目录

Table of contents

 1. 元件介绍
Introduction of components
 2. 电气系统总体介绍
General introduction of electrical system
 3. 电气系统功能介绍和故障分析
Electrical control system function introduce and failure
analyze
 元件位置
Components position
 元件位置
Components position
 元件位置
Components position
元件位置
Components position
 1.1 压力传感器
Pressure sensor
零件号 Part No.：30B0171

作用 Function：检测左、右泵压力，可在显示器上读数。
Check pressures of left pump and right pump, the value can be showed on
the display.

参数 Parameters:
输出电流 Current Output：4-20mA
工作电压 Working Voltage：9-34Vd.c.
极限电流 Limiting Current：28mA
压力范围 Pressure Range：0-400bar
螺纹规格 Thread Specification：G1/4A
 1.1 压力传感器
Pressure sensor
检测过程 Test process:
1. 用万用表电阻档测量传感器1脚与2脚间电阻，可检测出11.4k欧左右的
电阻（单向）。
Measure the resistance between pin 1 and pin 2 with Resistance Position
of the multimeter, the resistance value is about 11.4 ohm(Unidirectional)

2.用万用表电流档（20mA），引脚2接万用表红色表笔，黑表笔搭铁，当
压力从0-40MP变化时，可检测到电流相应从4-20mA变化
Measure with Current Position(20mA) of the multimeter, connect red
probe with pin 2 and black probe with ground. Check the reading change
from 4-20mA with a pressure range of 0-40MP.
 1.2 压力传感器
Pressure sensor

零件号 Part No.：30B0173

作用 Function：检测先导泵压力，可在显示器上读数
Check pressures of pilot pump, the reading can be
showed on the display.

参数 Parameters:
输出电流 Current Output：4-20mA
工作电压 Working Voltage：9-34Vd.c.
极限电流 Limiting Current：28mA
压力范围 Pressure Range：0-60bar
螺纹规格 Thread Specification：G1/4A
 1.2 压力传感器
Pressure sensor
检测过程 Test process:
1.用万用表电阻档测量传感器1脚与2脚间电阻，可检测出11.4k欧左右的
电阻（单向）。
Measure the resistance between pin 1 and pin 2 with Resistance
Position of the multimeter, the resistance value is about 11.4
ohm(Unidirectional)

2.用万用表电流档（20mA），引脚2接万用表红色表笔，黑表笔搭铁，
当压力从0-6MP变化时，可检测到电流相应从4-20mA变化
Measure with Current Position(20mA) of the multimeter, connect red
probe with pin 2 and black probe with ground. Check the reading
change from 4-20mA with a pressure range of 0-6MP.
 1.3 压力开关
Pressure Switch
零件号 Part No.：30B0502

作用 Function：
1.检测手、脚先导压力，用于自动怠速。
Check hand & foot pilot Pressure, for auto
idle.
2.检测脚先导压力，用于行走报警。 Check
foot pilot pressure, use for travel alarm.
Auto idle
参数 Parameters:
常闭 Normal close: Actuates when
pressure is above 1.6 Mpa;
(The connector is a DT04-2P; The thread
is G1/4).
安全过压不超过30Mpa
The safety pressure must be less than
30MPa. Travel alarm
 1.3 压力开关
Pressure Switch
检测过程 Test process:
1.停机，用数字万用表200Ω电阻档测量压力开关两接线柱之间的电阻，显示0
（说明开关为关闭状态）为正常。
Shut down the engine, measure the resistance for the two terminals of the
pressure switch with position 200Ω of the multimeter. The reading is normal is
the switch is closed.

2.启动发动机，进行挖掘动作的同时测量手先导压力开关接线柱两端的电阻，
显示1为正常。（说明开关打开）
Start the engine, operate the machine for digging, measure the resistance for
the two terminals of the hand pilot pressure switch. The reading is normal is
the switch is open.
 1.3 压力开关
Pressure Switch
3.启动发动机，进行行走操作的同时测量脚先导压力开关接线柱两端的电阻，
显示1为正常。（说明开关打开）
Start the engine,operate the machine for digging, measure the resistance for
the two terminals of the foot pilot pressure switch. The reading is normal is the
switch is open.
 1.4 冷却液位报警开关
Coolant Level Alert Switch
零件号 Part No.：30B0401

作用 Function：
检测水散水位，水位低时报警
Check the water level of radiator, alarm hoot

参数 Parameters:
螺纹规格 Thread Specification：M14X1.5
报警时开关闭合，否则断开 The witch is on when
warning, otherwise is off.
 1.4 冷却液位报警开关
Coolant Level Alert Switch
检测过程 Test process:
用万用表电阻档测量，当浮子距离传感器底部小于3mm时，开关闭合，否则
断开。
Measure with the Resistance Position of the multimeter. When the float and
the sensor distance is less than 3mm, the switch closes, otherwise the
switch opens.
 1.5 天线
Antenna
零件号 Part No.：37B0221

作用 Function：Radio antenna.

参数 Parameters:
频率范围 Frequency Range：806～960
带宽 Bandwidth（MHz）：70
增益 Gain（dBi）：5.5
同轴电缆线 Coaxial line（mm）：2500

检测过程 Test process:

检查外观有无破损 Check the appearance
for damage
 1.6 保险盒
Fuse box
零件号 Part No.：46C3370

作用 Function：The fuse box

contains the fuses that
protect the individual circuits
within the excavator, along
with the low current relays
used for switching some of
those circuits.

参数 Parameters:24V
1.6 保险盒
1.6 Fuse
Fuse box
box
 1.7 主电源开关
Main Power Switch
零件号 Part No.：34B0297

作用 Function：
控制整机电源的通/断
Switch on/off the electric power of the
complete machine

参数 Parameters:
螺纹端规格
Terminal Thread Specification：M10
Contactor Constant Through
电流 Current≤200A
瞬间电流 Instant (5s) Current ：1200A
1.7 主电源开关
Main Power Switch

位置
Position
 1.8 标准/应急系统开关
Standard/Emergency system Swith
零件号 Part No.：34B0212

作用 Function：
标准系统/应急系统切换开关
To exchange standard/emergency system

参数 Parameters:
额定负载 Rated Load：300V d.c 3A
1.8 标准/应急系统开关
Standard/Emergency system Swith

位置
Position
1.9 喇叭按钮
Horn Button
参数 Parameters:
额定负载 Rated Load：24V 8A
 1.10 增压按钮
Power boost button
参数 Parameters:
额定负载 Rated Load：24V 8A
 1.11 启动继电器
Start relay
零件号 Part No.：31B0072

作用 Function:
启动继电器，断油阀继电器 Start relay, oil cutoff
valve relay

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V DC
触点额定电流 Contact Rated Current：120A
线圈接线端螺纹规格Thread size at coil wire
terminal: M5
触点接线端螺纹规格Thread size at contact wire
terminal: M8
 1.11 启动继电器
Start relay
检测过程 Test process:
1. M5接线柱间的电阻为63欧左右
Resistance at the M5 terminal is about 63 ohm.
2.线圈不通电时，M8接线柱间的电阻为0；线圈通电时，M8接线柱
间电阻为无穷大（开关断开）
When coil is deenergized, resistance at M8 terminal is 0, when coil
is energized, resistance at M8 is infinite(Switch opens)

位置
Position
 1.12 预热继电器
Preheat relay
零件号 Part No.：31B0042

作用 Function:
预热继电器 Preheat relay

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V DC
触点额定值 Contact Rated Value：48V DC 200A
线圈接线端螺纹规格 Winding Terminal Thread
Specification：M4
触点接线端螺纹规格 Contact Terminal Thread
Specification：M8
 1.12 预热继电器
Preheat relay

