Professional Documents
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3_DH24-B2装修手册-中译英-20220319-英译文
3_DH24-B2装修手册-中译英-20220319-英译文
Bulldozer
Contents
Contents
Safety .................................................................................................................................... 1
Safety Notice ................................................................................................................... 1
Safety Precautions .......................................................................................................... 1
Safety Principles ....................................................................................................... 1
General Hazard Information ..................................................................................... 1
Preventive Measures against Crush or Cut Injuries .................................................. 4
Preventive Measures against Scald .......................................................................... 5
Preventive Measures against Fire and Explosion ..................................................... 6
Precautions of Track ............................................................................................... 11
HP Fuel Pipelines ................................................................................................... 11
Precautions for Refitting ......................................................................................... 12
Safety Rules .................................................................................................................. 13
Before Starting of Engine ........................................................................................ 13
Starting the Engine ................................................................................................. 15
Before Operation .................................................................................................... 15
Operating the Machine ........................................................................................... 16
Driving on Slopes ................................................................................................... 18
Parking of Machine ................................................................................................. 19
Engine Stop ............................................................................................................ 19
Transportation ........................................................................................................ 19
Dragging ................................................................................................................. 20
Before Service ........................................................................................................ 20
During Service ........................................................................................................ 21
Foreword.............................................................................................................................. 25
Overview ....................................................................................................................... 25
Structure and Function .................................................................................................. 25
Test and Adjustment ...................................................................................................... 25
Disassembling and Assembling ..................................................................................... 25
Maintenance and Service Standards ............................................................................. 25
Fault Diagnosis ............................................................................................................. 25
How to Read this Installation and Maintenance Manual ................................................ 25
Lifting Instructions ......................................................................................................... 26
Shantui Construction Machinery Co., Ltd. I
Contents
Steel Wire Rope ............................................................................................................ 26
Standard Tightening Torque .......................................................................................... 28
Conversion Table........................................................................................................... 28
Use Methods .......................................................................................................... 28
Chapter 1 Overview.......................................................................................................... 35
1.1 General Information and Technical Specifications of Machines ........................ 35
1.1.1 General Information of Complete Machine ................................................ 35
1.1.2 Engine ........................................................................................................... 35
1.1.3 Drive System ................................................................................................. 36
1.1.4 Undercarriage System .............................................................................. 36
1.1.5 Work Tools ................................................................................................ 36
Chapter 2 Power System.................................................................................................. 39
2.1 Structure and Function Description of Power Components .............................. 39
2.1.1 Installation of Engine Accessories and Engine .......................................... 39
2.1.2 Engine Cooling System ............................................................................. 39
2.2 Removal and Installation of Power Components .............................................. 40
2.2.1 Engine....................................................................................................... 40
2.2.2 Removal and Installation of Cooling System ............................................. 44
2.2.3 Removal and Installation of Fuel System .................................................. 46
Chapter 3 Undercarriage System ..................................................................................... 49
3.1 Structure and Function..................................................................................... 49
3.1.1 Trolley Assembly ....................................................................................... 49
3.1.2 Tensioning Device ..................................................................................... 49
3.1.3 Front Idler ................................................................................................. 50
3.1.4 Track Roller ............................................................................................... 52
3.1.5 Carrier Roller ................................................................................................. 53
3.1.6 Track ......................................................................................................... 55
3.2 Disassembling and Assembling ....................................................................... 56
3.2.1 Test and Adjustment of Track Tension ....................................................... 56
3.2.2 Removal and Installation of Trolley Assembly............................................ 57
3.2.3 Removal and Installation of Front Idler Assembly ...................................... 60
3.2.4 Removal and Installation of Tensioning Assembly ..................................... 61
3.2.5 Removal and Installation of Track Roller Assembly ................................... 61
Safety
Safety Notice
Proper maintenance is of great significance for working safety of the machine. The
maintenance and repair techniques recommended by Shantui Construction Machinery Co.,
Ltd. (“Shantui”) and described in this Manual are both effective and safe. Some of these
techniques require special tools designed by Shantui.
To avoid injuries to workers, safety precautions are marked with the symbol in this Manual.
The precautions with these symbols must be handled with care. Safety shall be guaranteed
first in case of danger or possible danger, with necessary measures being taken.
Safety Precautions
Safety Principles
Only those specially trained and permitted are allowed to be engaged in operation and service
of the machine. Those drunken or exhausted shall never operate the machine, which shall not
work with any fault or overload.
Safety rules, preventive measures and instructions shall be strictly followed during operation
and service of the machine.
It must be guaranteed that relevant personnel understand all gestures and signals while
working with other operators or those in charge of traffic guidance on the construction site.
In case of any abnormality during running of the machine, it shall be stopped immediately for
maintenance, until such abnormality is eliminated. Besides, all relevant provisions shall be
followed.
