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Omm DH17 PDF
Omm DH17 PDF
Chapter 1 Safety
Chapter 1
1.1.1 Designated Use
This machine is mainly used for: highways, airports, and other large areas of farmland
floor leveling, trenching, transportation, backfilling bulldozing, scarification and other earth
work. Construction and water conservancy construction, farmland improvement and other
defense projects, mine construction, urban and rural roads construction conditions.
Overload; load manipulation with blade rotation; when uneven roads, prohibited the use of
high speed; rapid acceleration or rapid deceleration. Super slope climbing or job.
If used for other purposes, or potentially dangerous environment, such as in high altitude
hypoxia, flammable and explosive environment or containing asbestos dust area, you must
comply with the special safety requirements, and must be for the device is equipped with a
device suitable for use for the corresponding.
Only 18 years of age and is trained and authorized personnel to operate the equipment;
operator must clearly and comply with the equipment operating specifications and
requirements; persons affected by alcohol, drugs or narcotics must not be affected by the
operation and maintenance of the equipment; Only trained and qualified and authorized
personnel to be able to present equipment perform maintenance work.
The following warning signs and safety signs apply to this vehicle.
• Be sure to know correct locations and information of the signs well.
• Ensure the information on the signs is legible normally. Ensure the signs are located in
Chapter 1
correct places and always kept clean. When cleaning a sign, do not use organic solvent
and gasoline so as to avoid causing it to come off.
• Some other signs are also available in addition to the warning signs and safety signs.
These signs should be handled in the same way.
• If any sign is broken, missing or illegible in normal conditions, please replace it with a
new one. Please refer to this manual or check the real objects for detailed part numbers
of the signs which can be ordered from dealers of Shantui.
1 2 3
Chapter 1
4
A to rotation
7 8
5 6
B to
A
9 10 11 12
Serial Serial
name name
number number
Sign(engine temperature, running
1 Sign(close attention) 2 attention)
09806
09806--10880
10880
09667- 10880
Chapter 1
09817 - 00880
注 意
注 意
09651 - 20480
Chapter 1
FILTER MUST BE REMOVED AND CLEANED EVERY 250 OPERATING
HOURS.
(SEE OPERATION AND MAINTENANCE MANUAL FOR DETAILS)
Cautions in Winter
(09658-00100)
Precautionsduring backing up
(09802-02000)
2 3
B to
1
Chapter 1
B E
4 5
E to rotation
7 6
Serial Serial
name name
number number
1 Lifting position sign 2 Blade control sign
1.MACHINE LIFT AND FIXED POSITIONS ARE SHOWN IN THE FIGUERS ABOVE.
2.BEFORE LIFTING MACHINE.TURN OFF ENGINE AND ENGACE THE PARKING BRAKE.
09963- 02100
09671-35468
09670 - 00001
Chapter 1
MAMUFACT YEAR
PIN(PRODUCT
IDENTIFICATION
NUMBER)
SHANTUI CONSTRUCTION MACHINERY CO.,LTD.
NO.58 NATIONAL HIGHWAY 327,HIGH-TECH ZONE,272073,
JINING,SHANDONG,PEOPLE’S REPUBLIC OF CHINA
• Only specially trained and licensed persons can operate and service the machine.
Chapter 1
People overfatigued or under the influence of alcohol are never allowed to drive. Never
allow the machine to work with defects or under overload.
• Machine operation and maintenance should be performed in strict accordance with the
safety regulations, precautions, and instructions.
• When you are working with other operators or a site traffic controller, make sure all
persons involved can understand all gestures and signals.
• If any abnormality is found while the machine is running, stop immediately to service it.
Do not continue to operate until the abnormality is eliminated.
• All relevant provisions should be observed.
• The machine is suitable for operation below an elevation of 3,000m. As elevation
increases, its power will drop. If it is used at elevations above that limit long, its parts
could be damaged. If this elevation limit is exceeded, it is recommended that you use a
plateau-type trimming dozer of Shantui.
• Ensure all guards and covers are placed in correct positions and damaged components
have been repaired.
• Use safety devices such as safety lever and seat belt properly.
• It is prohibited to remove any safety device. Ensure they are in good working order.
• Incorrect use of safety devices may result in serious personal injury or death.
Chapter 1
• When operating and servicing your machine, be sure
to wear helmet, safety goggles, face shield or gloves,
and safety shoes. If you will be exposed to splashing
chips and other fine particles during working, be
sure to wear goggles, hard helmet, and thick gloves.
Especially, when hammering on a dowel or using
compressed air to clean the filter element of the air
cleaner, you must check that there is nobody near the
machine.
1
1.3.4 Unauthorized retrofit
1.3.5 R e q u i r e d l o c k i n g b e f o r e l e a v i n g t h e
driver's seat
• When the driver leaves his/her seat, he/she must
make sure that the safety lever and parking brake
lever are in the locked position. Otherwise, a joystick
not locked may be touched to make the attachment
move abruptly thus causing serious injury or damage
Chapter 1
• When refueling and oiling, be sure to shut down the
engine; in addition, smoking is strictly prohibited.
• Tighten the caps on the fuel tank and hydraulic oil tank
securely.
• Add fuel or lubricating oil in well-ventilated places.
• Keep fuel and engine oil in the designated place where
access by unauthorized persons is forbidden.
• Do not let the oil spill to hot surfaces or electrical system
components.
• After filling fuel oil or engine oil, mop the spilled part.
• When grinding and welding on the chassis, move all the
flammable materials to safe place before it starts.
• When flushing parts with oil, use non-flammable oil. use
diesel or gasoline which is easy to catch fire.
• Put the oily cloth or other inflammable materials into
containers to ensure the safety of workplace.
• Do not weld or torch cut the pipeline containing
flammable liquid.
• When checking fuel, oil, battery electrolyte, window washing liquid or cooling liquid,
use the lighting equipment with explosion-proof performance. There will be a risk of
serious injury caused by the explosion without this.
• When using the power of machine, follow the instructions in this manual.
Chapter 1
1.3.11 Nobody allowed on the ancillary equipments
Don’t let anyone sitting on the working device or other accessories. If there is somebody
on the accessories, it may bring about the risk of falling and serious damage.
• Do not reach your hands, arms or other part of your body into or put them between
moving parts (e.g. attachment and cylinder, body and attachment, etc.). The gap
between the parts may change when the machine is working so that serious part
damage or personal injury may result.
• When an optional extra is fitted and used, read related sections in its Users Guide and
this manual first.
• Do not use any optional extra not approved by Shantui or your dealer. Use of
unauthorized optional extra will cause safety problems and the normal operation and
service life of the machine will be affected.
• Shantui will assume no liability for any injury, accident, and mechanical failure resulted
from use of any unapproved optional extra.
Chapter 1
• Check the terrain and soil texture and then select the best working method. Do not work
in any area where is susceptible to falling objects.
• When the machine is working on a road, someone should be specially assigned to
direct traffic and roadblocks should be set up to ensure traffic safety and safety of
pedestrians.
• When working in the places where have underground buried facilities such as water
pipes, gas conduits, and high voltage cables, you should contact related departments to
determine the locations of the pipelines. During construction, take care not to damage
them.
• When working in the water or getting over a sand barrier, check the ground quality,
water depth, and flow rate first. The permissible water depth must not be exceeded.
Fire prevention
• Completely remove inflammables such as wood chips, leaves, and paper accumulated
on the engine case so as to avoid fire.
• Check fuel, lubricating oil and hydraulic systems for leakage and repair any leaks.
Remove all excess oil, fuel or other flammable liquids.
• Ensure a reliable fire extinguisher (optional or self-contained) is available.
• Do not operate the machine in the vicinity of any open flame.
In the cab
• Be sure to keep tools or spare parts in the tool kit in the vehicle. Do not place them
in the cab in a scattered manner so as to avoid damaging or breaking any joystick or
switch.
• Keep the cab floor, joysticks, pedals, and handrails free of oil, grease, snow or other
dirt.
• Check the seat belt, retaining ring and parts for damage or wear; replace damaged
components. When driving, be sure to buckle up.
• Do not bring flammable or explosive dangerous articles into the cab.
• Smoking is prohibited in the cab.
Closed space ventilation
• If you have to operate the engine in a closed space, be sure to maintain adequate
ventilation. Excessive engine exhaust gas could cause death.
Driving precautions
• When moving on a flat road, the height of the blade above ground should be 40~50 cm.
• When traveling on an uneven road, drive at low speed, make turns smoothly, and avoid making
sudden turns.Otherwise, the machine may turn over, the working device will hit the ground, and
make the machine be out of balance.
Chapter 1
• Do not use a mobile phone when driving your vehicle.
• When operating the machine,be careful not to exceed the performance values, such as stability,
the maximum applied load, ect. In order to prevent rolling danger caused by an overload work or
accidents caused by the working device damage.
Driving on a slope
• When driving on steep hillsides, dams or slopes, rollover or slipping may result.
• When driving on hillsides, dams or slopes, you should keep the blade close to (approx. 20~30
cm above) the ground. In case of emergency, lower the blade to the ground rapidly to help stop
the vehicle or prevent it from overturning.
• Neither make turns on nor cross slopes. Instead, perform such operations after driving to flat
places.
• Do not pass through on grasslands, deciduous leaves or wet steel plates. These places may
cause the vehicle to slip. When driving along a slope edge, maintain very low travel speed.
• When going down a slope, drive slowly and use engine brake.
• When the engine stalls on a slope, depress the brake pedal immediately, lower the blade, and
apply the parking brake
Precautions during operation
• Do not perform dozing operation while facing the wind so as to prevent dust.
• Especially prevent sudden starting, turning or braking when the vehicle is laden.
Ensuring good vision
• When working in the dark, be sure to use the work lights and ceiling light and you need to set up
lighting devices on the site.
• In the case of poor vision (e.g. in foggy, snowy and rainy days), stop working and do not proceed
until the weather gets better.
• Soil in the vicinity of a gully is softer so that it may collapse due to the weight of and the
shock from your machine.
• When your machine is working in hazardous areas and in places that are at risk of falling
sandstones, a falling object protective structure (FOPS) must be fitted.
• When your machine is working in places that are at risk of falling sandstones and vehicle
overturning, a roll-over protective structure (ROPS) and a seat belt must be fitted.
• Place the attachment on the ground, put the steering and shifting joystick etc. to mid
position.
• Tighten flameout stay,make the engine stalled.
Chapter 1
• Totating the key to OFF location.
1.4.3 Transport
Transport
• Trimming dozer handling always involves potential hazards so you must use extra care. When
handling, run the engine and drive the vehicle at low speed.
• Handle on a flat hard ground. A safe distance must be maintained from the road edge.
• Before handling, be sure to support the wheels of the trailer and the sloping plate with pads.
• Use a sloping plate having enough strength. Ensure the sloping plate have adequate length and
width for forming a slope with a safe gradient.
• Ensure the sloping plate is placed and secured firmly and that the 2 pieces of the plate are in the
same plane.