检测过程 Test process:

1. M4接线柱间的电阻为4欧左右
Resistance at the M4 terminal is about 4 ohm.
2.线圈不通电时，M8接线柱间的电阻为0；线圈通电时，M8接线柱间电阻
为无穷大（开关断开）
When coil is deenergized, resistance at M8 terminal is 0, when coil is
energized, resistance at M8 is infinite(Switch opens)

位置
Position
 1.13 起动辅助继电器
Start aid relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
1.14 行走报警继电器
Travel alarm relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
 1.15 雨刮继电器
Wiper relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
 1.16 动臂灯继电器
Boom lamp relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
 1.17 车架灯继电器 Chassic relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
 1.18 行走速度继电器
Travel speed relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
 1.19 顶灯继电器
Lamp relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
1.20 油泵继电器
Pump relay

零件号 Part No.：31B0059

参数 Parameters:
线圈额定电压 Winding Rated Voltage：24V
触点额定电流 Contact Rated Voltage：30A
1.21 电源插座
Power supply socket
零件号 Part No.：36B0641

作用 Function：
12V电源插座，给车载设备供电
12V power supply receptacle. Supply 12V
power to electrical appliances.

参数 Parameters:
通过电流 Through Current：8A
 1.22 点烟器
Cigarette Lighter
零件号 Part No.：37B0061

作用 Function：
1、点烟器。2、24V电源插座，给车载设备供电。
1. Lighter; 2. 24V electricity supply for automobile
devices.

参数 Parameters:
功率 Power：108W ，电流 Current≤4.5A
 1.22 点烟器
Cigarette Lighter
检测过程 Test process:

检查与点烟器对接的插头是否带24V电压，如果带电但是不能点烟，则
说明点烟器损坏。
Check the connector that connects to lighter for 24 V voltage, if voltage
is found, but lighter fails to work, then the bulb is damaged.

位置
Position
 1.23 先导切断开关
Pilot Shut Switch
零件号 Part No.：34B0119

作用 Function：
先导切断阀 Use for shut-off valve

Parameters:
外部尺寸 Exterior Dimension：
32X24X10mm
额定值 Rated Value DC：15V 6A
 1.24 门控雨刮开关
Wiper Lock Switch
零件号 Part No.：34B0134

作用 Function：
前窗位置开关，当前窗打开时，雨刮功能切断Front
window position switch. When the front window is
open, wiper circuit is cut off.

参数 Parameters:
常闭 Normally closed
额定值 Rated Value：24V DC 0.75A；12V DC 1.5A
1.24 门控雨刮开关
Wiper Lock Switch

位置
Position
 1.25 旋转信号灯
Rotating Beacon
零件号 Part No.：32B0080

作用 Function：
旋转信号灯 Rotating beacon

参数 Parameters:
额定值 Rated Value：24V 55W
 1.25 旋转信号灯
Rotating Beacon
检测 Test process:
检查与旋转信号灯对接的插头是否带24V电压，如果带电但是灯不亮，则说
明灯泡损坏。
Check the connector that connects to rotating beacon for 24 V voltage, if
voltage is found, but no illumination, then the bulb is burnt out.

位置
Position
 1.26 顶灯
Dome light
零件号 Part No.：32B0084

作用 Function：
顶灯 Dome light

参数 Parameters:
额定值 Rated Value：24V 10W
1.26 顶灯
Dome light

检测过程 Test process:

位置
Position 检查与顶灯对接的插头是否带24V电压，如
果带电但是灯不亮，则说明灯泡损坏。
Check the connector that connects to dome
light for 24 V voltage, if voltage is found, but
no illumination, then the bulb is burnt out.
 1.27 雨刮开关
Wiper switch

零件号 Part No.：34B0742

参数 Parameters:
额定值 Rated Value：24V 8A
 1.28 快换装置开关
Quick Coupler Switch
零件号 Part No.：34B0744

作用 Function：
控制快换装置 Controls quick coupler.

参数 Parameters:
额定值 Rated Value：24V 8A
 1.29 发动机速度开关
Engine speed switch
零件号 Part No.：34B0324

作用 Function：
在标准模式下控制发动机的速度
Controls the engine speed under standard
system.
 1.29 发动机速度开关
Engine speed switch
检测过程 Test process:
Check the start switch for power state with Resistance Position of the
multimeter, using the following table

位置
Position
 1.30 加速旋钮
Accelerator Knob
零件号 Part No.：34B0729

作用 Function：
在应急模式下控制发动机速度
Controls the engine speed under emergency
system.
1.31 开关盒
Switch Box
零件号 Part No.：37B0719

作用 Function：
1.控制行走速度 Control the travel speed
2.控制动臂灯和车架灯 Control the boom light
and frame light
3.控制雨刮 Control the wiper.
4.行走报警取消 Travel alarm cancel

参数 Parameters:
额定电压 Rated Voltage：24V dc
1.31 开关盒
Switch Box

位置
Position
 1.32 雨刮电机和传动机构
Wiper Motor & Linkage
零件号 Part No.：37B0718

作用 Function：
驱动雨刮工作 Used to drive the wiper to work

参数 Parameters:
额定电压 Rated voltage: 24V
额定功率 Rated power: 35W
低速电流（无负载） Current at low
speed(without load≤1.2A
低速电流（有负载） Current at low
speed(with load)≤3.0A
 1.32 雨刮电机和传动机构
Wiper Motor & Linkage
检测过程 Test process:
电机外观不得有划痕、碰伤；通24V电电机工作并无异响，传动机构与电机
固定座无干涉，输出轴初始摆动为顺时针摆动。

位置
Position
1.33 显示器
Monitor
零件号 Part No.：35B0149

功能 Function：显示器 Monitor.

参数 Parameters:
额定电压 Rated Voltage：24Vdc CAN
Communication

位置
Position
 1.34 AMG保险丝
AMG Fuse
零件号 Part No.：37B0299

作用 Function：
预热回路保险 Fuse for preheat circuit

参数 Parameters:
额定电流 Rated Current：150A

检测过程 Test process:

检查外观 Check the appearance
 1.35 蓄电池
Battery
零件号 Part No.：37B0108

作用 Function：蓄电池 Battery

参数 Parameters:
额定电压 Rated voltage：12V
储备能力 Reserve capacity：230min
低温起动电流 Low temperature 位置
starting current Position
（-180C）：850A
检测过程 Test process:
 1.36 收音机
Radio
零件号 Part No.：37B0769

作用 Function：收音机 Radio

参数 Parameters:
额定电压 Rated Voltage：24V dc
 1.36 收音机
Radio
检测过程 Test process:
黑色插头共接有3根线，其中一根黑色的为地线，其余两根为电源线，分别测
量两根电源线与地线间的电压，如果电压为24V，但是收音机不能使用，则
说明收音机损坏。
3 wires are available for the black connector. One is ground wire and the
others are power supply wires. Check the voltage between the ground wire
and each power supply wire respectively. If the voltage is 24V, but radio
fails to work, then the radio is damaged.

