure 4
1.2.5 Oil Tank
Fuel Tank (L) 100
Hydraulic Tank 132
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1.2.6 Electric System
System Voltage 24 Volt Starting, 24-Volt Accessories
Electric Theory See Figure 5
1.2.7 Operator’s Arrangement
Side Seated Operator For Bi-Directional Operation Maximum Visibility
1.2.8 Steering
Central Joint Hydraulic Kinetic Steering
Steering Angle ±42 Degree
Minimum Volv Radius Inside 2500±150mm
Outside 4800±250mm
Chapter two Scooptram Operating Operating scooptram in safety and norm is good to ensure its lifetime and reduce its
broken-down, please users operate comply with manual.
2.1 Safety Regulation
2.1.1 before you start the engine and operate this vehicle make sure you have read and
understood the operation of the vehicle. Make sure you have read and understand all
the safety messages in the operator’s manual, safety manual and the safety decals on
the vehicle. It is your responsibility to understand and follow the manufacturer’s
instructions on vehicle operation, service, and safety.
2.1.2 implement special person to drive scooptram, forbid anonymous person to operate.
2.1.3Never drive with illness; every section should be retained clean and prevented
from leakage.
2.1.4 never operate an engine with explosion and combustion easily such as dynamite.
2.1.5 tool and working place should be clean.
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2.1.6 make sure depress park brake knob when parking; if the engine is parked on the
ramp the tire should be used plate against.
2.1.7 never smoke when fill oil.
2.1.8 stand on safe space when inflating the tires.
Forbid to stand here
2.2 Pre-Startup Check And Maintenance
2.2.1 Check oil level in diesel and change gear case basin; check oil level in diesel case and hydraulic oil case; check oil level in electricity flask, supply immediately if its level is below the add mark on the dipstick and change it if it is polluted. 2.2.2 Check the seal about the oil pipe and joint and other sections, deal if there is any trouble. 2.2.3 Check whether the operating, steering and brake system can operate smartly and safely, make sure no any potential danger. Move the steering linkage lever to the NEUTRAL position. 2.2.4 Check bolt and nut in every section especially in change gear case, diesel, drive shaft, drive axle, tyre and so on. Wrench tightly or change immediately if they are loose or crack. 2.2.5 check the diesel fan and the engine belt loose degree. 2.2.6 Check hydraulic hose, wires that are located firmly and cannot lie on the exhaust pipe or drive shaft. 2.2.7 check whether there are unwelty or crack in welt section. Especially pay
attention to the joint, axle bracket and beam welt section.
2.2.8 Check whether there is any damage about oil nozzle in lubrication mark, and
regulate to fill lubricating oil.
2.2.9 Check the pressure in tires, fill air until arrive to the regulated value (front wheel:
0.68 Mpa rear wheel:0. 414Mpa).
2.2.10 Pre-Startup in first time, manipulate the hand pump and excel air in the fuel
system.
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2.3 Pre-Startup Check Term
2.3.1 Fuel oil level
2.3.2 Engine oil level
2.3.3 Change gear case oil level
2.3.4 Cooling fluid level
2.3.5 all parts tightening
2.3.6 Pressure in tire
2.3.7 Operating in brake
2.3.8 Steering operating
2.3.9 Lighten system
2.3.10 all operating parts and control apparatus function
2.4 Poststart Check And Maintainment
2.4.1 check the working parts near to floor.
2.4.2 Park on dry and plane floor. Don’t allow the drive cab to face the material side
on ramp.
2.4.3 depress the switch off.
2.4.4 move the entire operating column to NEUTRAL position.
2.4.5 disconnect the Electricity Switch.
2.4.6 clean the Machine.
2.4.7 check whether the machine figure damage and whether any bolt and nut is loose.
2.5 Engine Startup
2.5.1 shut the Switch
2.5.2 Move The Change Gear Handle to Neutral Position.
2.5.3 Insert Key and turn Startup Switch to “1” Position.
2.5.4 If need Pre-heat, turn startup switch to “2” position for several seconds (pay
attention to the pre-heat lamp lighting). When the pre-warm lamp is extinguish, at the
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same time turn the startup switch to “3” position for 2-3 seconds and turn the startup
switch to “1” position immediately. If the engine hasn’t been started, start it following
the above steps 1 second later.
2.5.5 as soon as the engine starts, release the pedal lightly to make the engine run
smoothly in medium speed. Warning: don’t allow overpass 10 seconds once starting,
if need repeat the starting process. Before starting again, make 1-minute interval.
2.5.6 after the engine start, please check whether the instructor light is on
2.5.6.1 instrument lamp
2.5.6.2 brake oil pressure
2.5.6.3 engine oil pressure
2.5.6.4 torque converter oil pressure
2.6 Engine Choke
2.6.1 depress “chock button”. When engine stops working, filling electrical instructor
lamp will relight.
2.6.2 depress “stop button”.
2.6.3 disconnect the outlet. If the temperature is lower than –30 degree outside, carry
the battery inside in case of freezing.
2.6.4 without emergency, not allow engine stop suddenly from full loads. Cool engine
first then stop.