• Ensure the sloping plate surface is clean and free of oil stains, ice or other loose materials. Remove
dirt on the tracks of the trimming dozer.
• Do not operate the steering joystick while on the sloping plate. If necessary, back off the sloping plate
and correct the direction, and then climb on the plate again.
• After the machine is loaded, support its tracks with wood blocks and stop the vehicle securely.
Shipment
• When dispatching the trimming dozer with a trailer, observe the national and local
regulations concerning length, width and height of the cargo as well as all applicable
laws.
• When determining the shipping route, you should take the length, width, and height of
the cargo into account so as to prevent out of limits.
1.4.4 Battery
Chapter 1
each other.
• When connecting auxiliary cables, turn starting
switches on the normal machine and the faulty
one OFF.Otherwise, the machine may move when
powered on.
• When using charging cables, be sure to connect
the positive cable first. When removing, be sure to
disconnect the negative cable (ground wire) first.
• If any tool touches the positive (+) and the chassis at
the same time, sparks will be generated. This is very
dangerous. Therefore, be sure to operate with care.
• When connecting 2 batteries in series, connect
positive (+) of one battery with negative (-) of the
other and negative (-) of the former with positive (+) of
the latter.
• When connecting the ground wire to the frame of the
vehicle to be started, ensure the connection is secure.
Personnel
• Only authorized personnel are allowed to perform
service and maintenance. When grinding, welding and
Chapter 1
using a sledge hammer, you should take some safety
measures.
Fittings
• The parts removed from the machine should be put in a safe
place. Ensure they will not drop and fall down; otherwise,
serious personal injury will result.
Illumination
• When checking the fuel, oil, coolant or electrolyte of
battery, always use explosion proof light, or else it will
explode.
Chapter 1
Precautions for maintaining battery
• When repairing the electrical system or using welding,
should disconnect the negative electrode of battery
and cut off supply power.
Waste
• Do not pour waste oils into sewers or rivers.
• The oils drained from the machine must be put
in vessels instead of being poured on the ground
directly.
• When disposing of engine oil, fuel, refrigerant fluid,
solvent, filters, battery and other toxic (harmful)
substances, you must observe related laws and
regulations.
ge
Pa
s
te
No
Figure 2-1
3088
Chapter 2
1010
520
5255
3 40 0(Semi-U blade)
1880
2390
Figure 2-2
3091
1010
Chapter 2
485
5340
2350
3450
4150
Figure 2-3
Chapter 2
Track central moment (mm) 1880 2350
Min. turning radius (mm) 1795 2265
Grade ability (°) 30
Description
1. Operating masses for this machine include cab, seat, blade, drive system, engine hood,
coolant and 30% of fuel.
2. The blade is included in calculation of the machine length.
This product uses the engine WD10 model of WeiChai, shape are shown as follow.
Chapter 2
Figure 2-4
Two-pump two-motor closed hydrostatic pressure driving system is used for the travel
hydraulic system
★ Travel pump
• Type: swash plate operated piston variable pump
• Operating pressure (MPa): 42
★ Travel motor
• Type: swash plate operated piston variable motor
• Operating pressure (MPa): 45
Chapter 2
One-pump open system is used for the hydraulic system of the working device, mainly
including working pump, working main valve and working cylinder
★ Working pump
• Type: gear pump
• Pressure (MPa): 21
The trolley pivoting connection by connecting the equalizing beam to right and left trolleys
is used for the travel mechanism
• Type: pivoting connection.
• Number of carrier rollers: 2 pieces/side.
• Number of track rollers: DH17-standard :7 pieces/side(2 in two sides, 5 in one side);
DH17L- wetland: 7 pieces/side(3 in two sides, 4 in one side).
• Track type: single track grouser combination;wetland type combined.
• Track shoe width (mm): DH17(560/610);DH17L(950/1100).
• Track grouser height (65): DH17(65);DH17L(217.5).
Chapter 2
Primary spur gear plus primary planetary gear reducer are used for the final transmission
Brake
• Brake type: disc spring locking
Sprocket
• Number of sprockets: 27
ge
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No
Chapter 3 Operation
3.1 Controls
7
6
Figure 3-1
Chapter 3
Figure 3-2
2
This lever is used to control the engine speed and 1
output.
① Engine idle speed position: Push the lever forward
fully.
② Low idling position of engine. Figure 3-3
③ High idling position of engine:Pull the lever to the last
Chapter 3
end.
Transmission Control Lever(Figure 3-4)
automatically engage. J H
C
(2) FORWARD(B)
Move lever to the forward position in order to move the
Figure3-4
machine forward.
(3) REVERSE(C)
Move lever to the backward position in order to move the
machine backward.
Chapter 3
Move lever to the right in order to turn the machine to the right. The turning radius for the
machine is proportion to the control lever position. In order to turn the machine to the right
slightly, move lever slightly to the right. If you want increase your turn, move lever further to
the right. If you want the machine to counterrotate, move lever all the way to the right past
the detent position. When the tracks counterrotate, the left side track will rotate forward,
while the right track rotates backward.
(8) REVERSE LEFT(H)
Move lever to the left in order to turn the machine to the left. The turning radius for the
machine is proportion to the control lever position. In order to turn the machine to the left
slightly, move lever slightly to the left. If you want increase your turn, move lever further to
the left. If you want the machine to counterrotate, move lever all the way to the left past the
detent position. When the tracks counterrotate, the right side track will rotate backward,
while the left track rotates forward.
(9)REVERSE RIGHT(J)
Move lever to the right in order to turn the machine to the right. The turning radius for the
machine is proportion to the control lever position. In order to turn the machine to the right
slightly, move lever slightly to the right. If you want increase your turn, move lever further to
the right. If you want the machine to counterrotate, move lever all the way to the right past
the detent position. When the tracks counterrotate, the left side track will rotate backward,
while the right track rotates forward.
CAUTION
• When and where the machine is parked,
always set the par king level to the
LOCK position.
• Put the undercarriage control level in
“Neutral” (N) before pull the safety
level in “Lock”.
Chapter 3
CAUTION
Figure 3-7(a)
• When released from FOLAT position, this
level will not return to HOLD position, so it
must be moved back by hand.
• When the tilt cylinder reaches the trip ends.
set the blade control level to the HOLD
position.
• When the blade at the highest or lowest
point,don't tilt the blade.
• When start the engine, set the blade control
level to the HOLD position.
Figure 3-7(b)
Chapter 3
2
(a) (b)
Figure 3-8
CAUTION
CAUTION
Figure 3-10
1
CAUTION
Chapter 3
max right revolution angle is 20°. 1
4
• Backrest inclination adjustment: lift handle "(4)", tilt
2
3
adjustment after appropriate, loosen the handle.
• The handle clockwise seat adjustment: hard and soft
"(3)", make the hard seat. The weight range from 50kg
to 130kg. Figure 3-12
CAUTION
• Before fastening the seat belt, inspect the Figure 3-13
Operation:
1、Start the engine;
2、Meanwhile keep pressing the button for 3 seconds,
then immediately switch off 1~3 seconds. Repeat the
above operation to gush the starting fluid into intake-
tube, until the engine work normally. Then stop the
operation. The button reclosing time is no more than 3
seconds and the frequency is no more than 10 times. If
the ether starting device works abnormally, check the pot Figure 3-15
and pipeline, or repeat the operation 1 minute later.
CAUTION
Ether starting device is only used for starting the engine ;
This device can only be used when the environment
temperature is below 0 degree.
Fuel heater is an optional and auxiliary device to start the engine at low temperature. It is
used to heat the minor-cycle cooling liquid for starting engine and provide hot power for
heating system. Exhausting gas can heat oil pan.
Operation:(Figure 3-16a,b)
1、Pressing the first gear of the rocker switch, the water pump (1) starts to work,
meanwhile fuel heater do not work. We can observe the green power light and red status
Chapter 3
light (on the heater) to check water-cycle well or not.
2、Pressing the second gear of rocker switch, the water pump and fuel heater (1and 3)
work at the same time to heat cooling liquid. When the water temperature reaches 80℃,
the fuel heater will stop work automatically.
(Reminder: Press the second gear of rocker switch, after about 2-3 minutes, the heater will
start working.)
3、Start the engine
(Remark: In order to start the engine more faster, we can turn off the heating system intake
valve(4) before;)
4、After starting the engine, turn off the rocker switch and heater intake valve(2).
1 2 3 4
Figure 3-17
Noise
Put on ear protector to protect your ears.
Chapter 3
firmly.
2. Use silicon rectification generator and match ic electronic regulator.
3. It introduces advanced solenoid relay,efficientley portect the starter and start switch.
4. When engine start switch on the switch-off,the battery relay can auto cut off power in
order to avoid leak out power.
5. When install the electrical component and connector,you should check-up the
connection color,model and position.Make sure not make a mistake.
6. When change the battery ,you should choose the same model.If you use the small
capacity one,it will mangle becaus of over loading on starting.
7. Make sure that the engine start switch key stay on the START position less than 10
seconds. If the engine fails to start, the engine start switch key must remain over 2
minutes in order to attempt to start the engine again.
8. The connection position of engine start switch:
automatic reset n
tom osit
sta
ati
rt p
cr
es
et
ion
Figure 3-18
the object as the fuck.The pictures is only for reference in this introduction.
This chapter aim to supply safe and efficient operating instuctions and electronic system
maintences for user.You could avoid all kinds of dangerous accidents through learn the
notices in this chapter.
• Make sure battery disconnect switch touch fine and the resistance below
0.001Ω.
• It's refused to allow jointing anywhere in the case of the controller and
battery disconnect switch are not disconnected.
Chapter 3
• Forbid removing GPS system component and wiring to avoid lockout
machine.
Switch-Off——
Step Note
1. Park the bulldozer into smooth zone.
2. Park.
3. Move all hydrolic component in low
speed.
4. Operate the engine for five minutes at
low idle with no load.
Chapter 3
1. Power supply:18~32VDC
2. Work temperature:-30~+70℃
3. Save temperature:-40~+85℃
4. Relative humidity:(30~90)%RH
5. Atmospheric pressure:86~106KPa
6. Protection :IP67
Chapter 3
When one or above parameters are out of range,electrical system will damage or work
abnomally.Please in strict enviroments to ensure the system work normally.
2
7
1 8
Figure 3-19
Nub Name Nub Name
1 Low Engine Oil Pressure 2 Transmission Oil Filter Indicator
Indicator
3 Engine Coolant Temperature 4 LCD Display
Gauge
5 H y d r a u l i c O i l Te m p e r a t u r e 6 Fuel Level Gauge
Gauge
7 Controller Accident Indicator 8 Parking Brake Indicator
Fuel Level
The gauge displays the fuel level in real-time(Figure3-20).
Dispay range:0~1.
The gauge has purple backlight to help observing in night.
Figure 3-20
Coolant Temperature
The gauge displays the coolant temperature in real-
time(Figure3-21)Display range is 40℃~120℃.The gauge has
purple backlight to help observing in night.
LCD intelligent monitor displays the coolant temperature in
real-time,enter the parameter menu to inquire.