位置
Position
 1.37 电喇叭
Horn
零件号 Part No.：38V0001

作用 Function：喇叭 Horn

参数 Parameters:
额定电压：24V
Rated voltage：24V
工作电流：2.0Amax
Current：2.0Amax
基频：420±30Hz
Basic frequency：420±30Hz
声级：105dB-118dB(A)
Sound level：105dB-118dB(A)

检测过程 Test process:

检查外观有无破损，通电无异响 Check the
appearance for damage，no noise when power on
 1.38 扬声器
Loudspeaker
零件号 Part No.：38B0057

作用 Function：
收音机扬声器Loudspeaker of Radio

检测过程 Test process:

检测接线柱两端电阻约为8欧，允许误差范围6.8欧~9.2欧
Check the resistance at both terminals. The value
should be 8 ohm. Allowable error range is 6.8 to 9.2
ohm
 1.39 行走报警器
Travel alarm
零件号 Part No.：38B0042

作用 Function：行走报警 Travel alarm

参数 Parameters:
分贝值 Decibel Value：112dB(A)
工作电压 Operating Voltage：12-48V dc
 1.40 电阻器
Resistor
零件号 Part No.：38B0055

作用 Function：
应急系统下，比例电磁阀限流电阻
Used to limit the flow of proportion valve
under emergency system

参数 Parameters:
额定值 Rated Value：100W 41Ω
 1.41 清洗器总成
Washer Assembly
零件号 Part No.：37B0116

作用 Function：清洗器总成 Washer Assembly

参数 Parameters:
储液箱容积 Liquid Saving Box：3L
电机额定功率 Rated Power of Motor：25W
负载电流 Load Current：≤1.5A
 1.42 动臂灯
Boom Lamp
零件号 Part No.：32B0028

作用 Function：动臂灯 Boom Light

参数 Parameters:
灯泡规格 Bulb Specification：24V 70W
1.43 快换装置电磁阀
Quick hitch solenoid

零件号 Part No.：12C0370

参数 Parameters: 24V
 1.44 温度传感器
Temperature Sensor
零件号 Part No.：32B0496

作用 Function：
检测液压油温，可以在显示器上读数。温度显示
范围40°C--100°C ，温度超过85℃ 时报警。
Check the temperature of hydraulic oil, show the
value on display. Temperature range on the
display: 40°C--100°C, the warning is activated
when the temperature surpass 85℃

参数 Parameters:
螺纹规格 Thread Specification：M18X1.5
连接器规格 Connector Specification：DJ7021-
1.5-10
传感元件 Sensing Element:Pt1000
 1.44 温度传感器
Temperature Sensor
检测过程 Test process:
用万用表的2K档测量传感器两个端子，比对阻值表
Test the two terminals of the sensor by using position 2K of the multimeter,
use following resistance table for reference
0
Temp( C) 50 60 70 80 85 90
Resistance( 3509 2401 1678 1195 1015 865.5
Ω)
0
Temp( C) 95 100 105 110 115
ResistanceΩ ) 741.2 637.1 549.8 476.3 414
 1.45 燃油传感器
Fuel Sensor
零件号 Part No.：30B0350
作用 Function：
检测柴油箱油位，可在显示器上读数
Detect diesel tank oil level, you can read from
monitor
参数 Parameters:
长度 Length：745mm
分段数 Number of segments：12
连接器规格 Connectors Specifications：
DJ7031-1.5-10
电流 Allows current≤100mA
功率 Allows electric power≤3W
最大阻值 Maximum resistance：900±9 Ohm
最小阻值 Minimum resistance：75±0.75 Ohm
 1.45 燃油传感器
Fuel Sensor
Test process:
用万用表测量燃油传感器插接器的1脚和2脚，检测时，以磁浮子由上往下运
动为测试方向。 观察万用表所显示电阻值。对应的与表格规定的电阻值相比
较，是否一致？如果不一致，则燃油传感器故障。

Test pin 1 and pin 2 of the fuel sensor connector by using a multimeter.
When testing, follow the up and down movement direction of the magnetic
float. Observe the resistance reading shown in the multimeter. Check the
resistance of multimeter values to see whether they are the same. If not,
trouble will occur to the fuel sensor.
浮球
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
L11
高位报警

51±4

79±4

156±4

226±4
1.45 燃油传感器
Fuel Sensor

296±4

366±4

436±4

506±4

576±4

646±4

695±4

745±4
 1.46 直流发电机
Direct current dynamo
零件号 Part No.：40C1029

作用 Function：直流发电机 Direct current dynamo

参数 Parameters: 24V 70A

 1.47 起动马达
Starter motor
零件号 Part No.：11C0589

作用 Function：起动马达 Starter motor

参数 Parameters: 24V 7.5KW

 1.48 电锁
Electric Switch Lock
零件号 Part No.：34B0118
作用 Function：
1. 整机电源接通 Complete machine electric supply
connection.
2. 停机/关闭整机电源 Stop/ Turn off power supply of the
complete machine
3. 启动档 Start position
4. 预热档 Preheat position
参数 Parameters:
1.B1，B2-G1，G2额定电流 30A， B1，B2-M额定电流 3A
2.B1，B2-M瞬时电流 10A B1，B1-S额定电流 3A B1，
B2-S瞬时电流 10A

1.B1，B2-G1，G2，Rated current 30A， B1，B2-M

Rated current 3A
2.B1，B2-M instantaneous current 10A B1，B1-S
Rated current 3A B1，B2-S instantaneous current 10A
 1.48 电锁
Electric Switch Lock
检测过程 Test process:
用万用表电阻档按电路导通图检测电锁通断情况
Check the start switch for power state with Resistance Position of the
multimeter, using the following table
 1.49 车架灯
Chassic Lamp
零件号 Part No.：32B0301

作用 Function：Frame Lamp

参数 Parameters: 24V 70W

 1.49 车架灯
Chassic Lamp
检测过程 Test process:
1.万用表检查两接线柱之间是否断路，断路则说明灯泡烧毁Check the two
terminals with a multimeter to look for an open circuit. If an open circuit is found,
the the light bulb is burnt out.

2.检查与车架灯对接的插头是否带24V电，如果带电但是灯不亮则说明灯泡烧毁
Check the connector that connects to frame light for 24 V voltage, if voltage is
found, but no illumination, then the bulb is burnt out.

位置
Position
 1.50 转换器
Converter
零件号 Part No.：37B0472
作用 Function：
24V转12V电压输出，接电源插座 Convert
output voltage from 24v to 12V, connecting
to electrical supply plug.
参数 Parameters:
峰值功率 Peak Power：130W
功率 Power：100W
频率 Frequency：52kHz
输入电压 Input Voltage：18/32V
输出电压 Output Voltage：13.5V
额定负载 Rated Load：12V 10A
输出电流 Output Current：7.5A
 目录
Table of contents

 1. 元件介绍
Introduction of components
 2. 电气系统总体介绍
General introduction of electrical system
 3. 电气系统功能介绍和故障分析
Electrical control system function introduce and failure
analyze
2.1 说明 Explanation

本ppt所有内容均以装CLG922 Tier2挖掘机为主来讲解和
描述问题，个别线号和参数可能有差异，但是功能均保持一致。
如有疑问请与柳工总部联系。
All content of this ppt are fitted CLG922 Tier2 excavator to
explain and describe the main issues， individual line
numbers and parameters may differ, but the functions are
consistent. If in doubt please contact the Liugong headquarters.
2.2 总体介绍
general introduction
柳工电控系统由主控制器、执行器控制器、执行器、十档旋钮开关组成，
相互之间通过线束连接。能根据司机的操作和机器的状态去执行相应的功能
如电子油门、功率跟随、自动怠速、手动怠速、瞬时增力、自动预热等等。
相关联的电子部件:显示器.
LiuGong electrical system is made up of main controller, actuator
controller,actuator,ten position engine accelerator switch and wiring
harnesses. Can perform corresponding function base on driver’s operation
and machine, for example, Electrical governor , Auto idle, Manual idle,
Power boost, Auto warm-up, and so on. Calibration via the electrical
assembly :monitor.