2.6.5 Stop engine immediately and make sure the reason if “the filling instructor
lamp” or “engine pressure” lamp is on. If “bucket temperature” beacon is light,
stop the scooptram working and make the engine come to cool, make the engine idle for
minutes then stop.
2.7 Poststart Operating
2.7.1 Never turn the ignite key to disconnect position after the engine start.
2.7.2 make the engine run in situation after the engine starts and drive in gear until the
pressure and temperature arrive to the criterion.
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2.7.3 Pre-heat the engine to 30~40 degree starts the engine in low temperature zone or
in winter.
2.7.4 See the detail operating and manipulate: random “engine manual”.
2.8 Engine Malfunction Diagnosement And
Eliminatement
Reefing to the following chart to diagnose the usual malfunction except checking
whether the fuel tank and fuel pipe is leakage.
The malfunction-contrasting chart:
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trouble Remedial measureengine fails to start
runs unevenly or stall check CHengine becomes too hot, temperature monitor gives warnadjust A
Renew Rclean CLtop up TU
engine oil consumption exessive lower level LLengine smoke -blue
-white -blackcause section
★ not declutched(where possibleoperation CH★ ★ below start limit temperature CH★ ★ engine shut-down level still in stop positio CH
★ ★ oil level too low TU★ ★ ★ ★ oil level too high LL
★ ★ ★ excessive inclination of engine CH★ ★ ★ wrong SAE-grade of engine o op.Media R★ ★ ★ ★ fuel quality grade not as specified in operaR
★ ★ ★ air cleaner contaminated combustion R★ ★ ★ indicator/switch defective R★ cooling fins soiled cooling syst CL★ cooling air temperature rise /hot air recircuCH/R★ cool wind temperature is too high/intake hCH★ oil cooler soiled Ch/Cl
★ bettery defective/flat electrics CH★ loose or oxidized CH★ starter faulty or pinion does not engage CH★ ★ ★ ★ ★ valve clearances incorrect engine A
★ ★ ★ injectionline leaky CH★ ★ ★ ★ ★ ★ ★ injector defective CH/R★ ★ ★ air in fuel system CH★ ★ ★ ★ diesel filter/start filter is choked ch/cl/r
★ oil in combustion case Ch/Cl
engine give poor performanceengine not working on all cylinders
engine has little/no oil pressure
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2.9 Scooptram Operating
2.9.1 Sound the horn to warn all persons that you are going to start the engine.
2.9.2 Release the park break before startup.
2.9.3 drive the scooptram to stop away the material pile for 1 meter about, make the
bucket toward the material pile. Operate the change gear handle to move the change
gear case toⅠgear.
2.9.4 operate the liter oil tank handle to descend the big boom to the lowest position.
2.9.5 move the handle to place the bucket to the insert position toward material pile.
2.9.6 Press the accelerate pedal to the floor, drive machine toward mineral (or rock
pipe), insert the bucket to the material pile until the wheel slither. The dump and hoist
lever controls the bucket and boom. Moving the lever toward the operator raises the
boom. Move the hoist lever away from the operator to lower the boom. Make the
bucket insert and dump until the bucket fills.
2.9.7 Drive the scooptram to the dump skip, raise the boom to the demand height
(toward ore car, mobile or well), and align to the container receiving the ore. Move
the handle to make the bucket turn down to pour ore.
2.9.8 Retreat the scooptram and lay down the boom, make the bucket to the
transportation situation, then drive the machine to the mineral pipe.
2.9.9 Never suspend the front wheel when bucket insert to the mineral pipe. If find the
front wheel is suspended, raise the bucket properly in order to touch well between the
front wheel and floor, to ensure the enough insert press.
2.9.10 Change gear when driving, needn’t stop and press brake pedal. If change from
the high speed to low gear then release the oil pedal and then change gear. If change
the driving direction (forward to reverse or reverse to forward), then move the change
gear handle to neutral position and then change gear latter.
2.10 Scooptram Shutup
2.10.1 Scooptram should park on entire plate and dry horizontal floor. If park on the
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ramp, make triangle mood to tighten the wheel and close the hand brake.
2.10.2 the park steps:
①lay down the boom and bucket
②move the change gear handle to the neutral position
③engine shutup and pull out the ignite key
④disconnect the outlet
2.10.3 implement the following work if the scooptram parks for a long time:
①move the operating handle to the neutral position
②retract all hydraulic oil tank
③cover the machine cap with white or lucent cloths and efface (butter) to the
exposure of piston stick and the joint.
④unfasten the battery and store it in a dry room about 20 degree.
Chapter three every mainly part structure and
maintenance ACY-2 includes 6 sections: engine system, transmission system, front engine
mount assembly, rear engine mount assembly, hydraulic system and electric system.
This chapter mainly introduces the structure and maintenance in transmission,
hydraulic and electric system. Please consult the <<operation and maintenance
manual>> the factory supply about the detail structure and common maintenance in
buying parts such as engine, change gear case, torque converter and drive axle,
hydraulic pump and valve. This chapter will not give any instruction.
3.1 Transmission System
Transmission system mainly consists of torque converter, change gear case and
drive axle, transmission shaft. Torque converter connects with pump wheel by the
engine flywheel, then output gear output by 2-turbo and connect the change gear case
output drive gear by transmission axle, then change gear case put the emotion to the
rear and front axle by transmission axle.