1. When the coolant temperature sensor in open circuit,
pointer points to the zero,intelligent monitor warning
Chapter 3
Chapter 3
"engine oil pressure short circuit", buzzer ring.
3. When engine oil pressure sensor the pressure below
1 Bar,intelligent monitor warning"engine oil pressure
low",buzzer ring.
4. Relieve warning shoud after 10s in normal conditions.
5. Press K1 can screen buzzer ring.(Figure3-27)
!
Figure 3-26
• When operating,check-up the indicators at
any moment, make sure it work normally.
The switch panel is composed of three push button reset switches ,one toggle switches
and one engine start switch.Figure3-27:
Chapter 3
5 4 3
Figure 3-27
Chapter 3
time,saving the battery.Turn the battery disconnect
switch to ON position in order to activate the electrical
system. Figure 3-29 Battery
Disconnect Switch
Intelligent Monitor
The work display of intelligent monitor are engine
hours,engine speed,forward speed(F),backward
speed(R) and error alarm .The example is Figure 3-31.
The mostly function of intelligent monitor are: Alternator failed
a. display the run parameters in real-time
b. supply error alarms Figure 3-31 Intelligent
c. system settings and viehile managements Monitor display
chinese
User setting language settings
English
flywheel tooth number(scale:
alarm parameters settings 000.00-300.00)
system setting engine oil pressure setting(scale:
0.5-1.5)
test information(spare)
vehicle site unlock open
vehicle management site unlock(dynamic password)
vehicle site unlock close
monitor informations part number:D2200-02500
Main interface
No Alarm Alarm
9999.9H 9999rpm 9999.9H 9999rpm
Chapter 3
Engine coolant temp high
Main menu
Working Para GPS Manage
Alarm Para Display Info.
User Set Engine Error.
System Set Control Error.
Working Para Alarm Para User Set System Set GPS Manage Monitor Information
Collant : ℃
Please Enter the Password Product:
OilT: ℃ Flywheel: 16.11 Langeuage Set GPS unlock live D2200-02500
Oil Pr: bar OilPress: 0.80Bar
Speed: rpm
L_motor rpm
R_motor rpm
Hours: h
Voltage: V
Current Value:0.80bar
Please Enter:
3)Error alarm :
When the LCD check-up the accient,it will display the error in the main interface,and
buzzer ring to remind the operator.Alarm informations classes are:
Chinese English
水温传感器断路 Water temp sensor open
水温传感器短路 Water temp sensor short
发动机水温高 Engine water too hot
Chapter 3
Chapter 3
zero.Contact with equipment suppliers to resolve.
4. When the intelligent monitor warning:Vehicle fault: 0011,dial gauges all return to
zero.GPS antenna connection is not normal,need to view and eliminate.
5. When the intelligent monitor warning:Vehicle fault: 0012,dial gauges all return to
zero.Communication card of intelligent service system have abnormalities,need to
view and eliminate.
6. When the intelligent monitor warning:Vehicle fault: 0020,dial gauges all return to
zero.Engine can not normally start.Contact with equipment suppliers to resolve.
7. When the intelligent monitor warning:Vehicle fault: 0030,dial gauges all return to
zero.Engine can not normally start.Contact with equipment suppliers to resolve.
8. When the intelligent monitor warning:Vehicle fault: 0031,dial gauges all return to
zero.Engine can not normally start.Contact with equipment suppliers to resolve.
9. When the intelligent monitor warning:Vehicle fault: 0032,dial gauges all return to
zero.Engine can not normally start.Contact with equipment suppliers to resolve.
There is delay for the fuel oil level gauge ,please notics especically when
oiling.
Heating(Figure 3-33)
1. Start the engine.
2. Open the heating valve.
3. Adjust the wind speed knob to the highest and "H".
4. Spin the wind direction knob to the position that you
want. heating valve
Figure 3-33
accumulator window
compressor
Figure 3-35
Chapter 3
the machine that the machine is backing
up. Figure 3-36
Figure 3-37
Fuse Box
Chapter 3
Open the left door mounted the back of the machine, you can
see the fuse box(Figure3-38).There are fuses in the box.The
function and model as follows.
1) F1-horn power(10A)
2) F2-transmission oil filter indicator power(1A)
3) F3-enmergency power source(5A)
4) F4-enmergency power source(20A)
5) F5-enmergency power source(2A)
6) F6-enmergency power source(2A)
7) F7-enmergency power source(2A)
8) F8-air condition(30A)
Figure 3-38 fuse box
9) F9-enmergency com(2A)
10) F10-gauge light power(5A)
11) F11-enmergency power source(2A)
12) F12-enmergency power source(2A)
13) F13-Main controller power10A)
14) F14-backup alarm relay power(10A)
15) F15-enmergency com(15A)
16) F16-engine start switch (20A)
Fuse box
Chapter 3
5)The front wiper switch 5A
6)The rear wiper switch 5A
7)Fan 10A
8)The left wiper switch 5A
9)The right wiper switch 5A Figure 3-39 fuse box
Online Fuse
There are some online fuse on the gauge box for
this machine(Figure3-40).When gauges and GPS no
power,you should check-up the correspoding fuse is bad
or not.Change fuse after exclude the correspoding error.
★ When change the fuse,you should use the fuse of
same capicity. Figure 3-40 Online Fuse
• Make sure that the safty lever is engaged in order to use steering and
transmission control.
• After using the machine, move the control lever to the center position in order
to put the machine in the neutral position, and pull up the safty lever in order to
lock the lever.
Chapter 3
6)REVERSE LEFT(F)
Move lever to the left in order to turn the machine to the left. The turning radius for the
machine is proportion to the control lever position. In order to turn the machine to the left
slightly, move lever slightly to the left. If you want increase your turn, move lever further
to the left. If you want the machine to counterrotate, move lever all the way to the left
past the detent position. When the tracks counterrotate, the right side track will rotate
backward, while the left track rotates forward.
7)REVERSE RIGHT(G)
Chapter 3
Move lever to the right in order to turn the machine to the right. The turning radius for
the machine is proportion to the control lever position. In order to turn the machine to the
right slightly, move lever slightly to the right. If you want increase your turn, move lever
further to the right. If you want the machine to counterrotate, move lever all the way to
the right past the detent position. When the tracks counterrotate, the left side track will
rotate backward, while the right track rotates forward. K
H
8)TRACK SPEED( H)
Push the deflector rod forward when a higher speed is desired. J
Pull the deflector rod backward when a lower speed is desired.
Note:There is a maximum limit of 10km/h on the forward speed
and on the reverse speed.
Figure 3-41(b)
9)Speed Recall Button(J)
The Speed Recall function will allow operators to preset a forward speed a reverse
speed. Press the Speed Recall Button (green) in order to activate the preset speed.
Perform the following procedures to preset speed.:
1. Ensure that lever lockout switch is on.
2. Move the transmission control lever to the FORWARD position, and move the
deflector rod to the desired speed.
3. Move the transmission control lever to the REVERSE position, and move the
deflector rod to the desired speed.
4. Move the transmission control lever to the NEUTRAL position. Hold the Speed
Recall Button for 3 seconds, then the preset speed will be saved in the system.
5. Press the Speed Recall Button while the machine is moving forward in order to
return to the preset speed. Press the Speed Recall Button while moving reverse and
the machine will return to the preset speed.
10)HORN(K)
Push down the button (red) in order to activate the horn.
2. LOCKOUT SWITCH
The lockout switch (Figure 3-42)is on the left side of the
transmission control lever. When the lockout switch is pull
up, it will cut off the output signal of the lever and the parking
brake also will be engaged.When the lockout switch is press 锁定
Figure 3-42
3.2.14 Other control switch
There is a set of switch on top of the cab’s right-hand window.(Figure 3-43)
F R L R
1 2 3 4 5 6 7
Figure 3-43
1)Forwardlight switch
As shown in Figure 3-44,press the top of the switch,the
forwardlight shine.Press the underside of the switch,the
forwardlight go out.
Figure 3-44
2)Backlight switch
As shown in Figure 3-45,press the top of the switch,the
backlight shine.Press the underside of the switch,the
backlight go out.
Figure 3-45
Chapter 3
3)Sidelight switch
As shown in Figure 3-46,press the top of the switch,the
sidelight shine.Press the underside of the switch,the sidelight
go out.
Figure 3-46
Figure 3-47
Figure 3-48
Figure 3-50
The wire code as follows can help understand the electrical diagram
Example:Wires code70A01
“70”:wires section,as follows:
external
section diameter
nub diameter Mainly Circuit
(mm2) (mm)
(mm)
0.5 16 0.2 2.4
Chapter 3
0.75 24 0.2 2.6
1 32 0.2 2.8 Gauge、Light、Signal
1.5 30 0.25 3.1 Gauge、Light、Signal、Start
2.5 49 0.25 3.7 Light、Signal
4 59 0.3 4.5 Power、Start
6 84 0.3 5.1 Start、Preheat、Charge
10 84 0.4 6.7 Start、Preheat、Charge
16 126 0.4 8.5 Start Circuit
25 196 0.4 10.6 Start Circuit
70 360 0.5 15.7 Start Circuit
3.3 Operation
WARNING
Before read this section must read–through the safety section as required
order.。
CAUTION
• Machine prior to delivery has been completely adjusted and tested.
However, at the beginning, operating machinery in harsh conditions
would seriously affect the machine's performance and shorten the life
of the machine
• In the initial 100 hours (hourly indication) must be run-in machine.
• In the run-in during the operation, to respect the precautions described
in this manual.
3.3.2 Inspection Before Operation
★ You must make a habit of checking your machine before starting it. Never be
rash and slack. This habit helps you ensure safety of you and your machine.
Check oil and water leaks
Go around the vehicle and inspect for oil leak, water leak and other abnormities. Special
attention should be paid to floating oil seals of high-pressure hose connectors, hydraulic
cylinders, final drive, track rollers, and carrier rollers and sealing of the water tank. If
abnormality such as leakage is found, repair.
Check bolts and nuts
Check tightening of the bolts and nuts of the parts where are liable to loosen. When
necessary, retighten. Especially studs of air cleaner, carrier roller brackets, and track
shoes carefully.
Check electric circuits
Check electric wires for damage and short circuit, check terminals for looseness.
Chapter 3
increases abnormally, pay attention to the place of leakage
and deal with it in time. When checking the water level, don't
only rely on the water monitor.
Figure 3-51
CAUTION
When the cooling water is overheating, slowly
loosen the cover (1) to release the side pressure
and then open it to prevent the hot water from
spurting out.
Check oil level in engine oil pan (Figure 3-52)
(1)Open the engine side cover on the left side of the chassis.
(2)Remove dipstick ○G and wipe the oil off with a cloth.
(3)Insert dipstick ○G fully in the filler pipe, then take it out
again.
(4)The oil level should be between the H and L marks on
G P
dipstick ○G. If the oil is below the L mark, add engine oil
through oil filler ○F
(5)If the oil is above the H mark, drain the excess engine oil
from drain plug ○P, and check the oil level again.