This machine can only be used at an altitude below 2,000 m, and the power will be lowered
with the increase in altitude. The parts and components will be damaged if working above the
specified altitude for a long term. Shantui Highland Bulldozers are recommended if working
above the specified altitude.
Safety Devices
• Guarantee that all shields and covers are at the correct position and repair the damaged
components.
• Properly use safety devices such as safety levers and seat belts.
• Prohibit removing any safety device, which shall be under a favorable working state.
• Improper use of safety devices may lead to severe personal injuries or death.
Please wear the hearing protection devices to protect the hearing of the driver.
• The hydraulic oil leaked will penetrate body tissues under the effect of pressure, leading
to severe personal injuries even death. A pinhole-sized leakage will trigger severe
personal injuries. Please use a plank or a hardboard while checking leakage in the
hydraulic pipelines. Please receive treatment immediately if being hit by pressure oil.
• Improper treatment of fuel, hydraulic oil, filters and batteries will do harm to the
environment. Pouring of waste oil into rivers or onto the ground is not allowed.
• Since the A/C refrigerant will pollute the atmosphere, only some designated service
centers are allowed to dispose and recycle refrigerant according to the systems stipulated
by some government authorities.
• Local relevant laws and provisions shall be followed while disposing engine oil, fuel,
refrigerant, solvent, filters, batteries and other toxic/harmful substances.
• Relative movement among linkage devices of equipment will lead to change in the gap.
Please do not stand at the gap of such devices.
• Do not approach rotating and moving components.
• Install the shields removed after maintenance and service.
• The debris generated will splash while knocking some object with force. If such
knocking is inevitable, please ensure no harm to the person around.
• Do not approach rotating fans and belts, to prevent injuries. The bodies or tools touching
fan blades may be cut or fly out, so never touch a rotating part.
Engine
• Do not touch any part of a working engine.
• The engine cooling water, engine oil and hydraulic oil are in a HT and HP state when the
machine just stops working. At this moment, oil/water drainage by taking down the cover
or replacement of the oil filter may lead to severe scald. Therefore, the operation
Shantui Construction Machinery Co., Ltd. 5
Safety
specifications must be followed when it cools down.
• To prevent splashing of hot water and hot oil, the engine must be turned off before taking
down the cover. Besides, the water and oil shall cool down, and then slowly unscrew the
cover, to release the internal HP gas.
• (Once the water and oil cools down, get close to the surface of the radiator and the
working oil tank to check the ambient temperature with hands. Do not touch the radiator
and the working oil tank.)
Coolant
• High-temperature coolant and steam will lead to severe scald. Do not operate it before
the cooling system cools down.
• The coolant level can only be checked after the cooling system cools down once the
engine stops working. Slowly unscrew the cover to release the internal HP gas, and then
take it down.
• Since the rust inhibitor added in the coolant contains alkaline substances, direct contact
will lead to burn. Please protect your skin and eyes.
Battery
• Direct contact with the electrolyte, an acidic material, will lead to burn. Please protect your
skin and eyes. It is recommended that the operator should wear protective gloves and
goggles during maintenance of the battery.
• The engine must be turned off during refueling and smoking is prohibited.
• Reliably tighten the covers of the fuel tank and the working oil tank.
• Save fuel and engine oil at the designated place and entry of unauthorized personnel is
prohibited.
• Save the damaged rag with oil stains and the flammables into a special container.
To lower the possibility of fire or explosion, SHANTUI suggests the user to follow the following
provisions:
• Do not operate the machine if the battery cables or relevant components are damaged,
and ask Shantui dealers for help timely.
• The provisions in safety steps shall be followed if starting the engine with firing cables.
Please refer to detailed instructions on this maintenance and service manual. Improper
cable connection will trigger explosion even personal injuries.
• Please do not charge non-rechargeable batteries since it may lead to explosion.
• The flammable hydrogen in the battery will lead to explosion, and the area above the
battery shall be kept away from open fire and spark. Do not smoke around the space in
which a battery is installed.
• Measure the voltage of the battery via a voltmeter.
8 Shantui Construction Machinery Co., Ltd.
Safety
• Check the cables in visible areas per day, and check cables and cable clamps for
damage and timely replace the damaged ones.
• Replace the damaged cables and relevant components. Clear the sediments which may
lead to insulation failure and damage and abrasion of electronic elements, to guarantee
that all elements can be properly set.
• Contact of the exposed conductors on battery cables with the grounding cables will lead
to short circuit of the battery. The current of the short-circuited battery will generate heat,
causing a hidden danger in fire.
• Maintenance of the machine will be in a unsafe state if the exposed conductors on the
grounding cables between the battery and the cut-off switch are not grounded. The
grounding cables shall be repaired or replaced first before maintenance.
Battery
• The sulfuric acid contained in the battery electrolyte will burn skin and clothes rapidly if
touched carelessly. In this case, you shall wash with water immediately. The acid liquor in
the battery will lead to blind if touching eyes. At this moment, you shall wash your eyes
with substantial clear water and see a doctor as soon as possible.