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3.1.1 Axle
To increase the drive force and improve the working capacity, ACY-2 scooptram
adopts double drive axle and four-drive wheel. Front axle equips NO-SPIN against
sliding differential .In order to fit for the hardship environment, both rear and front
axle equip brake system with Spring-Applied, Hydraulically Released; Fully Enclosed,
Force Cooled Multiple Wet Discs at Each Wheel.
Power from the diesel engine is transmitted directly from the engine flywheel to
the torque converter. The converter output shaft transmits the power via driveline to
the transmission input shaft. The transmission output shafts transmit power via
drivelines to the front and rear differentials. The bevel gear and bevel pinion of each
differential transmits power through the differential to the free-floating axles. The
planetary final drive sun gears are splined to the axles. As the axles rotate, planet
gears mounted in the carrier are forced to walk around the stationary gear, imparting
rotation to the hub and wheel, which is attached to it. 3.1.1.1Decelerator by the wheel
The decelerator is one planet gear transmission organization by the wheel,
enclose and link one and fix on the axis of supporting by the wheel through a gear
wheel with interior tooth. Planetary shelf and rim are fixing and rotating together. Its
sport was got through the semi-axis and the sun wheel. Task of it is to increase
transmission torsion of department and reduce transmission rotational speed of
department further, in order to obtain the suitable speed of wheel. 3.1.1.2Multiple Wet Discs brake 3.1.1.2.1Advantage of this brake:
① This brake is not affected by external temperature and dust, working
performance is steady, it is very little to wear and tear, needn't generally change
while using.
② The annular work areas is large, have bigger making motive force torque.
③ Heat dissipation is effectual in cooling, it is reliable to apply the brake steadily
and its working temperature is low. It has long performance life generally for
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3-5 times of the dry type brake.
3.1.1.2.2 the maintenance of the brake is checked
① Whether check the brake shell and overlay have crack, nick and whether spline
that are worn and torn excessively, change it if necessary.
② Checking the regular one of brake, pressing one, thrust one, rubbing one etc.,
they should totally level and have no burr, crack, nick, shave wounded,fritting
etc., change it if necessary.
③ As rub disc of thickness is smaller than 4mm, or surface cannelure depth is
smaller than 0.2mm,and locating disc of thickness is lighter than 2.5mm, should
change it.
3.1.2 Transmission Shaft
The ACY-2 scooptram has five drive shafts: the changing speed drive shaft link
torque converter and gearbox; rear axle drive shaft link the gearbox fronts output
flange and rear drive axle; middle drive shafts link gearbox back and transaxle
bracket; the front axle drive shaft link the transaxle and front axle flange.
When the scooptram runs, the drive shaft should bear very big torsion and
impact, in addition, the condition of work is very abominable, so must carry on
serious maintenance and maintenance to the drive shaft, please pay attention to the
following several points while installing and using:
① Assign at horizontal plane drive shaft per section. There is a certain skew
angle between the change speed transmission shaft and rear front axle
transmission shaft at horizontal plane. Must guarantee installation that the
universal joint of both ends of each drive shaft lies in the same level
② When spline axle works, frequently slipping fork does the axial motion.
The cross axle is that the high speed and heavily loaded moveable piece in
addition, must lubricate regularly according to the regulation. Spline axle
oil seal prevents lubricating oil from overflowing and soaking with muddy
water, dust, must keep it intact.
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③ To dispel unequally transmission to final drive and prevent drive shaft
producing additional vibration and impact the gear wheel in drive axle.
Drive shaft joint yoke of both ends lay the same level. Carry on dynamic
equilibrium test and have arrow indicated already. While unpicking and
washing and repairing, pay attention to not destroying balance.
④ The apt and limit measurement of wearing and tearing the position of the
drive shaft is: the biggest interval between the spline axle and sliding fork
spline tooth side is 0.03mm; the biggest interval of the bearing underport
and cardan bearing is 0. 052mm; the biggest interval of cross axle and
bearing underport is 0.052mm.
⑤ The drive shaft must be overhauled while wearing and tearing allays to the
size of above-mentioned limit or change.
3.1.3 Tire, Rim
Tire, rim main walking part of machine. Tires in that machine use 12.00-24, 20
level smooth plane with inner tyre. Section size is heavy and elasticity fine, little than
pigeonhole earth have and has good wear-resisting performance
Dismantlement and resolving of the tire, rim:
① Support the frame with the jack or the support; make the transaxle leave the
ground. Unscrew the oil screw plug in the decelerator and brake by turning on
final drive, wheel and the net to let out lubricating oil among them.
② Put atmospheric pressure of tire to the same as environmental atmospheric
pressure, back out rim nut of bolt, pull down the tire and rim from transaxle.
Choose and open the lock ring, unload block enclosing and outer fringe then pull
down the tire, thus can resolve it.
③ Back out the planetary shelf and set bolt of the rim, carry the planetary shelf
from hub to loose with the top cover screw (M12) and hang and put a shelf of
planet to become always.
④ Take the sun wheel and semi-axis out.