(6)If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.
• The model of used oil depends on the ambient temperature.
Please refer to the attached table "MODEL AND QUANTITY
F
OF FUEL, COOLING WATER AND LUBRICATION OIL".
• If the machine is at an angle, make it horizontal before Figure 3-52
checking.
• When checking the oil level after the engine has been
operated, wait for at least 15 minutes after stopping the
engine before checking.
CAUTION
Open the cover slowly since the hot water may
hurt you.
Turn engine off and allow oil to cool to prevent hot
oil from spurting before operating.
F G
Check fuel level (Flgure 3-53)
(1)Removed the cap and check the fuel level using fuel gauge
Chapter 3
G.(Figure 3-53)
(2)After completing work, fill the fuel tank through oil filler port F.
(3)After adding fuel, tighten the cap securely. Figure 3-53
CAUTION G
Chapter 3
AND QUANTITY OF FUEL, COOLING WATER AND
Figure 3-55 b
LUBRICATION OIL".
CAUTION
When checking the oil level after the engine has been
operated, wait for at least 15 minutes after stopping the
engine before checking.
If the machine is at an angle, make it horizontal before
checking.
Look
2
Float
Lower
Hold
Raise
Figure 3-61
5、Starting engine
Chapter 3
• Pull fuel control level 5 to the center position between Figure 3-62
LOW IDLING and HIGH IDLING. (Figure 3-63)
• Insert the key into starting switch (ON) and turn the
High idling
key to the START position. (Figure 3-64)
Low idling
CAUTION
CAUTION
• Do not accelerate speed suddenly before preheat.
• Do not idle or race the engine for more than 20 minutes. If engine
idling is required, be sure to apply some load from time to time or rev
up the engine to medium speed range.
WARNING
• When moving machine, check that the area
around the machine is safe, and sound the
horn before moving. Clear all personnel from
the machine and the area, Use extreme care
自由
when reversing the machine. Note there is an
Chapter 3
blind spot behind the machine.
Free
• When starting on slopes, always keep brake
pedal depressed even after releasing parking Figure 3-65
lever 5.
Float
• When starting the machine on a steep uphill
Lower
grade, run the engine at full-throttle and shift Hold
Figure 3-67(b)
2
Chapter 3
Figure 3-68
Figure 3-69
3-70)
• For the sake of safety, comfort and the service life of
the transmission system, don't change the direction of
walking when the engine running at full speed.
• Before the change the direction of walking, step up the
reducer pedal to reduce the engine speed.
Figure 3-70
3.3.5 Turning
WARNING
• On the slope should avoid turning sharply.
Otherwise the machine will produce
sideslip, pay mor e attention to in soft
ground or clay ground.
• Do not turning sharply while traveling on
Chapter 3
high speed walking
WARNING
L
On steep downhill slopes where the machine Forward
N
m a y t r ave l u n d e r i t s ow n we i g h t , o r o n
downhill slopes where it is being pushed by a
towed machine, the machine will steer in the
opposite direction, so do as follows.
Chapter 3
CAUTION
Cross steering means such phenomenon: the
machine is in the opposite direction to the
direction of the actual turning.
Walking in front of a left shift gradually
Push the steering and directional level 2 and
move to the right, the machine tur n to left
gradually. (In the opposite direction)
WARNING
• Avoid stopping suddenly. Give yourself
ample room when stopping.
B
F G
1.Walking handle is the A ((neutral) position. (Figure 3-73)
Chapter 3
D E
A
J H
C
Figure 3-73
Figure 3-74
Look
2
Free
Figure 3-75
to put the blade on the ground. Loosen the blade control Lower
Hold
level 3 and it will automatically returned to the HOLD
Raise
position . (Figure 3-76)
an emergency.
3.3.8 Driving under special climates
Hot weather precautions:
To prevent damage to the locomotive, click instructions:
1.Coolant tank and radiator coolant to ensure that the
correct level。
2.Under hot weather motorcycle test before the start of the
radiator cap, if necessary, replace the lid.
3.Clean dirt and debris from the radiator and the engine
area daily.
4.Check the fan belt condition.
5.Use the correct viscosity of the lubricant.
6.A cooling system using suitable antifreeze.
7.Under the more severe conditions of dust when using
the motorcycle, you should always check the air filter dust
valve.
8.Clean the strainer every day on the dirt.
Chapter 3
3. Before adding prepared antifreeze solution, clean the cooling system thoroughly.
4. When the weather becomes warm, drain the antifreeze (except for the permanent
antifreeze), and clean the cooling system, before replacing the clean water.
5. It should be especially noted that the snow or water on hydraulic cylinder piston rods
should be wiped off. If freezing occurs, cylinder oil seals will be damaged.
6. When the temperature is low,it is need to fire the engine for warm-up the dozer,until
the hydraulic oil temperature rise to more than 40℃,we can dozing operation.
CAUTION
• On winter nights, drain water without antifreeze added completely
so as to prevent parts from frost cracks. Caution: Remember to drain
water in oil cooler, etc.
• Use standard antifreeze. Never use the antifreeze solution prepared
using methanol or alcohol which may result in engine trouble.
• Antifreeze solutions are combustibles. Be careful not to cause fire.
• Batter y capacity will be reduced as air temperature drops, which
often results in reduction in charge level and electrolyte freezing. The
battery shows resistance to low temperature when you maintain its
charge level at approx. 100% and keep it insulated
Fluit temperature
20℃ 0℃ -10℃ -20℃
Change rate
CAUTION
• Always travel straight up or down a slope. Traveling at an angle o r
across the slope is extremely dangerous.
• Do not shift gear or cross obstacles on a slope.
• If the fuel level in the fuel tank becomes low when working on slopes,
the engine may suck in air because of the angle of the machine or the
swaying of the machine. If this makes the engine stop, the braking
effect will be reduced, so be careful not to let the fuel level in the fuel
tank become too low.
Chapter 3
3.4.1 Blade and winch opreration
Figure 3-79
2.Ripper Adjustment
H
Figure 3-82
3.4.3 Dozing
Chapter 3
3.4.4 Smoothing (Figure 3-84 )
CAUTION
Figure 3-85
• Tilt the ripper backwards, and lower the ripper tooth tip to the ground to be ripped, and
lift the rear part of the machine.
• In order to step on the decelerator pedal to reduce the engine speed, set the speed
range to F1, and tilt the ripper to allow the tooth tip to be inserted into the specified
depth.
• The shovel in the floating state,the vehicle slowly back to drag the ground flat.
• When the tooth tip reaches the specified depth, increase the engine speed to full speed
and advance the machine. Tilt the ripper shank for ripping operation.If the ripper shank
has already been tilted, but the ripping circuit can still trip, in this case, the hole on the
lower part shall be used as the mounting hole for the ripper shank to reduce the ripping
depth.
• After ripping operation, advance the machine, and lift the ripper shank from the rock bed
and then reverse the machine.
• When reversing the machine, tilt the ripper backwards to the starting point for ripping
CAUTION
• If the ripper is applied when the rear part of the machine is lifted from the ground, the
ground contact length of the track A will be reduced ,the traction force will be reduced
and thus the ripping efficiency is reduced. As shown in Figure 3-86
• If the ripping depth keeps constant, the ripping operation is even which will increase the
dozing operation efficiency.
Chapter 3
A
Figure 3-86
3.Ripping Near Cliff(Figure 3-87)
• When ripping near a cliff, the ripper shall be tilted backwards to increase the ripping
depth (L).
• Step on the decelerator pedal, slowly advance the machine, and tilt the ripper (A) when
the ripper tip contacts the cliff.
L
Figure 3-87
Chapter 3
towing devices can be reliably connected and locked,
and that the towing cables can safely carry the towing Towing
load.(Figure 3-90)
CAUTION
The effective safe load of the bulldozer's front
and rear towing device is 15tons. Figure 3-90
09963- 02100
CAUTION
Figure 3-91
When lifting, set the work equipment lock
l eve r a n d b r a ke l o ck l eve r o n " l o cko u t "
position" to prevent the machine moving
accidentally.
3.5.3 Transportion
During transit of the vehicle, you must familiarize with
and observe road rules as well as traffic rules such
as road transport vehicle laws and vehicle restriction
regulations
When passing through bridges and tunnels, you must
measure throughput weights of the bridges and space
dimensions of the tunnels. (Figure 3-92)
Chapter 3
CAUTION
When driving on the climbing ladder, do not
adjust direction of travel. If such adjustment Figure 3-92
is required, you can do it after backing up
your vehicle to the ground.
1. The trailer’s brake must be applied and its tires must be secured properly using
square timbers.
2. The climbing ladder must be wide, long, and thick enough to ensure safe handling
of the vehicle. When necessary, square timbers can be placed under it as
reinforcements.
3. Place the climbing ladder straight ahead, and then mount or dismount the vehicle
slowly.
4. The vehicle must be mounted at appropriate place on the trailer. Then put wood
blocks before, after and under the tracks and secure the machine with firm chains or
ropes in order to prevent it from slipping and causing accident on the road.
5. Lower the blade and set levers to the following positions.
• Place the throttle lever in the LOW position, and remove the starting key.
• Place the shift lever in "N" (the neutral) position
• Place the blade joystick in the HOLD position
• Place the brake lock lever in the LOCK position
CAUTION
• If the width of the blade bit exceeds that of the trailer, you can tilt
the blade to an angle or remove and mount it separately.
• During a long-distance water transpor t, antirust measures must
be taken and exposed parts such as cylinder piston rods should be
coated with rust preventative oil.
3.5.4 Storage
Before storage
When putting the machine in storage for more than one month, do as follows to ensure that less
maintenance workload is required before reuse.
1. After every part is washed and dried, the machine shall be housed in a dry building.
Never leave it outdoors. In case it is indispensable to leave it outdoors, then you should
lay wood boards on the ground. The machine should be placed on the boards and be
covered with a canvas.
Chapter 3
2. Completely fill the fuel tank, lubricate and change the oil before storage.
3. Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler
adjusting rods.
4. Disconnect the negative terminals of battery and cover it, or remove it from the machine
and store it separately.
5. If the ambient temperature is expected to drop below 0℃, always add antifreeze to the
cooling water.
6. Set all control levers and pedals as follows:
★ Move the gear lever to the neutral position.
★ Move the fuel control lever to the low idling position.
★ Move the blade control level to the hold position.
★ Move the brake pedal to the free position.
During storage
Operate the engine and move the machine for a short distance once a month so that a new
film of oil will be coated over movable parts and component surfaces.
★ Before operating the work equipment, wipe off the grease on the hydraulic piston rod.
After storage
Carry out the following procedure after storage (for example, without housing or carrying out the monthly
rust prevention operation)
1.Remove drain plugs of the oil pan and other oil tanks to drain mixture water.
2.Remove the cylinder head, lubricate valves and rockers, and check valve movement.
3. To bleed the hydraulic system, run the engine at low speed and operate as follows:
• Reciprocate each hydraulic cylinder with its piston stopped 100 mm from its stroke end
for 4-5 times.