Main Actuator Actuator Ten position engine Monitor

controller accelerator switch
controller
2.3 TIER2 阶段挖掘机用电控系统
TIER2 excavator electrical system
 2.4 电控系统安装位置
Electronic control system installation location
主控制器 继电器
Main controller Relay

Wiper controller
执行器控制器
 目录
Table of contents

 1. 元件介绍
Introduction of components
 2. 电气系统总体介绍
General introduction of electrical system
 3. 电气系统功能介绍和故障分析
Electrical control system function introduce and failure
analyze
3.1 电控系统的功能介绍
Electrical control system function introduce
柳工电控系统的功能较多，本PPT仅介绍比较常用的功能。
LiuGong’s electronic control system have many features, the
PPT only describes the commonly used functions.

1、电子油门
The electronic throttle
2、自动怠速
Automatic idle
3、手动怠速
Manual idle
4、功率跟随
Electrical power control function
5、整机参数监控
Machine date collection function
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

1、使用电子油门一定要学会使用转速标定，在什么情况下需要做转速标
定？
You must learn to use the speed calibration when use the electronic
throttle, Under what circumstances need to do speed calibration?

a、如果更换主控制器、执行器控制器、执行器任意一个则都需要做转
速标定；
If replace anyone of main controller, actuator controller, actuator , you
will have to do speed calibration

b、如果在实际使用中个别档位转速出现较大偏差时也需要做转速标定
If the actual use of individual stalls, large deviations occur when speed
needs to be done speed calibration
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

2、为什么需要进行转速标定？
why we need to do speed calibration?
由于油门软轴、执行器、油门拉杆安装位置的精度问题，必须进行转
速标定，否则每档转速存在很大的偏差。
Due to position accuracy issues of the throttle shaft, actuator, throttle
lever , must to do speed calibration, or there is a big deviation of each
stall speed.
3、有什么机型不需要做转速标定吗？
What models do not need to do speed calibration?
只有Tier3阶段及以上的挖掘机不需要进行转速标定。
Only tier 3 and above the excavator do not need to do speed calibration.
下表为各档空载转速：
The following table shows each stall noload speed :
档位 Stall 1 2 3 4 5 6 7 8 9 10
空载转速
1000 1250 1400 1500 1560 1700 1750 1800 2050 2180
noload speed
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

4、如何使用转速标定？
How to use speed calibration?
标定步骤分三步：
Three-step calibration procedure
a、标定前相关问题确认；
Confirmation related issues before calibration;
b、标定过程中；
In the process of calibration
c、标定结束后检查。
Check after calibration
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

a、标定前相关问题确认；
Confirmation related issues before calibration
① 控制器与显示器通讯是否正常？
whether it is normal that Controllers communicate with the monitor?
② 发动机转速显示是否正常？
Engine speed display is normal?
③ 该机型有没有执行器?
The models have the actuator?
④ 是否工作在标准模式下?
Is working in standard mode?
⑤ 软轴安装是否正常？
Shaft installation is normal?
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

b、标定过程中；
The calibration process;
①在不发动机器的前提下输入密码30000000,密码正确则等候,提示后起动发动机
Input the password 30000000 without start engine, If the password is correct,
please wait , start the engine after being briefed on.

②等候标定结束(<10min)，显示器有标定进度
Waiting for the end of calibration (<10min), monitor have the progress of a
calibration
③观察显示器相关提示后关闭电锁
When the monitor prompt, close the electric lock
3.2 柳工电控系统的功能说明-电子油门
Electrical control system function introduce-The electronic throttle

c、标定结束后检查；
Check after calibration
①如果提示要调整软轴则表示最高转速达不到要求，则要调整.
If prompted to adjust the flexible shaft said maximum speed does
not meet the requirements,please adjust.
②如果提示重新启动发动机则表示标定正常结束.
If you are prompted to restart the engine said calibration is normal
end.
③检查每档转速是否正常(对照该机型的转速表).
Check each stall speed is normal (control the speed of the machine
table).
3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

发动机启动前
LED1 LED2 LED3 现象描述 维修提示(注意安全,禁止在发动机运行时维修!)

常亮 — — 给控制器的电源正常

①检查保险；②检查保险与控制器连接线束；③检查控制器的
不亮 不亮 不亮 给控制器的电源故障
接地线

常亮 闪烁 不亮 控制器CPU工作正常 LED2一直闪烁,闪烁频率1次/秒

常亮 1 1 水温传感器短路 ①检查水温传感器；②检查水温传感器与控制器连接线束

常亮 1 2 油温传感器短路 ①检查油温传感器；②检查油温传感器与控制器连接线束

常亮 1 3 油位传感器短路故障 ①检查油位传感器；②检查油位传感器与控制器连接线束

指示灯从左到右：LED1 LED2 LED3

常亮 1 4 油位传感器断路故障 ①检查油位传感器；②检查油位传感器与控制器连接线束

常亮 2 1 油门档位丢失或未重新转速标定 ①重新做转速标定

①重新做转速标定；②多次转速标定但不能消除此故障，则更
常亮 2 2 部分档位转速不正常
换控制器
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

Before starting the engine

LED1 LED2 LED3 Description of the phenomenon Maintenance tips (safety, prohibit the maintenance of the engine is running!)

Always — — Normal power supply to the controller

① Check the insurance; ② Check the wiring harness connected to the controllers
Off Off Off To the controller's power failure
Insurance; ③ Check the ground wire controller

Always Flicker Off Controller CPU is working LED2 keeps flashing, blinking frequency of 1 times / sec

① Check the temperature sensor; ② Check the water temperature sensor and
Always 1 1 Temperature sensor short circuit
controller wiring harness connector

① Check the oil temperature sensor; ② Check the oil temperature sensor and
Always 1 2 Oil temperature sensor short circuit
controller wiring harness connector

① Check the oil level sensor; ② Check the oil level sensor and controller wiring
Always 1 3 Oil level sensor short circuit
harness connector

Light from left to right:

LED1 LED2 LED3

① Check the oil level sensor; ② Check the oil level sensor and controller wiring
Always 1 4 Oil level sensor circuit fault
harness connector

Always 2 1 Stall speed throttle loss or re-calibration ① re-do speed calibration

① re-do speed calibration; ② speed calibration several times but can not
Always 2 2
Part of the stall speed is not normal eliminate this failure, replace the controller
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

转速标定过程中
维修提示(注意安全,禁止在发动机运行时维
LED1 LED2 LED3 现象描述
修!)

常亮 常亮 1 转速标定，发动机在增速

常亮 常亮 2 转速标定，发动机在减速

①检查油门软轴；②检查转速传感器；③检
查执行器；④检查执行器控制器；⑤检查控
常亮 不亮 3 转速标定失败
制器到执行器控制器的“油门控制”线；⑥
重新做转速标定

常亮 常亮 常亮 转速标定成功 ①完成转速标定，重新起动
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

The calibration process

Description of the Maintenance tips (safety, prohibit the
LED1 LED2 LED3
phenomenon maintenance of the engine is running!)
Speed ​calibration, the
Always Always 1
engine in the growth rate
Speed ​calibration, engine
Always Always 2
speed reducer
①Check the throttle shaft;
②Check the speed sensor;
③Check actuator;
④Check the actuator controller;
Always Off 3 Speed ​calibration failure
⑤Check the “throttle control” line of the
controller to the actuator controller ;
⑥Re doing speed calibration.