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⑤ Unscrew the interior wheel lock bolt and take down the lock plate then take
down interior tooth enclose.
⑥ Fasten and open the nut, take down the tooth and enclose locating one.
⑦ Rock and hang and put down the hub gently
⑧ After the tire and rim are assembled, guarantee safely inflates.
3.2 Hydraulic Systems
3.2.1 Hydraulic System Component
ACY-2 scooptram consists of working hydraulic system, steering hydraulic
system, braking hydraulic system and change gear supplying oil hydraulic system.
3.2.1.1 steering and working hydraulic system
Hydraulic oil is supplied by the dump/hoist pump on the converter directly to the
dump/hoist main control valve. The system also receives additional flow from the
steering system. With monostick steering, oil flows through the Steering Control
valve from the high-pressure carry over (HCPO) port and through the Priority valve
from the excess flow (EF) port to the dump/hoist Main Control valve. With orbital
(Wheel) steering, oil flows from the power beyond (PB) port of the Steering Control
valve to the dump/hoist Main Control valve. The Pilot Control valve, located in the
operators cab, using 14MPa pressure supplied from the Pilot Pressure valve,
hydraulically operates the Main Control valve. The operator control lever directly
operates the Pilot Control valve. Oil travels from the Main Control valve to the boom
and dump cylinders. 3.2.1.2 braking hydraulic system
Braking hydraulic system includes Brake pump, SAFIM filling fluid Uncharging
valve, SAFIM foot brake valve .The above-mentioned components belong to the
international advanced products. In order to maintain the systematic pressure and
guarantee that the completed car can be dragged away from the job place when the
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engine breaks down, set up three device of holding energy which pressure is keeping
by the unload valve and its pressure range is 13-15MPa.
The characteristic of this system is the hydraulic pressure applies the brake and the
spring is released when driving a vehicle. If apply the brake, step on the brake pedal.
Then the pressure oil that the valve outputs is transmitted to the wet DISC brake, thus
realize brake. Oil pressure that output in direct radio journey under with pedal valve.
When all step on, the oil pressure that the pedal valve outputs reaches the maximum
designed, the complete machine is in the state of totally applying the brake.
In order to guarantee it while driving a vehicle park and apply the brake to totally
release, set up the pressure relay. When lower than the pressure of releasing in
pressure, the indicator lamp in the cab will give warning. 3.2.1.3 Change speed and mend the system of hydraulic pressure of oil
Mend oil hydraulic pressure system consists of mend oil pump, pressure regulating
valve, direction choose valve, gear choose valve, oil filter and cooler etc., main
hydraulic pressure component except the cooler is offered by DEUTZ Company, the
others are offered by DANA Company. Maintenance and maintenance working
content of system see former factory offer " the use safeguard manual ".
3.2.1.3.1 the pressure oil supplied device
Torque converter support oil gear wheel pump is installed in Torque converter,
driven by the diesel engine. The suction oil pipe links with oil bottom shell of gearbox,
output oil pipe connect with torque converter by 10um precision oil filter.
3.2.1.3.2 torque converter Control and mend the oil in oil pressure
The pressure of oil the pump output is control 1.76~1.96Mpa by the pilot valve
installed in the torque converter. The pressure is the need of gearbox rub clutch work.
Gear wheel oil that pumps discharges mend oil is mainly to the gearbox lubrication
and the gearbox to handle. It is extremely essential to go on to cool because of hot
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load the torque converter device produce. Pump wheel and turbine use the aluminium
alloy to make, and a relief valve prevents the inside pressure from being too high.
Leakage oil from the torque converter concentrate to oil bottom shell, and through one
hose flow back to the gearbox. In attention, the oil from the spray nozzle to lubricate
the gear in torque case flow back into oil bottom then back to gearbox.
3.2.1.3.3Directional control of the gearbox
Gearbox changes gear by many slice rub clutch. Oil consumption is low and
invariable. Multi-plate clutch doesn’t clench at ordinary times. The pressure oil that
the valve supplies flow through the valve out of supply of the clutch at first, and then
enter clutch. After carrying on brake, this valve cut of the pressure oil to reach the
clutch and make the clutch unclamp. Scooptram go advance or go backwards through
manual choose valve move position to control. Because of the function of the pressure
oil, after the clutch of a direction clenches, the other clutches are uncoupled because
of there is no pressure oil.