• Subsequently, reciprocate each hydraulic cylinder to strike end for another 3-4 times.
★ If the engine runs at high speed or pistons run to stroke end initially, then entrained air
may damage piston gaskets, etc.
4.After the engine is started, run it until it adequately heats up.
ge
Pa
s
te
No
Following precautions shall be strictly followed by drivers and maintenance staff in addition
to reading and understanding requirements specified in "Safety Precautions".
• Maintenance and servicing staff shall be familiar with vehicle structure, performance,
disassembly procedures, technical requirements and precautions before operation
commences, rather than blindly performing difficult maintenance and servicing activities.
If you are not sure about this, consult with the manufacturer. Routine maintenance is
Chapter 4
generally done before starting and after work. Stop the vehicle on a flat ground before
maintenance, lower the blade and ripper and lock the locking mechanism, and then
perform maintenance activities. There shall be two persons working together to perform
maintenance activities when the engine is not stopped, with one in the cab and the
other performing maintenance activities. Be careful not to contact your body with moving
parts.
• Before maintenance commences, completely clean and flush surroundings of the part to
be maintained, especially oil filler, filter, nozzle and tank cover, to prevent dust into oil.
CAUTION
starting 7 Checking dust indicator Check and clean the air filter
9 Check the oil level inside the travel oil tank Check and refill
4.1.1 Servicing Schedule
1 ● ● ●
3 Fuel-water separator filter element Check the water level and refill ● ● ● ● ● ● ● ●
Initial 250 hours
maintenance 4 Engine oil and filter element Replace ● ● ● ● ● ● ● ●
101
Refer to the following servicing schedule when servicing of the machine is required. Items marked with
Chapter 4
Chapter 4
Continued
102
Item S/N Maintenance Item Content 50 100 250 500 750 1000 1250 1500 1750 2000
Center pin at the equalizing beam and pins at two sides Lubrication, 3 place ● ● ● ● ● ● ● ●
Maintenance every 1000 H 3 Operating oil tank filter element Replace the filter element ● ● ●
4 Travel oil tank filter element Replace the filter element ● ● ●
5 Lubricant for the final transmission Check and replace ● ● ●
1 Engine valve clearance Check and adjust ● ●
2 Operating oil tank hydraulic oil Replace ●
3 Travel oil tank hydraulic oil Replace ●
4 Engine damper Check and replace ●
Cooling System - Clean...................................P109 Engine Oil and Filter Element - Replace .........P117
Chapter 4
Air Filter Safety Element - Replace .................P114
Tank Cap - Clean..............................................P120
Radiator Core - Clean .....................................P115
..........P128
4.1.4 Maintenance every 50 H or
Weekly 4.1.11 Maintenance every 2000 H or
Balance Beam Central Pin - Lubricate...............P126 1 Year
Balance Beam Side Pin - Lubricate...................P126 Engine Valve Clearance - Check .....................P121
Idler Clearance - Check/Adjust..........................P127 Operating Oil Tank Hydraulic Oil - Replace .....P122
Track Pin - Check .............................................P127 Travel Oil Tank Hydraulic Oil - Replace ...........P122
WARNING
• To avoid explosion of the batter y,
keep the batter y away fr om the
source of ignition;
• If the electrolyte is splashed onto
skin or clothes, immediately flush
skin or clothes with plenty of water.
Battery - Recycling
Always recycle used batteries and do not dis-
pose them randomly. Recycle used batteries in
one of following methods:
• Battery supplier
• Disposal organization qualifier for recycling
batteries
• Recycling agent or organization
WARNING
• Improper disposal of used battery may result in personal injury.
• The battery may release explosive and flammable gas. The electrolyte
is acid solution that may cause personal injury when contacting skin or
eyes.
• Prevent naked flame around the battery. Naked flame may result in ex-
plosion. Do not bridge two ends of the cable or contact the engine. In-
correct bridging may result in explosion.
• Always wear safety glasses during operation.
Battery and Conductor - Check/Replace
1. Turn the engine start switch to "OFF" position. Remove the key.
2. Turn the battery switch anticlockwise to "OFF" position, and remove the key.
3. Disconnect the conductor for the battery cathode switch from the switch. (Do not con-
Chapter 4
nect the battery cable to the switch)
4. Disconnect the battery cathode.
5. Disconnect the battery anode.
6. Check if the battery is corrosive and its cable is worn or damaged.
7. If necessary, replace the battery or its cable.
8. It is more difficult to start the machine than usual with more than 1 ignition, and the bat-
tery is low.
9. In idle speed, the head light quickly turns from bright to dim, indicating that the battery
should be replaced.
10. The engine gives abnormal sound when starting, generally, slight squeak, but this
sound may disappear after 2~3 s or more; as the electricity become lower, the frequen-
cy of the sound increases, indicating that the battery lacks power deeply.
CAUTION
• In general, a battery serves for 36 months ~ 48 months. It is recom-
mended to replace the battery during this period to ensure safe driving.
• If the batter y is left unused for a prolonged time, turn the batter y
switch off and disconnect the battery cable and store it. Regularly
charge the battery (once two months); otherwise the battery may be
completely discharged, thus shortening its service life.
hicle is moved;
8. Pull the travel control level back to the neutral position and keep the throttle control lever
(1) unchanged;
9. Place the travel lock lever (7) in "Lock" position, and repeat step (6). Check that the ve-
hicle is not moved in this case; if the vehicle is moved, go to step (13);
10. Pull the travel control level back to the neutral position and keep the throttle control le-
ver (1) unchanged; the travel lock lever (7) is placed in "Free" position;
11. Push the travel control handle to the "Forward" position to start traveling. The vehicle
shall stop when completely stepping on the decelerator pedal (3). If it still moves, go to step
(13)
12. Pull the travel control handle back to the neutral position. Pull the throttle control lever (1)
to idle position to complete the safety locking capability test.
13. Contact your local SHANTUI distributor for maintenance.Am aciliquam hil imi, nus, nim
vid qui cus.
2
1
4 5
Figure 4-2
Chapter 4
Coolant Level - Check (Figure 4-3)
1. Open the right engine hood.
2. Observe coolant level through the sight glass in the
right side of the expansion tank. If it is visible, then it
is in normal level; otherwise, refill coolant.
3. If it is required to refill coolant every day, then check
if the cooling system pipeline is leaked.
4. Close the right engine hood.
Figure 4-3
CAUTION
• Do not tighten the pipeline when the cool-
ant is still hot; otherwise, the pipeline may
be fell off, resulting in burn.
• The modifier for the cooling system con-
tains strong base that shall not be contact-
ed with skin and eyes.
• The engine coolant is hot and pressurized
in nor mal conditions. Water tank and all
connected pipelines or radiators contain
hot coolant or stream that shall not be con-
tacted to avoid serious burn.
Chapter 4
5. During drainage, adjust the flow rate to let the water
added be equal to that drained, and also always keep
the water tank full.
6. When water is fully clean, stop the engine. Open the
Figure 4-6
water drain valve to discharge water, and then close it.
7. • Use commercially available cleaning agent to clean the
cooling system by following instructions.
CAUTION
• The antifreeze is flammable and shall be kept
away from the combustion source.
• Do not remove the cover when the water is
hot. Otherwise, hot water may be splashed.
Coolant - Refill
1. After cleaning the cooling system, discharge all water,
and then close the water drain valve and slowly add wa-
ter (coolant prepared according to the related region) to
the filler lip.
2. Operate the engine in idle speed for 5 minutes, and
then in intermediate speed for 5 minutes to exhaust air
inside the cooling system (the water tank cap shall be
opened during operation). Stop the engine and wait for
3 minutes. Refill the coolant till it reaches the specified
level and then tighten the cover.
SHANTUI CONSTRUCTION MACHINERY CO.,LTD 109
Maintenance and Service | Maintenance and Service
Clean the inside of the cooling system and replace the coolant and Corrosion resistor as
specified in the following table.
river water or well water (hard water) contains large amount of mineral substance (cal-
cium, magnesium) that may stain inside the engine or radiator. Stain on the engine or
radiator is hard to be removed. It is recommended to use water below 100 PPM;
4. For the mixture ratio of cooling water and antifreeze, please define the ratio by referring
to previous lowest temperature in your region and according to the following table.
5. When defining the mixture ratio, it would be better to take the temperature about 10°
below the estimated temperature.
6. The mixture ratio of antifreeze and water during transportation shall be defined accord-
ing to 20°C below the lowest predicted temperature on the way. (if it is unpredictable,
please mix them according to the maximum possible ratio, or if the condition is limited,
drain the coolant, and refill it before operation as required).
The following table shows the mixture ratio of water and antifreeze:
Minimum
atmospheric -10 or
-15 -20 -25 -30 -35 -40
temperature above
°C
Antifreeze % 30 36 41 46 50 54 58
Water % 70 64 59 54 50 46 42
Chapter 4
Place a timber pile or other supports under the seg-
mental support of the blade. Before remove the cut-
ting edge of the blade, ensure that the blade is low-
ered to the lowest position and stop the engine.
2. Remove the bolt.
3. Remove the end bit and cutting edge.
4. Completely clean all contact surfaces.
5. Check wearing in two sides.
6. If two sides of the end bit and cutting edge are seri-
ously worn, then replace it with a new one.
7. If only one side of the end bit and cutting edge is
worn, then replace it as below:
For cutting edge, as it is symmetric, lower part and
upper part can be exchanged.
8. Install the end bit and cutting edge.
9. Install all bots and apply the required tightening
torque.
10. Lift the blade and remove the support block, and then
lower the blade on the ground.
11. Check if the tightening torque of the bolt is compliant
after operating for several hours.
4 5
6 2
1
2
2
3
Figure 4-8
Tip、Guard Board
Chapter 4
When the ripper tip (3) or guard board (1) is worn close to the shank, replace the ripper
tip. If the tip is too blunt, the tip will not penetrate properly.
1.Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking.
The ripper should be high enough so that the ripper tip can be removed. Do not place
the ripper too high.
2.If the ripper tip is worn, drive out pin (2). Remove tip (3) and the guard board (1)
retainer.
3.Install the new tip and the retainer.
4.Install pin (2) from the opposite side of the retainer.
5.Raise the ripper and remove the blocking.
6.Lower the ripper to the ground.
Shank
When the ripper shank is worn or damaged, replace the ripper shank (6).
1.Raise the ripper. Place blocking under the ripper. Lower the ripper onto the blocking.
The ripper should be high enough so that the ripper shank can be removed. Do not
place the ripper too high.
2.If the shank is worn or damaged, remove cotter pin (4). Then drive out pin (5).
Remove shank (6).
3.Install the new shank and pin .
4.Install cotter pin (4).
5.Raise the ripper and remove the blocking.
6.Lower the ripper to the ground.