Alway Speed ​Calibration ①complete demarcation speed, re-start

Always Always
s successful
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

发动机2分钟之后的工作指示
维修提示(注意安全,禁止在发动机运
LED1 LED2 LED3 现象描述
行时维修!)

控制器取不到转 ①检查转速传感器；
常亮 2 1
速信号 ②检查转速传感器与控制器连接线束

①检查转速传感器；
常亮 1 不亮 转速控制失效 ②检查转速传感器与控制器连接线束；
③检查控制器的“点火开关起动”线

常亮 1 1 串口通讯故障 ①检查控制器与GPS串口通讯连接线束

常亮 不亮 1 控制器工作正常
 3.3 柳工电控系统的使用说明-故障指示灯
Electrical control system function introduce-The fault indicators

2 minutes after the engine work instructions

LED LED LED Description of the
Maintenance tips (safety, prohibit the
1 2 3 phenomenon
maintenance of the engine is running!)

① Check the speed sensor;

Controller to get any
Always 2 1 speed signal
② Check the speed sensor and controller wiring
harness connector

① Check the speed sensor;

② Check the speed sensor wiring harness
Speed control
Always 1 Off connected to the controllers;
failure ③ Check the controller of the "ignition
switch start " line
① Check the serial communication
Serial communication
Always 1 1 failure
controller and the GPS wiring harness
connector
Controller is working
Always Off 1 properly
 3.4 柳工电控系统的相互关联故障-显示器
Electrical control system interrelated failure - monitor

1、显示器的液晶屏受低温影响显示不全
LCD display shows incomplete by low temperature impact
2、显示器的通讯接口出现故障，与电控系统无法通讯
Failure of monitor’s communication interface, and electronic
control system can not communicate
3、显示器软件问题
Monitor software problem
 3.5 柳工电控系统的相互关联故障-执行器
Electrical control system interrelated failure - actuator

1、执行器受低温影响
Actuator is affected by low temperature
2、执行器的线形度发生漂移:
Actuator linearity drift：
执行器的移动距离与执行器的反馈电阻是一一对应的，且对应
系数为常数。如果发生故障，某些点的对应关系将会错误。
The moving distance of the actuator and actuator
feedback resistor is one to one, and the corresponding
coefficient is constant. If a fault occurs, certain points
of the correspondence will be wrong.
3、执行器接头等自身故障
Actuator connector itself failure
 3.6 柳工电控系统的故障类型
Failure type of Liugong electric control system

1、电子油门相关故障；
Electronic throttle relevant fault;
无法标定转速/通讯异常/转速标定失败/各档转速紊乱
Can not calibration speed/Communication anomaly/Speed ​
calibration failure/Disorders of the stall speed
2、数据显示等有关故障；
Data display and other relevant failure
数据始终为0/显示器仪表跳变/数据异常
Data always 0/ Monitor and meter jumping /Data is exception
3、全功率相关故障
Full power-related failures
 3.7 柳工电控系统的故障分析
Liugong electronic control system fault analysis
故障产生的原因:
Causes for the failure:
1、电子部件问题(个别电子器件问题、硬软件设计问题)；
Electronics issues (the issue of individual electronic devices, hardware and
software design issues)
2、线路连接问题(插接头松、导线断路或搭铁)；
Line connection problems (loose plug connectors, wire circuit or grounding);
3、干扰问题(环境问题、抗干扰能力差)；
Interference problems (environmental issues, anti-jamming ability is poor)；
4、系统保护问题(不具备防错接)；
System Protection (do not have the connection error prevention)；
5、人为原因(维修水平、沟通原因)。
Artificial reason (maintenance level, communication reasons).
 3.8 维修前准备工作
Preparing for maintenance work
检查故障需要有以下一些常用工具:
To check for a fault, we will need to have the following common tools:
1、万用表 2、M8扳手 3、十字螺丝刀 4、专用套筒 5、大头针
1.DVOM 2. 8mm wrench 3. Phillips screwdriver 4.special sleeve 5.
Small Pins for probing wires
柳工电控系统的故障分析列表

1、 油门加不起来的排除方法
2、 转速标定故障的排除方法
3、 通讯故障的排除方法
4、 档位显示故障的排除方法
5、 转速信号故障排除方法
6、 全功率故障排除方法
7、 手、自动怠速故障排除方法
8、 水温故障排除方法
9、 液压油温故障排除方法
10、燃油油位故障排除方法
11、执行器控制器故障的排除方法
12、执行器故障的排除方法
13、水位报警的排除方法
14、机油压力报警的排除方法
 3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

油门无法加起的原因有多种，具体如下：
Accelerator can not add up due to many reasons, as follows:
1、转速传感器问题导致：
Speed ​sensor problem caused:
正常情况下，转速传感器不会影响电子油门使用，但是点火线
180#中间断路时，转速传感器损坏会导致油门无法加起。
Under normal circumstances, the speed sensor will not affect
the use of electronic throttle, but the middle of the ignition
circuit # 180, the speed sensor can cause damage to the
accelerator can not add up.
解决办法：检查传感器和传感器到控制器之间的线束。
Solution: Check sensor and wiring harness that between the
sensor to the controller.
 3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

2、更换控制器等部件后未进行转速标定
Not do speed calibration after replace the controller and other
components
注意：更换控制器、执行器控制器、执行器任意一个需要进行
转速标定。

Notice:if replace anyone of main controller, actuator

controller, actuator , you will have to do speed
calibration
解决办法：重新标定后即可
Solution: do speed calibration
3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

3、手动怠速导致怠速
Manual idle causing idle speed
手动怠速会使机器工作在一档，旋动档位时转速不会增加。
Manual idle makes machines work in one gear ,
speed will not increase when rotating stall.
手动怠速标志如右图所示：
Manual idle symbol as right picture shows
解决办法：按下图所示按钮，取消手动怠速
Solution: Press the button shown in the
following picture , cancel manual idle speed
 3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

4、十档油门开关导致怠速
Ten stalls throttle switch lead to Idle
十档油门开关故障可能会导致仪表上始终显示1档。
Ten stalls throttle switch failure may cause the monitor
always display 1 stall
解决办法：参考档位显示异常的方法排除
Solution: reference ways of stalls show unusual to removing
 3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

5、系统处于备用模式下
System is in standby mode
如果系统处于备用模式下，488#得电，执行器控制器被切换到备用
模式，拨动备用油门开关可以调节转速。
If the system is in standby mode, the 488 # was electric, the actuator
controller is switched to standby mode, toggle switch can adjust the
speed of the accelerator backup.
解决办法：切换到标准模式
Solution: switch to standard mode
 3.9 故障诊断—油门加不起的分析方法
Troubleshooting- the analytical methods of accelerator growth

6、其他原因
Other reasons
其他原因可能是控制器、执行器控制器没有得电工作或损坏；
软轴问题；执行器问题等等。
Other reasons may be the controller, actuator controller does
not have power to work or damage; shaft problem; the
actuator problems, and so on.
 3.10 故障诊断—转速标定故障的分析方法
Troubleshooting- the analytical methods of speed calibration