3.2.1.3.4Cooling of the oil and lubrication of the gearbox
The oil from the torque converter is too high and need to cool by cooler in order to
prevent oil from excessively high to making oil wear out and damage bearing too
early. The oil cooled flows and lubricates gear wheel and bearing to gather the shell of
oil bottom of gearbox. Every oil pipe, Cooler and lubricate distributor obstruction
make oil produce sure pressure lower, prevent the torque converter from air corrosion
phenomenon
3.2.2Fluid That The System Uses
3.2.2.1 Hydraulic oil
Machine adopts L-HM46 symbol or L-HV46 hydraulic oil; the complete machine
uses about 132 liters of oil. While using other oil to replace, need to meet the
following technical indicator:
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When the 50 degree, sport viscidity then 40 lics
Glue temperature index≥95
Condensation point is lower than - 20 degrees Centigrade
Clean and spend more than 10 grades (NAS1638)
3.2.2.2Hydraulic transmission oil
Hydraulic transmission oil No. 8
3.2.3 Fuel Tank Of The Hydraulic Pressure
The fuel tank of the hydraulic pressure is the oil storage device offering the
hydraulic oil for hydraulic pressure system. It is made up of several following parts
mainly: Case body, go back oil filter, air filter (and concurrently fuel-injection mouth),
wash oil mouth, liquid location instruction count, put oil mouth, suction oil pipe
package, etc. 3.2.3.1 the oil level checking
Is it should check oil level every 100-150 hour to work each time, for this reason,
all hydraulic pressure jar should withdrawal and engine stops working. Observing
liquid location height to count by location from liquid, in time the hydraulic oil should
be supplemented originally when being insufficient. 3.2.3.2 Oil filter
Containing two kinds of oil filter in the fuel tank, one is oil filter back to the oil
mounted on apron on the fuel tank; another kind of suction oil filter installed in the oil
device mouthing.
After the 20 hours to work and first change filter core. Work the second change
filter core after 100-150 hour work. Work each time after this to change and strain the
core in 400-500 hours and change and strain the core while changing hydraulic oil
each time. While straining the oil device seriously polluted, send news device to send
out signal point out and change and strain the core in time at this moment.
The method Strain and change the core:
A: the returns oil filter: Back out top cover and take out old filter core then change the
new core.
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B: the sucks oil filter: Put off oil of fuel tank first, lift hand hole apron off, loose suck
oil the connect bolt to unclamp and back out the old one change the new one.
Before putting and covering, check hand hole cover and suck oil O-ring. If
damage, change it immediately. While enclosing O-ring to put, the surface should
apply some butter. 3.2.3.3Air filter
To keep hydraulic pressure normal pressure of fuel tank and clean degree, change
the core of the air filter in 400-500 hours to work each time. Before packing into and
straining the core newly, should check whether the sealed cushion is intact and wash it.
If sealed cushion is damaged, should change immediately. 3.2.3.4 the fuel tank washing
When work for 3000 hours and change oil, wash wall and bottom in the all fuel
tank with cleaner completely each time; While washing, not use the washing cloth
fluffing, must remove the cleaner clean finally. Before covering put hand hole, check
O-enclose intact and the ones that damaged should change immediately.
3.2.4The Changing Of Hydraulic Oil
3.2.4.1 put oil
Change hydraulic oil in 3000 hour to work each time, system should change the oil
at appearing great troubling in hydraulic pressure. When the hydraulic oil used queues
up and varies change the oil. While changing the oil, cylinder should all withdrawal.
Insert the funnel under the oil plug then loose open oil screw plug and puts all the
hydraulic oil in the fuel tank neatly. 3.2.4.1 irrigate oil
Turn on empty filter cover; pour into hydraulic oil to fuel tank. After pouring,
check the situation of the strain core pollute, change if necessary. Forbid sucking the
oil from the bottom of the barrel while irritating the oil.
3.2.5the System Exhausts
Carry on system exhaust after refueling. Start engine dally for 5-10 minute and
24
make every cylinder unloaded and flexible for several times in order to get rid of the
air in the system. Then make the oil level of final inspection and supplements in case
of necessity.
3.2.6Systematic Accident Analysis Of The Hydraulic Pressure And
Safeguarding
The accident analysis systematic in hydraulic pressure is the focal point of the
repair work of completed car and difficult point, need relevant maintenance personals
to deal with the scene, On the basis of consult relevant materials or ask about
maintenance engineers and technician to go to the accident analysis arranged forms
and deal with the measure, some experience summarized and summing up is as
follows:
The accident analysis systematic in hydraulic pressure and Remedial
method
Steering system
Trouble Cause Remedial method
The steering core of the valve
is blocked
① The fluid is polluted ②
There is booty or the valve core
that is damaged in the valve ③
Damage to hitting the spring
① Wash the valve body, change
the fluid ② Wash the valve body,
change the core of the valve ③
Change the spring Operation of changing direction
is ineffective ① The handle is not flexible ②
There is air in the system ① Repair or reinstallation ②
Exhaust systematically
The systematic pressure is too
low
① The steering pump breaks
down ② The systematic relief
valve sets the pressure low ③
The overload valve sets the
pressure low
① Repair or reinstallation ②
Adjust the systematic pressure
again ③ Revitalize
The systematic pressure
fluctuates
① There is air in the system ②
Hydraulic oil viscidity is abnormal
③ The fluid is polluted ④ The
work of the valve is unstable
① Exhaust systematically ②
Adopt the qualified hydraulic oil ③
Change the fluid ④ Repair or
change
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Brake system
Trouble Cause Remedial method
the brakes do not have
pressure or the pressure is low
① The systematic pressure is
adjusted too low ② The pump
is out of order to apply the brake
③ hold the device out of order
④Hold device low to fill pressure
in advance
① Readjust the pressure ②
Repair or change ③ Repair or
change ④ Fill and press it to
7MPa
The foot a brake valve does not
work
① The foot brake valve body is
connected with footboard and
the bolt in the place becomes
flexible ② Hold the device low
to fill pressure in advance
① Revitalize ② Fill and press it to
7MPa
Park and brake does not work
① The systematic pressure is
adjusted too low ② The
electromagnetic valve is out of
order
① Revitalize the pressure ②
Repair or change
The pressure of the device is
unstable that can hold
① hold the device serve as the
pressure in advance low ②
hold the device leak the vapor
① Fill and press it to 7MPa ②
Repair or change
Job system
Trouble Cause Remedial method
The cylinder does not act ① the fuel tank liquid is low ②
The systematic pressure is low
③ Exceed load work
① Mend the oil ② Revitalize the
pressure ③ Reduce load
Movements of the cylinder are
slow
① The cylinder is out of order
② The systematic pressure is
too low ③ Mixed with the air in
the system
① Repair the cylinder ②
Revitalize the pressure ③ The
system exhausts
The hydraulic oil is warm and
too high
① Repair the cylinder ②
Revitalize the pressure ③ The
system exhausts
① Change and strain the core ②
Fill the hydraulic oil ③ Carry on
the hydraulic pressure system and
exhaust
The hydraulic pressure system
shakes the noise
① The oil level is too low ②
Mixed with the air in the system
③ suction oil pipe to stop up ④
Hydraulic oil emulsification goes
bad ⑤main overflow valve is
tremble.