Chapter 4
4. Clean dust deposited inside the inner cavity and thread before re-install the external fil-
ter element, and use a brush or rag to clean dust to ensure smooth thread and prevent
intrusion of dust into the external filter element;
5. Reinstall all parts in the reverse order. Ensure correct installation with all parts.
Air Filter Main Element - Replace
1. Loosen five buckles at ends of the air filter to remove its back cover, and then clean the
back cover
2. Turn the seal cover anticlockwise to remove it. Hold the hanger on the back cover of
the external filter element to remove the main filter element
3. Replace it with clean main filter element
4. Reinstall all parts in the reverse order. Ensure correct installation with all parts.
CAUTION
• Incorrect maintenance will significantly shorten the service life of the
engine!
• Do not remove or clean the safety filter element!
• Do not impact or hit the filter element to clean it. This may damage
the sealing element. Do not use a filter element with wrinkle, gasket
or seal damaged. A damaged filter element will not effectively prevent
passage of dust that may damage the engine.
• Visually inspect the filter element to check if the seal and shell are cut,
cracked or impressed. Do not install it if any visible damage is found.
CAUTION
• Carefully read following rules before cleaning the filter element:
• Do not clean or replace the air filter element when the engine is operat-
ing.
• Do not impact or hit the filter element to remove dust.
• Do not purge to maintain the safety filter element.
• The air pressure shall not exceed 207 kPa (30 psi) when purge the filter
element with compressed air for maintenance. Purge evenly the filter
paper along wrinkles. Do not damage these wrinkles.
• Do not use the air filter element with wrinkles or sear damaged. Dust
intruded into the engine may damage the engine components.
Figure 4-9
Chapter 4
behind the machine.
3. The reversing alarm bell can stop warning only when the travel control handle returns
to the Neutral position or Forward position and the vehicle stops reversing.
4. The reversing alarm bell is located in the left rear of the machine.
5. The sound pressure level of the reversing alarm bell is factory set that cannot be
changed.
Figure 4-10
CAUTION
• Parts and oil are hot immediately after the
engine stops which will cause serious burn.
Wait to cool down before operation.
SHANTUI distributor. 2
G P
4. Install the drain plug (P).
5. Use the filter wrench to anticlockwise rotate the filter
cartridge (1) (2) to remove it.
6. To prevent oil splashing on your body, do not perform
this operation immediately underneath the filter car-
Chapter 4
tridge. Clean the filter holder and fill engine oil into
the new filter cartridge. Apply engine oil on the seal-
ing surface and thread (or apply a thin layer of lubri- F
cating grease). Then install the filter cartridge.
7. Firstly allow contact of the sealing surface with the
Figure 4-12
filter holder and then further tighten from 3/4 turns to
1 turn when installing the filter cartridge.
8. After replacing the filter cartridge, add engine oil
through the oil filler (F) to allow the oil level in be-
tween mark H and L
9. of the dipstick (G).
10. Operate the engine in idle speed for a short time, and
then stop the engine to check if the oil level is be-
tween mark H and L of the dipstick (G).
2 3
1
Chapter 4
Figure 4-13
WARNING
• Failure to follow procedures below may result in personal injury or even
death.
• Fuel leakage or splashing on the surface of hot parts or electrical com-
ponents may cause fire.
• Clean all overflowed or splashed fuel. No smoke when working near
fuel.
• Turn the battery cathode switch to "OFF" position when replacing the
filter element.
CAUTION
• Ensure that liquid is under control during inspection, maintenance,
test, adjustment and repair. When opening any component or remove
any part, prepare a proper container to collect liquid.
• Dispose effluent according to local regulations and laws.
Chapter 4
4. Please remove the filter element when maintenance is required.
5. Clean the filter shell and remove the used seal ring.
6. Do not allow intrusion of dust into the new filter element.
7. Do not add fuel into the filter element before installation unless the fuel is completely
clean.
8. Apply a layer of clean fuel on the new filter element and manually install the new fuel
element.
9. The fuel system pumps oil. Before starting the engine, ensure that the oil-water separa-
tor drain value is completely closed. Start the engine to check if it is leaked.
10. Close the right engine hood.
Fuel Oil-water Separator(Spin-on)-Drain Away Water
1. Turn off the engine.
2. Open the oil-water separator drain plug.Countercolockwise the plug about 2~3
circles,until it outflows the lipuid .
CAUTION
• Drain water and deposit out of the fuel-water separator every day.
• To avoid thread mismatching, do not over-tighten when closing the
drain valve.
• When the engine operates, the drain valve on the bottom of the fuel-
water separator has a certain negative pressure. Always ensure that
the drain valve is reliably tightened to prevent intrusion of air into the
fuel system.
Chapter 4
a special tool and professional training and can be
done by qualified maintenance staff.
Figure 4-15
Figure 4-18
Chapter 4
pipeline.
2. The travel filter is located on the right rear of the machine. L
Open the access door on the left rear side.
3. Loose the filter shell of the filter (L), and turn it anticlock-
wise to remove the filter shell.
Figure 4-20a
4. Remove the old filter element.
5. Observe the filter shell and use the same hydraulic oil used
for the travel mechanism to clean the filter shell.
6. Replace it with a new filter element, install the filter shell
and apply the specified tightening torque.
WARNING
• Parts and oil are hot immediately after the
engine stops which will cause serious burn.
Wait to cool down before operation.
• Slowly rotate the cap to release the inner
pressure before removing the filler cap.
• Operating oil tank capacity: 65 L
• Travel oil tank capacity: 60 L
• The new oil shall be as specified and en-
sure cleanliness above NAS8.
Turbocharger - Clean/Check
Contact your local SHANTUI distributor for cleaning or
inspection.
Chapter 4
Figure 4-20b
13
1
14
14
6
5
15
16
7
Chapter 4
9 15
11
8
10
17
12
Figure 4-21
Main Lubricating Points (Figure 4-21)
Locations requiring regular lubrication include blade, cylinder, ripper and equalizing beam
where moving parts exist. The following table shows main locations:
S/N Point Quantity S/N Point Quantity
1 Inclined support pin 1 2 Left lift cylinder pin 1
3 Right lift cylinder pin 1 4 Angle-modulated cylinder spherical 1
hinge
5 Left level support spherical hinge 1 6 Right level support spherical hinge 1
7 Ripper cylinder pin a 1 8 Ripper cylinder pin b 1
9 Ripper pin connection a 2 10 Ripper pin connection b 2
11 Ripper pin connection c 2 12 Ripper pin connection d 2
13 Lift cylinder bracket shaft 4 14 Lift cylinder bracket shaft 2
15 Side pins at the equalizing beam 2 16 Center pin at the equalizing beam 1
17 Engine fan shaft 1
points as shown in Figure 4-20, and 2 lubricating points at left and right sides respec-
tively.
Balance Beam Side Pin - Lubricate (Figure 4-22)
1 place at right and left side respectively
1. Clean all impurities on the top of the track frame and
cap (1 place).
2. Clean the grease fitting as indicated by the arrow,
and then use the grease pump to add grease through
the grease fitting. Figure 4-22
• Inject 3 grease volumes through the grease fittings
(operate the grease pump handle three times), and
check if there is new lubricating grease draining out of
the sealing lip.
• If no, use the grease pump to further add grease
15
through the grease fitting.
16
Balance Beam Central Pin - Lubricate (Figure 4-23)
1. Open the cover on the left of the machine 15
2. Clean the grease fitting as indicated by (16), and
then use the grease pump to add grease through the Figure 4-23
grease fitting.
Chapter 4
(1). Remove a certain number of gaskets (a), and
adjust it to the standard clearance: 0.5~1.0 mm; the
gasket is 0.5 ~ 1.0 mm thick.
3. Loose the bolt (1). Be careful not to rotate the bolt
more than 3 turns.
Track Pin - Check
1. When the machine operates, be careful with sharp
squeal under abnormal condition that is known a sign
of dry friction of the track pin and pin bush.
2. Weekly check if the pin bush has dry friction, and
check it immediately after the machine stops.
3. After the machine stops, gently touch each track pin
or bush end with your hand back, and mark the hot
joint.
4. If the pin has dry friction or leakage, consult with your
local SHANTUI agent or distributor.
5. Use the IR thermometer or thermal imaging camera
to check the temperature of the track pin.
4. When oil is drained out of the oil level plug (2), stop
refilling and install the oil level plug (2) and oil filler
plug (1).
Chapter 4
WARNING
• Oil is hot immediately after the machine
stops. Wait till oil is cooled down before
checking.
• If the tank is pressurized, oil or drain plug
may be flied. Always slowly loosen the
drain plug to release pressure.
pulley Tightening
just the belt tension. When about 60 N of force is ap- pulley
plied, the belt shall normally be drooped (b) about 10 Fan belt
tightening
mm. pulley
3. Tighten the bolt and nut (2) and (3) to fix the alterna-
Bent axle pulley
Chapter 4
tor (1) in place.
Figure 4-26
CAUTION
• Check if each pulley is damaged, and if the
3
V-groove or V-belt is worn. Pay special at-
4
tention to check that the V-belt is not con-
tacted with the bottom of the V-groove.
1
• If the pulley is damaged, contact your 2
SHANTUI distributor.
• If the belt is stretched and there is not ad-
justment allowance, or the belt is cut or
Figure 4-27
cracked, replace the belt too.
• When adjusting the V-belt, do not directly
use a steel rod to push the tension pulley,
but place a wood padding block between
the pulley and steel rod.
• After replacing the V-belt, operate it for 1
hour, and then check and adjust the belt
tension.
CAUTION
Inspection and Inspection after Maintenance
• Unexpected fault may result and thus cause
serious injury or property loss when inspec-
tion is not performed after maintenance.
Always perform operations according to fol-
lowing requirements.