转速标定的原因有多种，具体如下：
Speed calibration due to many reasons, as follows:
1、密码问题导致无法进行转速标定
Password issue caused speed calibration failure
密码问题一般为通讯故障的原因所致或者是在发动机启动后输
入密码导致
Password problems are generally due to the reasons for
communication failures, or due to enter a password after
starting the engine
解决办法：a/若是通讯故障则相应故障排除方法检查
Solution: a/ If communication failure, corresponding
troubleshooting method to check
b/若是启动后输入密码则请在发动机器前输入密码即可
b/ If due to enter a password after starting the engine, please
enter a password before starting the engine
 3.10 故障诊断—转速标定故障的分析方法
Troubleshooting- the analytical methods of speed calibration

2、转速标定正常结束后仍无法调节油门或始终高转速
The throttle can not be adjusted after the normal
speed ​calibration end or speed is always high
一般是标定前的检验步骤没有完成，如转速传感器问题
Generally the inspection procedures is not completed before
calibration, such as the speed sensor problem
解决办法： a/重新检查一遍
Solution: a / re-check again
b/如果检查均正常需要与设计人员联系
b / It is need to contact with the designer if the examination were normal
3、标定结束时有故障原因提示
There are reasons prompt for failure at the end demarcation
解决办法： 请按照提示检查（控制器指示灯也有提示）
Solution: Please follow the prompts to check (controller indicator also
prompted)
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

通讯故障是指的控制器与显示器之间的通讯故障，一般原因如下：
Communication failure is the communication between the
controller and display failures, usually for the following reasons:
1、总线匹配电阻的原因
Reason of the bus termination resistor
解决办法：测量总线匹配电阻是否为60欧姆左右，两步如下：
Solution: measurement the bus termination resistor around 60
ohm, two steps are as follows:
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

检测步骤1：先拆开座椅后面驾驶室内饰，找到总线匹配电阻的三通接头，再
找到CAN总线的两根线号750#和751# (752#地线)，最后将大头针或细
导线插入三通接头，用万用表200欧姆电阻档测得电阻为120欧姆左右。(此
时量的电阻为显示器处)
Detection Step 1: First open the back seat of cab interior, to find the bus
termination resistor The tee, and then find two CAN bus line number 750 #
And 751 # (752 # ground), and finally a pin or thin wire Insert tee, 200 ohms
with a multimeter measured electrical resistance profile Resistance of 120
ohms or so. (At this point the monitor at the amount of resistance)
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

检测步骤2：拆下如图所示的驾驶室内的匹配电阻。最后将大头
针或细导线插入三通接头的A孔和B孔，用万用表
200欧姆电阻档测得电阻为120欧姆左右。
Detection Step 2: Remove the cab as shown matching resistor. Finally, the
bulk of Three needles or thin wires into holes A and B connector hole, with
a multimeter 200 ohm resistance profile measured resistance of 120 ohms
or so.
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

i、如果步骤1测得电阻为无穷大或者很小，则说明显示器处的总线匹配电阻
有问题，松脱或者断路、短路。
i. if the resistance measured in step 1 is infinite or very small,
then the resistance of the bus wire have problems at display ,
loose or open circuit, short circuit

三通接头松脱 Loose tee

ii、如果步骤2测得电阻为无穷大或者很小，则说明这个总线匹配电阻有问题，
需要更换。
ii. if the resistance measured in step 2 is infinite or very small,
then the resistance of the bus wire have problems ,need to be
replaced.
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

2、总线接反的原因
Causes of bus wire connected reverse
该原因一般是由于线束设计、加工和装配的过程中出现问题未解决导致故障的
发生(即750#与751#接反)。
The reason usually is due to unresolved problems of harness design,
fabrication and assembly process led to the faults occurrence ( 751 # and
750 # connected reverse).
解决办法：在完全断电的情况下(包括负极开关断开)，采用单线搭铁(任选
750#或751#来测试)的方式来确认问题出在哪一段线束上。找到故障点后调
换两根线即可。
Solution: in the case of power off (including negative switch is off), with the
way using one wire ground (either 750# or 751# to test) to confirm the
problem in which a line on the beam. Change the two lines after find the
point of failure .
3.11 故障诊断—通讯故障的分析方法
Troubleshooting- the analytical methods of communication failure

3、显示器接口损坏或控制器JP201接头松动的原因
The causes of monitor interface damage or controller JP201
connection loose
由于是显示器和控制器通讯，如果任意一方出现故障，均会导致通讯
故障，因此需要在排除上述两种原因的前提下，才怀疑显示器或控制
器接口损坏
As a monitor and controller communications, if either party fails, will
lead to communication failure, requiring exclusion the above two
reasons , only suspected damage to the monitor or controller
interface
解决办法：使用电控系统故障诊断仪来判断故障点。
Solution: use the electronic control system fault diagnosis instrument
to determine the point of failure.
3.11 通讯口原理图及线号
Communication port schematics and line number
显示器处匹配电阻
Matching resistor at the monitor

控制器处匹配电阻
Matching resistor at the controller
3.12 故障诊断—档位显示异常的分析方法
Troubleshooting- the analytical methods of stalls show unusual
档位显示异常是指旋动十档油门旋钮开关时，显示器上显示的档位值出现跳跃
的现象。一般原因如下：
Stalls display abnormal is rotating ten stalls throttle knob switch, stalls value
leaps on the display. General for the following reasons:
1、十档油门旋钮开关线束搭铁或断路
Ten stalls throttle knob switch harness Ground or circuit open
调节十档油门旋钮，观察显示器上档位显示是否能跟随变化，如果档位
显示不一致：
例如：1~10档显示 (For example: 1 to 10 stalls display)
1、1、1、4、5、4、5、8、9、8。与F对接的导线断路 (With F
docking wire abruption)
例如：1~10档显示 (For example: 1 to 10 stalls display)
1、3、3、5、5、7、7、9、9、9。与A对接的导线搭铁 (With A
docking wire ground connection)
3.12 故障诊断—档位显示异常的分析方法
Troubleshooting- the analytical methods of stalls show unusual
档位显示的原理如下：
Stalls display works as follows: 档位开关原理图
原理图中，D为地线，A\F\B\E分别表示旋钮中几个触点，它们分 Stall switch
别跟D接通表示不同的值(见真值表)
In the schematic diagram , D for the ground, A \ F \ B \ E,
schematic
respectively, the knob several contacts, they were connected
with the express different D values ​(see truth table)
例：只有A和D接通表示1档；
Example: Only A and D connected expresses 1 grade ;
只有B和D接通表示4档；
Only B and D connected expresses 4 grade ;
A、F、B和D接通表示7档；
A, F, B and D connected expresses 7 grade ;
档位开关真值表
Stall switch truth table
A F B E D
档位值 1 2 4 8 0
3.12 故障诊断—档位显示异常的分析方法
Troubleshooting- the analytical methods of stalls show unusual
2、十档油门旋钮开关内部触点故障
Ten stalls throttle knob switch within contacts failure
由于十档油门旋钮开关是纯机械的开关，必然存在磨损，出现
故障后，只有更换新的配件。
As ten stalls throttle knob switch is purely mechanical switch,
there must be wear and tear, only replace the parts after
failure.
更换前最好测试1、2、4、8档来确认是否真的开关内部损坏，以
免造成不必要的更换。
Had better test 1, 2, 4, 8 stalls confirmed whether it is or not and
damaged within a true switch before replace, so as not to
cause unnecessary replace.
 3.13 故障诊断—转速信号的分析方法
Troubleshooting- the analytical methods of speed ​signal