① Check the oil level, fill the
hydraulic oil ② Carry on the
hydraulic pressure system and
exhaust ③ Check and suck the
oil and strain the core, change in
case of necessity ④ Change the
hydraulic oil ⑤Check the overflow
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valve, change in case of necessity
rise jar is unable to lift
① The hydraulic pressure
pipeline is let out ② the
pressure is too low in the main
overflow valve ③The reversing
valve blocking
① Check the pipeline to let out ②
Adjust the overflow valve ③
Overhaul the reversing valve
3.3Electric system
3.3.1Power system
Battery 6-Q (A-165) 12V 2
Generator 28V 35A take the regulator
3.3.2Start system
· Starter 24V 4.8KW enclose the relay
· Key switch
· Resistance that preheat
3.3.3Lighting system
Light from beginning to end; Cab light
3.3.4Signal system
Include signal lamp and chime
3.3.5Instrument system
Engine oil manometer (number 1788)
Engine oil thermometer (number 3425)
The rotational speed hour instrument
27
Voltmeter –30~+30
3.3.6Electric circuit
Electric equipment connect in arallel, 24V is made one-way, negative pole put
up irons.
Consider the job electric current as well as consider the mechanical intensity in
choice of the circuit wire. To guarantee starter power give play, require circuit
every 100A electric current voltage produced lower exceeding 0.1-0.15V, so
this circuit adopts 50mm2 wire. Electrical wiring harness can't be played tight
very much, especially move round the acute angle in the corner.
3.3.7Precautions of using of the regulator of the current alternating
generator
Polarity cannot link by mistake unless discharge will pass and will burn out other
electronic elements of the regulator.
Battery has electric capacity function. It protect transistor. So the line of
generator"+" receive by battery" + " lead must be firm. The battery can absorb the
instantaneous over voltage to a certain extent, as follows:
Add the instantaneous over voltage on the generator and regulator
Cause Voltage value (V) Lasting time
The battery is connected
inside out
-12V 或-24V -
The battery contacting in
series
+24V -
Switch key disconnection +20~+40V Several ms
The regulator Work +50~+100V Several 100us
All load disconnection +50~+150V 0.1~0.5s
Battery disconnection +50~+100V 0.1~0.5s
28
Transistor regulator and generator wiring is the correct," F " of regulator and "-
" binding post separately with " F " of generator and "- "binding post meet, and
the two specification should be matched.
Do not promise the insulation of checking generator and regulator by exchange
voltmeter of Europe's form or 220V handily
While changing the diode, the power of the electric iron can't be greater than
45W
The generator ceases fire, disconnect the starting switch in time
At the time of the normal running of the generator, electric apparatus line is
removable
3.3.8The trouble preventing
If QF1 circuit breaker trip, engine preheat circuit and start control break down
If QF2 circuit breaker trips, the generator circuit breaks down.
If QF3 circuit breaker trips, the previous light circuit breaks down.
If QF4 circuit breaker trips, the back light circuit breaks down.
If QF5 circuit breaker trips, energy storage pressure switch or its signal lamp and
brake, stop working to stop, horn circuit break down.
If QF6 circuit breaker trips, jarhead thermometer and sensor, engine oil
manometer and sensor, rotational speed form, voltmeter, jarhead temperature
switch and engine oil signal lamp circuit break down.
Battery fuse wire fuses start cable electromechanical circuit break down.
Connecting wire unwell causes the resistance to increase, thus generate heat. Pull
down the terminal box to check and connect electrically.
3.3.9Accident analysis and Remedial method
Electric system accident analysis needs specialized electric engineers and
technicians to measure and deal with, the following are some common trouble, reason
and measure.