• The inside and part intrusion are dangerous
Chapter 4
Befor starting or per
Initial
Per
Per
Per
Per
winch
Chapter 4
6
8 7
2 4
9
10
Figure 4-30a
1
Chapter 4
8 7
2 4
9
10
Figure 4-30b
Chapter 4
Radial wearing of the dimension Allowance Repair limit
7 top of the sprocket
899 ±2.0 887
Radial wearing of the 810.79 +1.0
8 799
root of the sprocket 0 Recover or
Wearing in the width Standard dimension Repair limit replace
9 direction of the top of
the sprocket 60 50
Wearing in the width
10 direction of the root of 87 77
the sprocket
A-A
1 2
A
Chapter 4
Figure 4-31
Inspection
S/N Criteria Measures
Items
Standard Allowance Standard Clearance
Clearance between dimension clearance limit
Shaft Hole
1 cylinder yoke and
bushing (external) -0.072 +0.054 0.072 Replace the
85 0.5
-0.126 0 0.180 bushing
Clearance between -0.060 +0.046 0.060
2 cylinder yoke and 65 0.5
0.106 0 0.152
bushing (internal)
Chapter 4
Figure 4-32
Figure 4-33
Figure 4-34
Chapter 4
Stretching OD of the Standard dimension Repair limit
1 track roller 210 195
Flange outer diam-
2 244 -
eter (outer side)
Flange outer diam-
3 eter (inner side) 236 -
(two sides)
Width of wheel face
4 49 55
(single side)
Width of wheel face Repair or
5 49.2 55.2 replace
(two sides)
Flange width (single
6 18.5 12.5
side)
Width of wheel face
7 (double flange outer 18.5 12.5
side)
Width of wheel face
8 (double flange inner 20 14
side)
9 Total width 235 -
Standard Allowance Standard Clearance
Clearance between dimension Shaft Hole clearance limit
10 shaft and bushing
-0.250 +0.13 0.310-
65 1.5
-0.290 -0.06 0.420 Replace the
Allowance Standard Recover bushing
Standard interfer-
Interference of track dimension Shaft Hole ence limit
11 roller and bushing
+0.089 0.027-
115 ±0.027
-0.054 0.116
Standard clearance Repair limit
12 Axial play Replace
0.27-0.9 1.5
1) Blade, holder, Inclined support and horizontal support
Figure 4-35
Chapter 4
Figure 4-36a
Single
Clearance between 3 —
8 side
links Adjust or re-
Two sides 6 — place
9 Pin protrusion 2.85
Tightening torque Tightening angle (de-
(Nm) gree)
Tightening torque of a standard
10 760±50 180±10 Re-tighten
the track bolt link
b master 300±49 180±10
link
Chapter 4
Figure 4-36b
Inspection
S/N Criteria Measures
Items
Standard Repair limit
dimension
Overturn or
1 Link spacing Heavy load Light load replace
203
206.45 208.45
Standard
Chain link Repair limit
dimension Weld、
2 height(LGP track
shoe) scalding
109.5 94.5 chain or
replace
3 Chain link height 116.0 110.0
Allowance
Interference be- Standard Standard Repair limit
tween main pin dimension interference
5 Shaft Hole
bush and chain
Chapter 4
2
3
A-A B-B
Chapter 4
6
C-C D-D
Figure 4-37
D
A
Figure 4-38
Criteria Measures
S/N Inspection Items Standard Allowance Standard Clearance
dimension Shaft Hole clearance limit
Clearance between -0.2 +2
1 ball and bracket sur- 90 1.2-2.4 3
-0.4 +1
face
Clearance between -0.3 +0.5
2 bearing and bushing 90 0.3-1 2
-0.5 0
sphere
Clearance between Replace
0 +0.5
3 the support pin and 55 0.5-1 2
-0.3 +0.2
the seat
Clearance between 0 +0.5
4 the seat and the sup- 55 0.5-1 2
-0.3 +0.2
port pin
Clearance between -0.3 +0.2
5 50 0.3-0.7 2
the connector and pin -0.5 0
Clearance between -0.3 +0.2
6 50 0.3-0.7 2
the connector and pin -0.5 0
Chapter 4
1
2
Chapter 4
Figure 4-39
CAUTION
• If bolts and nuts or other parts are not tightened according to specified
tightening torque, then parts may be loosened or damaged, thereby
damaging the machine or causing fault.
• Be careful with tightening torque when tightening parts.
Figure 4-40
1. Tighten the hydraulic hose according to tightening torque listed in the following table
Specification
Thread Endface
Specification Width Target Value Torque Range
Code (a) (b)(mm)
N.m kgf.m ibft N.m kgf.m ibft
9/16-18UNF 19 44 4.5 32.5 35-63 3.5-6.5 25.3-47.0
Chapter 4
11/16-16UN 22 74 7.5 54.2 54-93 5.5-9.5 39.8-68.7
13/16-16UN 27 103 10.5 75.9 84-132 8.5-13.5 61.5-97.6
1-14UNS 32 157 16 115.7 128-186 13.0-19.0 94.0-137.4
13/16-12UN 36 216 22 159.1 177-245 18.0-25.0 130.2-180.8
Figure 4-41
ing technical requirements and application characteristics, and then consult related
data for maintenance. Utilize your knowledge and experience during analysis and
judgment. For those not knowing too much or lacking basic knowledge, be sure to
consult an experienced colleague or engineer for assistance.
4. Ensure that parts are clean during repair, and avoid equipment damage to oil or
part contamination.
1. Hear: Judge the fault according to sound characteristics. Pay attention to the rela-
tionship between abnormal noise and temperature, load and where the noise is lo-
cated, and then be careful with abnormal noise and accompanying phenomenon.
2. Look: check abnormality of the machine. For example, oil leakage, water leakage and
fume color from the engine as well as looseness or crack can be observed to judge
faults.
3. Smell: Smell with your nose to judge the fault. For example, scorched flavor may be
generated when parts are burnt, and you can judge the fault according to different
abnormal flavor.
4. Test: replace the suspect part (replace the part suspect of a fault with that of the
same specification) to test. Check if the fault is eliminated. If yes, the replaced part is
faulty. It shall be noted that when some parts exhibit serious abnormal sound, do not
conduct fault reproduction test to prevent major mechanical accident.
1. Touch: use your hands to touch the part suspect of a fault or related to the fault to find
out the reason. For example, touch the pulsation of the high pressure oil tube of the
fuel supply system of the diesel engine to check if the fuel injection pump or injector is
faulty.
2. Measure: use a simple instrument to measure and judge the fault according to the mea-
surement result. For example, use a multimeter to measure the resistance and voltage
value in the circuit based on which the fault in the circuit and electrical part can be iden-
tified.
3. Ask: ask the driver to know the operating condition and time of the engineering ma-
chine, as well as symptom and fault history to identify the fault or provide the fault with
reference.
This section does not contain all faults and troubleshooting in all cases, but most of com-
mon faults are listed.
Chapter 4
4.2.3 Engine
Common
S/N Judgment and Inspection Troubleshooting or Measures
Troubles
The throttle handle is not fixed firmly Tighten the throttle handle to the le-
to the lever or flexible shaft ver or flexible shaft
Spare travel of the flexible shaft is
Engine Replace the flexible shaft
high
not operat- Clean the fuel filter or replace the fil-
1 Check if the fuel filter is blocked
ing in high ter element
speed Clean the air filter or replace the filter
Check if the air filter is blocked element
Check if the fuel pipe is blocked Clean the pipeline or exhaust the air
Poor fuel quality, large moisture con- Replace it with qualified fuel
tent
Check the operating temperature of
Cooling water temperature too low the thermostat, and replace it if nec-
essary
Air distribution or oil supply timing in- Check and adjust
correct
Poor injector atomization Check and repair
Low compression pressure, incom-
Engine Check the piston ring, cylinder sleeve
plete combustion and piston expan-
gives white and cylinder gasket, and repair
2 sion
fume or
blue fume Piston ring and cylinder sleeve are Continue running-in
not well ran in
Too large fitting gap of the piston cyl- Repair and replace
inder sleeve
Supercharger sealing ring worn Check and replace
Supercharger thrust bearing worn Check and replace
Supercharger oil return pipe blocked Clean or repair
Oil level too high Refill according to standard range
Common
S/N Judgment and Inspection Troubleshooting or Measures
Troubles
Check the air filter and the inlet pipe,
Inlet blocked (air filter blocked) and then clean or replace the filter
element
Check the airtightness of the oil pipe
and connector, contamination of the
Fuel pipe leaked or blocked filter and the fuel pipe, repair or clean
the fouling, replace the filter element
Clean the fuel tank, filter parts and oil
Poor fuel quality pipe, replace the fuel
Check the valve timing, check if the
Exhaust back pressure too high exhaust pipe is blocked, adjust and
repair
Low power
3 of the en- Insufficient pressurization system Inspect, and eliminate leakage at the
gine pressure pipe connection
Supercharger abnormal Replace the assembly
Check the dipstick and drain exces-
Too high oil level on the oil pan sive oil
Check the compression pressure
Cylinder gasket leaked when warming the vehicle, replace
the damaged cylinder gasket
The piston ring worn or broken, too Replace the worn part, or engine
large bearing bus gap overhauling
The load is higher than the rated
Chapter 4
Common
S/N Judgment and Inspection Troubleshooting or Measures
Troubles
Oil level too low or lack of oil on the Check the oil level and leakage, re-
oil pan pair or refill if necessary
Inlet strainer or the hose of the feed Check and clean impurities and
Chapter 4
Engine pump blocked check fuel cleanliness
6 cannot be Exhaust air and check the airtight-
started Air intruded into the fuel system ness of the connector, and repair
No fuel inside the fuel tank Refill fuel
Too much oil on the engine oil pan Drain excessive oil
Common
S/N Judgment and Inspection Troubleshooting or Measures
Troubles
The inlet pipe blocked or high ex- Clean
haust back pressure
Clean the filter and replace if neces-
Poor fuel quality sary
Air distribution or oil supply timing in- Adjust as specified
correct
Check and adjust (by the qualified
Too much oil in the injection pump
Engine ex- factory)
9 hausts black Insufficient pressurization system Inspect, and eliminate leakage at the
fume pressure pipe connection
Supercharger abnormal Check and replace the assembly
Valve clearance Adjust the valve clearance
Check the valve and valve retainer,
Poor valve airtightness and repair if necessary
Intercooler blocked Clean the intercooler
Chapter 4
S/N
Filter element blocked Check and clean the filter element
Air intruded into the operating pump Replace or repair the pipeline.
Working pump faulty Replace
The working pump driving key or
The working pump inoperative gear damaged, replace or repair
The pipeline from the working pump Check and replace or repair
to the working valve leaked
The oil pipe between the valve and
Insufficient Check and replace or repair
lift cylinder head leaked
lifting force Overflow valve blocked Check and replace or repair
for the blade
1 The sealing piston of the lift cylinder
or the blade Check and replace
is slowly leaked
lifted Quick drop valve blocked or faulty Check and replace or repair
Too low oil level in the oil tank Refill the oil
Too low pilot pressure Pilot overflow valve blocked
Lock ball valve rocker arm is not in
Chapter 4
Adjust the rocker arm linkage
place
Filter element inside the overflow Check and clean
valve set blocked
The valve element inside the pilot Check and replace
handle blocked
Quick drop valve not tightly closed Replace or repair
Piston cushion valve damaged or Replace or repair
blocked
Cylinder Piston seal damaged Replace
2 dropping Cylinder scuffing Replace the cylinder
Refill valve blocked or the seal dam- Check and replace or repair
aged
Shuttle valve excessively worn Check and replace or repair
Filter element blocked Check and clean the filter element
Air intruded into the operating pump Replace or repair the pipeline.
Pressure Working pump faulty Replace
loss of the The working pump driving key or
3 operating The working pump inoperative gear damaged, replace or repair
hydraulic The pipeline from the working pump
system Check and replace or repair
to the working valve leaked
Overflow valve blocked Check and replace or repair
The return spring inside the valve el- Check and replace
ement broken or failed
two situations:
1. When the valve element is blocked
in the closing position, off tracking Stop operation
occurs only when operating in high
speed;
Off track
(single side/ 2. When the valve element is blocked Check if the motor solenoid valve el-
dual direc- in the opening position, off-tracking is
2 ement is worn, and replace if neces-
tions off- more serious when operating in low sary
tracking) speed.