转速信号故障一般是以下原因：
Speed signal failure is usually the following reasons
传感器损坏、线束断路或搭铁
Sensor damage, wiring harness circuit or grounding
解决方法：转速传感器的正常输出信号类似交流电，转速越高则频率越快，幅值越高。
转速越低则频率越慢，幅值越小；因此可以用万用表的交流档来测试传感器的好坏；
通常怠速到高怠速传感器可输出3~28V。
Solution: The normal speed sensor output signal similar to the alternating current, the
faster the speed the higher the frequency, magnitude higher. the lower the speed the
slower the frequency, smaller amplitude; so you can exchange files with a multimeter
to test the sensor is good or bad; usually at idle to high idle speed sensor can output
3 ~ 28V.
3.13 故障诊断—转速信号的分析方法
Troubleshooting- the analytical methods of speed ​signal

测量步骤：
Measurement steps:
i\关电锁的情况下，拆下JP201，找到转速信号线728#和地线213#；
i \ in the case of power off t, remove the JP201, find the speed signal lines
728 # and ground 213 #;
ii\将大头针或细导线插入对应的插孔，用万用表的交流200V档来测量电压；
ii \ the pins or fine wires into the corresponding jack, AC 200V files with a
multimeter to measure voltage;
iii\启动机器，切换到备用模式下，用手动档来增减油门，通过万用表来读数.
iii \ start the machine, switch to the standby mode, with the manual to
change the throttle through the multimeter to read.
3.13 转速传感器原理图
Speed ​sensor schematic
3.14 故障诊断—全功率故障的分析方法
Troubleshooting- the analytical methods of full power

全功率故障一般表现为掉速严重或动作慢等，下面判断方法是在发动机和液压系统
都正常的情况下作出的判断。
General performance of the full power failure, or serious off-speed and slow
motion, the following method to determine the engine and hydraulic systems in
normal circumstances to make judgments
主要原因为转速问题或处在备用油门下，其中转速问题分为转速为0或该档转速偏
离正常±50rpm以上。解决办法为更换传感器或重新标定转速。
Mainly reason is speed problems or at alternate throttle, the speed problem is
divided into the speed is 0 or the stall speed deviated from the normal ± 50rpm or
more. Solution is replace speed sensor or re-calibration speed.
电比例减压阀接头
Electronic proportional valve connector
3.15 故障诊断—手、自动怠速故障的分析方法
Troubleshooting- the analytical methods of manual, automatic idle fault

自动怠速 Auto idle ：

机器工作在3档以上工况下，如果自动怠速有效，且连续5秒钟没有操作手、脚先导，
机器会自动降到2档以达到降噪、省油的目的；
Machine working in the above 3 files, if automatic idle valid, and there is
no operate hand 、feet pilot for 5 seconds, the machine will automatically
drop 2 files in order to achieve noise reduction, fuel-efficient purpose;
手动怠速 Manual idle ：
机器工作在任何档位，只要按下手动怠速按键，机器会直接降到1档。只有取消手
动怠速，机器才会恢复到设定档位。
Machines work in any gear, just press the button manually idle, the machine will
be directly reduced to 1 file. Only cancel the manual idle, the machine will return to
the stall.

自动怠速 Auto idle 手动怠速 Manual idle

3.15 故障诊断—手、自动怠速故障的分析方法
Troubleshooting- the analytical methods of manual, automatic idle fault

自动怠速典型故障：没有自动怠速。
Auto idle speed typically fault: No auto idle speed.
1. 自动怠速开关是否有效？（看显示器上图标）
Check is auto idle switch on? (see icon on monitor)
2. 压力开关接插头是否悬空？
Pilot pressure switch wiring connection at swing motor.
3.脱开接插头量传感器两端电阻是否接近0欧姆。（接近为正确）
Disconnect sensor’s wiring connector, check resistance of sensor. If near 0
ohm. (near 0 ohm is correct)
3.15 故障诊断—手、自动怠速故障的分析方法
Troubleshooting- the analytical methods of manual, automatic idle fault

手动怠速故障一般是开关盒或从开关盒到控制器之间的线束问题：
Manual idle speed fault generally is switch box problem or problem of the
wiring harness between switch box to the controller.

检查 check：
仪表上有无手动怠速图标？没有则检查从开关盒到控制器之间的线路。
Check is manual idle icon on the monitor ? If none , please check the wiring
harness between switch box to the controller.

手动怠速
manual idle
3.15 手、自动怠速原理图
Manual, automatic idle schematic
3.16 故障诊断—水温故障的分析方法
Troubleshooting-the analytical methods of water temperature fault

水温传感器为康明斯发动机Tier3专用水温传感器，是
属于负温度系数热敏电阻类型的传感器。温度越低，表现出
阻值越大。具体温度对应点见下表：
Water temperature sensor is Cummins engine Tier3
special water temperature sensors, are negative
temperature coefficient thermistor type of sensor. The
lower the temperature, showing greater resistance.
Temperature corresponding to the specific points below:
温度 40℃ 80℃ 90℃ 100℃ 110℃
temperature
阻值 4973 1195 865.5 637.1 476.3
resistance
3.16 故障诊断—水温故障的分析方法
Troubleshooting-the analytical methods of water temperature fault

水温传感器的故障一般表现为始终显示40℃、或显示不准、或跳动。
Water temperature sensor fault general performance is always show 40 ℃, or display are not
allowed, or beating.
其中传感器或线束短路的故障在机器未发动前通过故障指示灯显示。
In which temperature sensor or wiring harness short-circuit fault is through the fault indicators
launched before the machine start.
测量方法Measuring method:
在断电的情况下，拆下与控制器对接的JP201,找到水温传感器的输入线723#、724#,用万用表
的电阻档20K量程来测量水温传感器的阻值，是否对应正确温度。
Under power turn off , remove JP201 connected with the controller , find the input line
723 #, 724 # of water temperature sensor, to measure temperature sensor’s
resistance with a multimeter in 20K range resistance, is corresponding to the
correct temperature.
3.17 故障诊断—液压油温故障的分析方法
Troubleshooting-the analytical methods of hydraulic oil temperature fault

液压油温传感器和水温传感器一样，均为康明斯发动机Tier3专用水温传感器，是属
于负温度系数热敏电阻类型的传感器。温度越低，表现出阻值越大。具体温度对应点见下
表：
Hydraulic oil temperature sensor and temperature sensor as, is Cummins engine
Tier3 special water temperature sensors, are negative temperature coefficient thermistor
type of sensor. The lower the temperature, showing greater resistance. Temperature
corresponding to the specific points below:

温度 Temperature 40℃ 80℃ 90℃ 100℃ 110℃

阻值 Resistance 4973 1195 865.5 637.1 476.3

3.17 故障诊断—液压油温故障的分析方法
Troubleshooting-the analytical methods of hydraulic oil temperature fault

液压油温传感器的故障一般表现为始终显示40℃、或显示不准、或跳动。
Hydraulic oil temperature sensor fault general performance is always show 40 ℃, or display are
not allowed, or beating.
其中传感器或线束短路的故障在机器未发动前通过故障指示灯显示。
In which temperature sensor or wiring harness short-circuit fault is through the fault indicators
launched before the machine start.
测量方法：
在断电的情况下，拆下与控制器对接的JP201,找到液压油温传感器的输入线729#、730#，用
万用表的电阻档20K量程来测量液压油温传感器的阻值，是否对应正确温度。
Under power turn off , remove JP201 connected with the controller , find the input line
729 #, 730 # of hydraulic oil temperature sensor, to measure temperature
sensor’s resistance with a multimeter in 20K range resistance, is corresponding to
the correct temperature.
3.17 液压油温传感器的原理图及线号
Hydraulic oil temperature sensor schematic and line number

Hydraulic oil
temperature sensor
 3.18 故障诊断—燃油油位的分析方法
Troubleshooting-the analytical methods of fuel oil level