29
Lighting system and indicator lamp circuit part
Trouble Cause Remedial mention
The headlight and taillight
go out
① The bulb is out of order ②
The circuit takes off broken
circuit loose ③ QF3, QF4
circuit breaker trip ④ The
switch damaging
① Change the bulb ② Change
the bulb or tighten the connect ③
Change the wire, check whether
short out or not ④ Change the
switch
All indicator lamps are not
bright
① Battery switch disconnection
② Power shortage of the
battery
① Open the switch ② Charge
Some indicator lamps are
not bright
① The specific sensor is out of
order ② The specific indicator
lamp damaging
① Change the sensor ②
Change the indicator lamp
Incorrect indication
① Power shortage of the
battery ② The specific
indicator lamp damaging ③
The specific sensor is out of
order
① Charge ② Change the
indicator lamp ③ Change the
sensor
Alternating current generator section
Trouble Cause Remedial mention
The battery is charged
excessively
① It is high to charge the voltage
② Binding post earth of electric
brush ③ regulate the resistance
too big
① Change the voltage regulator
②Correct installation alternating
current generator ③ Check
and maintain The battery is too big in
power consumption ① It is excessive to charge ②
The shell of the battery is let out ① Check the alternating current
generator ②Change the battery
The battery can't keep
charging the state
① Connect and damage with the
wire ② The alternating current
generator damaging ③ The
battery damaging
① Wash , maintain or change
30
Chapter four Maintenance and maintenance of
the scraper Fixed maintenance and maintenance work depend on the operation of the vehicle
operates the number hour; it according to maintain regularly to go on hour to serve.
Because the driver's skilled degree of operation and maintaining the difference of
the situation to the scooptram, some spare parts of the machine can not be damaged
according to the same regulation, observe and maintain some spare parts irregularly.
4.1 Generally safeguard the step and method of
maintaining the work regularly:
4.1.1Wash the machine
Before beginning any work, wash the spare part lying in relevant working ranges.
Selecting cleaner and wash medium correctly depends on material of spare part. For
example rubber or electric apparatus part should wash to spray with benzene or steam.
4.1.2 Put lubricating oil
After the machine is washed, put the lubricating oil in all movable-bearing places. After lubricating oil, removing the excessive lubricating oil.
4.1.3Antirust and protect
Mend lacquer destroyed and surface damaged frequently.
4.1.4Change the part
Change the spare part damaged in order to prevent greater trouble from taking place
in time
31
4.1.5The circuit maintaining
The dangerous wire is joined well with the tool; go on in close down the switch cases
4.1.6check the oil level
After the machine operates for 15 minutes, check the oil level. While checking and
mobilizing the engine oil location. Suspend the machine on a smooth ground and go
on after the engine stop working for about 10 minutes.
4.1.7Change the oil
Only under hot car state, put oil from oil mouth and not remove the filter screen from
the fuel-injection mouth when refueling
4.1.8Check the seal and its surface
Check the damaged condition of the sealed component. If need changing, change the
sealed component damaged at once. Before reinstallation, wash the whole seal surface
and check install-sealed situation.
4.1.9Check and lock the component
When dismantle the part, pay attention to lock component (lock washer, the flat pin
etc.)
4.2 General unscheduled maintenance and project
maintained
⑴ Check the hydraulic pressure and oil level of the fuel tank.
⑵ Check all points lubricated situations.
⑶ Check case , lid , covering , plug , pipeline etc..
32
⑷ Check the tightening torque of the rim bolt.
⑸ Check the atmospheric pressure of the tire.
⑹ Check the function of the electric system.
⑺ Check the operate component and control the function of the instrument.
⑻ Check the function of the brake system.
⑼ Check the unload / raise the function promoted and turn to the hydraulic pressure
system.
4.3 Safeguard and maintain tabulating regularly
According to server time to maintain regularly figure 1:
Engine Safeguard the work
Measurement
Observation
Consult each other The hours of Operate Opinion
The eye depend on that
checks seepage 10 50 150 300 600 1200
Check and mobilize the
engine oil location
Check with the dipstick
by eye, need to add
fuel-injection /
Check firm junction, tube
and hose If need to tighten /
Check transferring speed
organization and
footboard stopping
device
/
Plan to carry on the
maintenance of the
engine according to the
maintenance of engine
manufacturers
Use the meaning of the symbol in the form: /: Real; X: need match.