The variable cylinder or swash plate
is mechanically damaged, cancel the Repair or replace the work pump
correction signal, and check that Z1
and P1 pressure are normal.
Servo valve is faulty (valve element
blocked and spring broken), cancel
the correction signal, check that refill- Repair or replace the servo valve
ing pressure is normal, and Z1 and
P1 pressure are not normal.
The single brake is locked. The pres- Repair the brake and find out the
sure in this side is high, and the reason.
brake is hot.
Fault of the mechanical system. If the
spline for the input shaft of the reduc-
er is worn, the power is lost in single Repair the mechanical part
side. Two ends of the motor in this
side present no pressure difference,
and other pressures are normal.
Check if the pipeline for the refilling
Obstructed pumping of the refilling pump is leaked or the bolt is tight-
pump or low volume efficiency ened.
Abnormal Check if the overflow valve of the
refilling The overflow valve of the refilling slippage pump is worn, clean the
pressure pump is blocked in the opening posi- valve element or replace with a new
3 (low static tion valve
pressure
or no pres- Replace the work pump, and clean
The work pump swash plate or oil
sure) the enclosed system, replace the hy-
distribution disc is worn seriously draulic oil and the work filter element
The coupling input shaft is broken or Repair
damaged
Chapter 4
pressure overflow valve of the right
pump, and loosen the adjusting
The ma- screw for 3 turns, and then apply
chine can- The high pressure overflow valve is the accelerator to turn left during
7 not turn blocked in the advance side of the advancing. Recover to normal state
left during right pump and then adjust the screw to the
advancing original state. If the problem persists,
clean or replace the high pressure
overflow valve.
Insufficient hydraulic oil Add hydraulic oil
The bypass check valve of the radia- If the check valve is blocked, clean
tor is opened. Check if the shell pres- and repair it. Find out the reason
sure is normal when the shell pressure is too high
High hy- The hydraulic system is blocked, and
8 draulic oil partial throttling is produced, gener-
temperature Find out reasons
ally accompanying with abnormal
pressure
The work pump and motor are seri- Replace the part
ously worn and high calorific value
Chapter 4
Check pin X2.41, and restart the controller after the fault is
1103 10V power supply faulty, pin X2.41 short circuited
eliminated
Close the safety link, and reset the emergency button or check pin
1110 Too low supply voltage (pin X1.14)
X1.14
(Function controller) EEProm storage fails, fail to store
1150 Recover factory settings or replace the controller
teach-in data
Communication failure between function controller and
1200 Replace the controller
safety controller
Model line is not matched with that for the system Check connection of the model encoding line, or check the model in
1300
software the software version
Recover the factory settings and then report then in Change the model encoding line, and then recover factory setting
1310
invalid model encoding state. again
The current of the solenoid valve of the right front
Check the connection of the solenoid valve of the right front pump
2001 pump is set to 0, but the actual current is higher than
and check pin X2.02 and X2.16
100 mA
The actual current of the solenoid valve of the right
front pump exceeds the maximum possible current (the Check the connection of the solenoid valve of the right front pump
2002
solenoid valve is short circuited to the power supply or and check pin X2.02 and X2.16
it is powered externally)
The actual current of the right front solenoid valve
cannot normally follow the set current, and the
2003 difference between set current and actual current is Check connection and pin X2.02, X2.16
large. The solenoid valve connection is broken or short
circuited
The right front solenoid valve connection is faulty,
Check connection and pin X2.02, X2.16, and check the solenoid
2004 or the solenoid coil is aged or dampened, causing
valve
abnormal current of the solenoid valve.
The current of the solenoid valve of the right rear pump
is set to 0, but the actual current is higher than 100 mA Check the connection of the solenoid valve of the right rear pump
2011
It may caused by the condition that the solenoid valve and check pin X2.03 and X2.17
is externally powered
The actual current of the solenoid valve of the right
rear pump exceeds the maximum possible current (the Check the connection of the solenoid valve of the right rear pump
2012
solenoid valve is short circuited to the power supply or and check pin X2.03 and X2.17
it is powered externally)
is set to 0, but the actual current is higher than 100 mA Check the connection of the solenoid valve of the left front pump
2031
It may caused by the condition that the solenoid valve and check pin X2.04 and X2.18
is externally powered
The actual current of the solenoid valve of the left
front pump exceeds the maximum possible current (the Check the connection of the solenoid valve of the left front pump
2032
solenoid valve is short circuited to the power supply or and check pin X2.04 and X2.18
it is powered externally)
The actual current of the left front solenoid valve
cannot normally follow the set current, and the
2033 difference between set current and actual current is Check connection and pin X2.04, X2.18
large. The solenoid valve connection is broken or short
circuited
The left front solenoid valve connection is faulty, or the
Check connection and pin X2.04, X2.18, and check the solenoid
2034 solenoid coil is aged or dampened, causing abnormal
valve
current of the solenoid valve.
The current of the solenoid valve of the right motor is
set to 0, but the actual current is higher than 100 mA. It
2041 Check motor solenoid valve connection and pin X2.19, X2.33
may caused by the condition that the solenoid valve is
externally powered
The actual current of the solenoid valve of the right
motor exceeds the maximum possible current (the
2042 Check motor solenoid valve connection and pin X2.19, X2.33
solenoid valve is short circuited to the power supply or
it is powered externally)
The actual current of the right motor cannot normally
follow the set current, and the difference between set
2043 Check motor solenoid valve connection and pin X2.19, X2.33
current and actual current is large. The solenoid valve
connection is broken or short circuited
The right motor solenoid valve connection is faulty,
Check connection and pin X2.19, X2.33, and check the solenoid
2044 or the solenoid coil is aged or dampened, causing
valve
abnormal current of the solenoid valve.
The current of the solenoid valve of the left motor is
set to 0, but the actual current is higher than 100 mA. It
2051 Check motor solenoid valve connection and pin X2.06, X2.20
may caused by the condition that the solenoid valve is
externally powered
The actual current of the solenoid valve of the left
motor exceeds the maximum possible current (the
2052 Check motor solenoid valve connection and pin X2.06, X2.20
solenoid valve is short circuited to the power supply or
it is powered externally)
Chapter 4
Check the mircroinch pedal connection and pin
2095 Reference signal voltage of the mircroinch pedal is out of limit
X1.11
Cross-checking of main signal and reference signal of the microinch
Check the mircroinch pedal connection and pin
2096 pedal fails, and the sum value of the main signal and reference signal
X1.11, X1.38
voltage is out of limit
For the handle in quadrant 2. Cross-checking of main signal and
2097 reference signal of the right steering pedal fails, and the sum value of the Check the right steering pedal connection and pin
main signal and reference signal voltage is out of limit
For the handle in quadrant 2. Cross-checking of main signal and
2098 reference signal of the left steering pedal fails, and the sum value of the Check the left steering pedal connection and pin
main signal and reference signal voltage is out of limit
Check the handle connection and pin X1.05,
2099 The handle model is wrongly identified
X1.10, X1.25 and X1.39
2100
Cross-checking of main signal and reference signal of the steering handle
Check the steering handle connection and pin
2101 fails, and the sum value of the main signal and reference signal voltage is
X1.23 and X1.37
out of limit
Check the mircroinch pedal connection and pin
2103 The microinch pedal is wrongly identified
X1.11 and X1.38
Check the driving handle connection and pin
2104 Main signal voltage of the driving handle is out of limit
X1.36
Check the driving handle connection and pin
2105 Reference signal voltage of the driving handle is out of limit
X1.09
Cross-checking of main signal and reference signal of the driving handle
Check the driving handle connection and pin
2106 fails, and the sum value of the main signal and reference signal voltage is
X1.09 and X1.36
out of limit
2109 Signal voltage of the handle thumb wheel is out of limit Check the handle connection and pin X1.26
2110 Main signal voltage of gear 3 speed switch is out of limit Check the handle connection and pin X1.10
Check the manual accelerator control connection
2111 Signal voltage of the manual accelerator control is out of limit
and pin X1.24
2113 Too low battery voltage Check the battery voltage
Engine RPM signal is unreliable. In a condition that higher engine RPM Check the engine RPM sensor connection and pin
2120
is required, it is found that the engine RPM is too low X1.01
Left motor RPM signal is unreliable. In high operating speed, the motor Check the left motor RPM sensor connection and
2130
RPM signal is beyond the range, and the signal is unreliable pin X1.29
Chapter 4
9022 Unreasonable current range during calibration Re-self learning
9024 Overspeed Check if the current is too high
9026 Check if the current is out of limit Check if the current is too high
9027 Controller system fault Replace the controller
9028 Current is too high when the vehicle stops Replace the controller
prevent dust. Use two kind of cleaners: one is to remove impurity, and the other is for
cleaning.
CAUTION
• Pay special attention when cleaning the filter, magnetic plug and vent
hood.
4.3.2 Assembly
1. All parts shall be kept clean before assembly. Spare parts for replacement are generally
applied with anti-rust agent that shall be wiped off firstly.
2. In most cases, installation of bearings, bushing, oil seal and similar parts require a spe-
cial tool. It is a bad habit to use a hammer to drive a part into its position. In general,
put a wooden block or soft metal to deliver the hammering force.
3. The spring washer, flat washer, tab washer and cotter are all important parts. But they
are small in size that they are prone to be lost during assembly. When installing tighten-
ing parts such as bolts or nuts, check that they are tightened according to requirements.
4. A torque wrench shall be used in cases where the torque limit is specified. When fixing
the cover or install bolts or similar parts (for example, valve body), symmetrically tighten
bolts to ensure even pressure distribution.
5. An alignment mark is not an identification mark for matching parts, but to indicate a
method to try to correctly align parts.
1. When installing the oil seal, the oil seal lip for blocking the engine oil or gear oil shall
face inside (the side the oil is blocked) to improve the oil resistance. The lip for block-
ing the lubricating grease (grease) shall face outside. The old lubricating grease can be
Chapter 4
easily squeezed out when new lubricating grease is sufficiently added.
2. Allow the oil seal to tightly contact the shoulder or seal race.
3. Before installing the oil seal, apply a layer of lithium base grease around the lip; other-
wise, the oil seal may be scratched due to dry friction in the early stage.
4. Install the oil seal by using a conduit to slide the oil seal into the seat (see Figure 4-43A).
If the conduit is not used, you can use a temporary conduit made of brass sheet instead
(see Figure 4-43B).
5. A proper tool shall be used to correctly install the oil seal into the seat (see Figure
4-43C). Apply even pressure on the oil seal end face, with the diameter of the tool being
0.5~1mm smaller than that of the seat hole. The free end shall be shaped applicable for
hammering.
SAE 10-30
Engine
24
Oil pan
*SAE15W -40
Chapter 4
Working SAE10W-30
hydraulic 65
oil tank *SAE15W -40
DH17(31)
Final SAE10W -30 DH17L(35)
Transmis- each for
*SAE15W -40 left
sion right
Track roller 0.32
Carri roller SAE85W -140 0.24
Idler 0.15
4.5 each
Pivot box SAE30 for left and
right
Chapter 4
168