燃油油位传感器是一种分段式电阻类型的传感器，每一段位置表现为一种电
阻值。每一段对应的电阻值如下图表所示，油位故障一般表现为显示一格或显示
不准。
Fuel level sensor is a resistance type of sensor , each of a position
performance as a resistance. Resistance value corresponding to each section
as shown in the table, oil level fault general performance display a grid or show
not allowed.
测量步骤：观察显示器上显示的燃油量是多少？关闭电锁，拔掉燃油油位传
感器的插头，用万用表电阻档2K量程，测量传感器对应722#和206#线的插针之间
的阻值是否对应？
 3.18 燃油油位传感器的原理图及线号
Fuel oil level sensor schematic and line number

燃油油位
Fuel oil level

控制器处传
感器接线图
3.19 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

执行器控制器的故障有无动作、一直动作、发热等表现形式，检查方法也是从
电源、输入信号到输出信号来检查。下图为执行器控制器的安装位置和相关
线束线号。
Actuator controller failure there is no action, actions, fever and so on, check
method is from the power, input signal to the output signal to check. Below is
where to install the actuator controller and associated wiring harness line
number.
3.19 执行器控制器原理图及线号
Actuator controller schematic and line number
3.20 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

执行器控制器的888#为控制信号输入线，发动机器后从1档到10档切换时888#
的输入电压逐渐增大，大概从几伏变化到十几伏，因此测量888#的输入电压是区分
故障查找方向的办法之一。
Actuator controller’s 888 # line as control signal input line, after start the engine,
switch from 1 to 10,the 888 # line input voltage increases, probably change from a
few volts to tens of volts, so measure 888 #’s the input voltage is one of the ways of
to distinguish fault’s find direction.

在备用模式下， 888#的输入信号不再参与控制。此时488#有电输入，执行器
控制器切换到备用模式，手动增加时606#线有电,手动减少转速时，447#线有电。
因此判断执行器控制器好坏必须确认执行器控制器是否工作在标准模式下。
In standby mode, the 888 #’s input signal is no longer involved in the control. At
this time the 488 # have power input, actuator controller switches to the standby
mode, when manually add the 606 # line has power, when manual reduction , the
447 # line has power. Accordingly, determining the actuator controller quality must
ensure the actuator controller is working in standard mode.
3.20 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

检查执行器控制器故障的步骤：
Check the actuator controller failure steps:
a\手动档情况下，执行器能否动作?(执行器线圈是否断路或短路)
Under the manual case, whether the actuator can work?
(actuator coil is open circuit or short circuit)
3.20 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

b\检查执行器控制器的供电电压(是否电源供电原因)
Check the actuator controller supply voltage (if the power supply causes)
145#\146#
3.20 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

c\检查输出电压(包括反馈电位器的电压和执行器线圈的电压)
Check the output voltage (including feedback potentiometer voltage and the
actuator coil voltage)
执行器线圈供电电压：497#、498#之间的电压；(5V)
The actuator coil voltage:the voltage between 497#、498# (5V)
反馈电位器供电电压：496#、494#之间的电压；(一根24V，一根12V)
Feedback potentiometer voltage: the voltage between 496#、494# (one is
24V，one is 12V)
3.20 故障诊断—执行器控制器故障的分析方法
Troubleshooting-the analytical methods of actuator controller failure

d\ 检查888#的电压变化情况
Check the voltage change of # 888
i\找到车架端的888#线，脱开插头；
Find the 888 # line in the frame side , Off Plug;
ii\在标准模式下，打开先导切断开关，发动机器（此时机器不会运转）；
In standard mode, open the pilot cut off switch, start the engine (in this case the
machine will not work);
iii\测量1档时888#对205#线的电压；
Measuring 888 # to 205 # line voltage when stall in one position ;
iv\增档时测量888#对205#线的电压；
Measuring 888 # to 205 # line voltage when stall in Increase;
如果电压逐渐增加，则说明888#输入信号没有问题
If the voltage is gradually increased, then the 888 # input signal is no problem
 3.21 故障诊断—执行器故障的排除方法
Troubleshooting-the analytical methods of actuator failure

执行器的故障表现为线圈断路、反馈电位器断路或短路、反馈
电阻线性度差等现象。因此判断执行器的故障无非是测量线圈的阻
值和反馈电位器的阻值。
The actuator failure performance as coil circuit, the
feedback potentiometer circuit open or short circuit, poor
linearity of the feedback resistor. Therefore, to determine the
actuator’s failure is measuring coil resistance and feedback
potentiometer resistance.
 3.21 故障诊断—执行器故障的排除方法
Troubleshooting-the analytical methods of actuator failure

1、测量线圈的阻值
Measuring coil resistance resistance
当执行器推杆处于极限位置时，用电阻200Ω 档均显示断路，则改
用二极管档测量，若测量数值为1，交换红、黑表笔后显示数值应为
400~700左右表明正常；
When actuator putting in the limits position, with the resistance
of 200Ω files show circuit, the switching diode profile measurement, if
the measured value is 1, after exchange the red and the black ,
displayed the value should be around 400 to 700 that is normal;
3.21 故障诊断—执行器故障的排除方法
Troubleshooting-the analytical methods of actuator failure

2、测量反馈电位器的阻值
Measuring the resistance of the feedback potentiometer
3、5脚之间的电阻约为10K
Resistance between the3,5 feet is about 10K
3、2脚之间的电阻与2、5脚之间的电阻等于3、5脚之间的电阻
Resistance between 3,2 feet and 2,5 feet is the same resistance
between 3,5 feet
 3.22 故障诊断—水位报警的排除方法
Troubleshooting-the analytical methods of water level alarm

水位开关用于检测发动机冷却水的水位高低，当水位低到一定程
度时，该开关闭合，显示器上出现报警提示。
Water level switch for detecting the engine cooling water level,
when the water level low to a certain extent, the switch is closed,
the display appears the alarm.
检查步骤：
1、确认挖机停在平坦的地方，检查发动机冷却液的实际多少，太
少则需要适量添加，合适则需要测量传感器的好坏。
2、如果传感器正常，则检查从控制器到传感器这段线束是否断路。
Check steps:
1, confirm the machine on a level place ,check the engine coolant, too
little, you will need to add the appropriate amount, you need
measure the sensor is good or bad if the engine coolant is
appropriate.
2, if the sensor normal, check the harness from the controller to the
sensor is open circuit.
3.22 故障诊断—水位报警的排除方法
Troubleshooting-the analytical methods of water level alarm

传感器损坏 传感器正常
Sensor damage Sensor normal

通过测量线
束端电压来
测量线束的
好坏
3.23 故障诊断—机油压力报警的排除方法
Troubleshooting-the analytical methods of oil pressure alarm

机油压力传感器内有传感器和开关，目前仅使用其开关功能，低压导通，显示器
上显示报警信息并记录。进入菜单项可观察到显示“正常”或“过低”的内容。
Within oil pressure sensor ,have the sensor and switches, using only the switching
current, low pressure turn-on, the display shows the alarm information and records.
Enter the menu items can be observed to display "normal" or "low" content.
检查步骤：目前机油压力报警基本属于接线问题，正确连接后基本恢复正常。其中
726#应接在WK端子上，如果接在G端子上则调换两根线即可。
Check steps: the current engine oil pressure warning basically is wiring problem,
returned to normal after correct connection. # 726 which should be connected to
the WK terminal, if connected to the G terminal ,the two lines can be swapped.
 谢谢！
THANK YOU!