According to server time to maintain regularly figure 2:
33
The hours of Operate Safeguard the job bridge,
the transmission
Measurement
Observation Consult
each other 10 50 150 300 600 1200 Opinion
The eye looks at and
checks the seepage
situation /
Axle: Changing with oil of
differential mechanism
See relevant chapters fill
the volume and technical
data with /
The changing of planet
gear oil
See relevant chapters fill
with the volume and
technical data /
Wash the air cleaner /
Check the interval that
the final drive inputs the
bearing of the gear wheel
Check the installing
flange in the drive shaft
with hands /
Transmission: Needle
bearing interval of the
Hooke’s joint Check on eye /
According to server time to maintain regularly figure 3:
The hours of Operate Maintenance Tire and wheel
Measurement
Observation Consult
each other 10 50 150 300 600 1200 Opinion
Check model and pressure
See technique date about inflating pressure
/
Check the destruction
situations of the tire and
the pattern profundity of
the tire
Check by eye /
Check the tightening torque in the rim
If need to tighten ,
tightening torque see in technique data
/
According to server time to maintain regularly figure 4:
34
The hours of Operate Maintenance Electric system
Measurement
Observation Consult
each other 10 50 150 300 600 1200 Opinion
Indictor instrument function、signal lamp、control component and illuminating system
/
Battery: check oil level. Put special battery fluid /
About the breaking-down of the cable
Check by eye /
According to server time to maintain regularly figure 5:
The hours of Operate Maintenance Working system
Measurement
Observation Consult
each other 10 50 150 300 600 1200 opinion
Check the interval of the bucket pin shaft
Check by eye
/
Check the interval of the boom pin shaft
Check by eye
/
Check the rotating joint pin shaft
Check by eye
/
Check the stabilized device/connecting stick of pin shaft interval (if have)
Check by eye
/
Unload device /
Check the bearing interval of scooptram bucket
/
Check the interval which rotates the pin joint bearing
/
Check rotator knuckle joint place fasten set bolt of device
If need to tighten,tightening torque see in technique data
/
According to server time to maintain regularly figure 6:
35
The hours of Operate Safeguard work
Steering and unload
Rise hydraulic pressure
Measurement
Observation Consult
each other 10 50 150 300 600 1200 opinion
Check the oil level of the
fuel tank
Count from liquid location
eye to check Flexible
cylinder
/
Check the seepage of
the junction, pipeline and
hose
If seepage, find out the
reason; If necessary,
would change the part
/
Check the steering
pressure
See the systematic
picture about test
pressure and
measurement
/
Changing the oil of fuel
tank See relevant chapters /
Change the returning
training core of oil filter
(strain tube)
Signal lamp is on or "
returning oil pressure "
indicator rise to 1.3 bar
most late in 300 after
operating hour. See
relevant chapters
/
According to server time to maintain regularly figure 7:
The hours of Operate Safeguard the work
torque converter and
gearbox Hydraulic part
Measurement
Observation Consult
each other 10 50 150 300 600 1200 Opinion
Check oil level
Make engine in operate
temperature to turn
round, test with oil chi or
gearbox oil spiral plug
check to look at.
/
Check the seepage
situations of the tube,
hose junction
If seepage, find out the
reason; If necessary,
would change the part /
Wash the oil cooler
Blow the tube by
compressing the air,
make it cross the tube /
Change the hydraulic oil
filter See relevant chapters /
Change oil See relevant chapters /
36
Clear up the oil filter in
the fuel tank See relevant chapters /
Check the interval of the
bearing: torque
converter output and the
gearbox output and
input
Manual on the flange of
the drive shaft /
Clear up the torque
converter to device - the
air vent hole of the
gearbox
/
Check the pressure of
the clutch
See the systematic
picture about the test
pressure /
According to server time to maintain regularly figure 8:
The hours of Operate Maintenance
Brake system
Measurement
Observation Consult
each other 10 50 150 300 600 1200
Opinion
Check the function of the
stopping brake and the
working brake
/
Check the seepage
situations of the tube,
hose junction
If seepage, find out the
reason; If necessary,
would change the part
/
Check the pressure of
the brake or check
respectively.
Daily test pressure
instrument (sensor). See
the systematic picture
about the test pressure
/
Text the brake with
recorder
The slope of car fully
loaded with the vehicle
stay: working brake
minimum 35%, park
minimum 25% of brake
/
Check the stop brake
install (installment: See the relevant chapter /
Multi-disc brake
/
Check the wearing away
situation of the brake Estimating a brake, the
minimum brake one is
lined with thickness 3mm
/
Check the wearing away The minimum thickness /
37
situation of working brake of brake slice isn’t
smaller than 3mm on
the brake disc and drum
brake
/
Change the filter input oil According to the
maintenance /
Check pressure of all
brake system
See the system picture
about test pressure /
According to server time to maintain regularly figure 9: The hours of operating Maintenance
Lubricating point Measure observe See each other 10 50 150 300 600 1200
Note
Drive shaft: converter-gearbox
Butter pump nozzle /
Drive shaft: gearbox-front axle
Butter pump nozzle(three) /
Drive shaft: gearbox-rear axle
Butter pump nozzle /
Swing rotation axis Butter pump nozzle /
Central knuckle joint
pivot Butter pump nozzle(tow)
The steering cylinder Butter pump nozzle(tow)
Rising cylinder Butter pump nozzle(tow) /
The tumble cylinder Butter pump nozzle(tow) /
Stabilization plant pole
(prop up the foot) Butter pump nozzle /
Big boom- connecting
rod Butter pump nozzle /
The big boom rotates
bearing Butter pump nozzle /
Big boom - bucket bearing
Butter pump nozzle(tow) /
Working operating shaft
Butter pump nozzle(tow) /
Steering operate shaft Butter pump nozzle /
38
Gearbox operating shaft
Butter pump nozzle(five)
Position that all joints
move about HD-engine oil /
.
39
Figure 1
40
Figure 2
41
R
R2
N
T2
T2′
T1′
T1
R1
Figure3
42
Figure 4
43
Figure 5
44