• If you accidentally drink acid liquor, you shall immediately drink a lot of water or milk, eggs
or vegetable oil, and see a doctor immediately
• Wear safety glasses or goggles while handling with the battery.
• A battery will give rise to hydrogen, which is explosive and may be ignited by spark or
flame.
• Before handling with the battery, stop the engine and turn the ignition switch to OFF.
Wire
• Perform routine inspection for wires, and replace before operating the machine in case of
any of the followings:
• Abrasion or damage;
• Cracking;
• Fading;
• Cracked insulating layers;
• Other forms of damage.
Contact between wires and debris and the hose containing flammable oil shall be avoided as
much as possible. To prevent abrasion and damage of the wires, please guarantee that the
wires have sufficient supports and pipe clamps.
Hydraulic Pipelines
Do not curve or knock HP hoses, and do not install the curved and damaged hoses. The
hydraulic oil leaked will penetrate body tissues under the effect of pressure, leading to severe
personal injuries even death. Please use a plank or a hardboard while checking leakage in the
hydraulic pipelines to prevent liquid penetration. Please receive treatment immediately if
being hit by pressure oil. Replace the hose with one of the followings:
• Damage or fuel leakage at joints;
• Worn or cut outer rubber layers;
• Exposed metal wires;
• Swollen or inflated outer rubber layers;
• Twisted flexible parts of the hose;
• Joint dislocation;
• Other forms of damage.
To prevent abrasion and damage of the hose, please guarantee that the hose has sufficient
Precautions of Track
• For the track tension adjustment system, the track is maintained in a tensioning state
through the HP grease or hydraulic oil.
• The HP grease and hydraulic oil leaked from the relief valve can penetrate human bodies,
leading to personal injuries or death. Do not observe the relief valve directly to judge on
leakage of the HP grease and hydraulic oil. The track or the track tension adjusting
cylinder can be observed directly to judge on whether the track is loose.
• The connections between the track pin and the axle sleeve will become extremely hot
after motion, so long-term contact with these components may lead to scald.
• Preventive Measures against Thunder and Lightning
• The operator shall remain inside the cab in case of intense thunder and lightning during
working, to prevent lightning stroke.
• The operator shall keep away from the machine immediately and go to a safe area in
case of intense thunder and lightning around the machine.
HP Fuel Pipelines
5
4
3
6
Unauthorized Refitting
Any refitting not recognized by Shantui may lead to danger. Please negotiate with Shantui
12 Shantui Construction Machinery Co., Ltd.
Safety
before refitting, and Shantui refuses to shoulder any liability for the injuries and damage
caused by any unauthorized refitting.
Safety Rules
Before Starting of Engine
On-site Safety
• Check surroundings for abnormalities which may trigger danger before starting.
• Check the landform and soil texture and select the optimal working methods, and do not
work in the area susceptible to falling objects.
• When working on the highway, special personnel shall be assigned to direct traffic and set
up roadblocks to ensure the safety of traffic and pedestrians.
• If working at the place with buried facilities such as water pipes, gas pipelines, HV cables
etc., contact relevant departments first, to determine the position of pipelines, so as to
prevent damage to them during construction.
• If working in water or passing through a sandbank, check ground mass, water depth and
flow velocity first, and do not work in a water area beyond the allowable water depth.
Fire Protection
• Remove garbage such as leaves, dead branches, waste paper and waste materials
accumulated at the engine and other hot parts of the machine to avoid fire caused by
thermal combustion.
Getting on/off
• Do not jump up and down while getting on/off the machine. Getting on/off of the machine
running is prohibited, or otherwise accidental injuries will be triggered.
• Face the machine while getting on/off the machine, and always maintain three-point
contact (feet and a single hand, or hands and a single foot) among the human body,
handrails and the ladder, to guarantee safety.
• Do not grasp any control lever while getting on/off the machine.
• Check handrails and ladders while getting on/off the machine. Wipe any oil stains or
sludge found on the handrail or ladders immediately. Timely repair the damaged parts,
and tighten the loose bolts.
Before Operation
• Prohibit approaching of irrelevant personnel towards the machine and working areas.
• Clear the obstacles on the path of the machine and pay attention to wires, ditches etc.
• Prohibit entry of any person in the cab except for the driver or lingering at other positions
of the machine, to prevent falling from the machine and influence on the field of view of
Shantui Construction Machinery Co., Ltd. 15
Safety
the driver.
• For the machine installed with a reversing alarm bell and a buzzer, guarantee that the
alarm can work normally.
• Firmly buckle the seat belt during driving.
Buckle
seat belt
100V-200V >2m
6600V >2m
22000V >3m
66000V >4m
154000V >5m
187000V >6m
275000V >7m
500000V > 11 m
Driving on Slopes
• When driving on steep hills, embankments or slopes, the vehicle may roll over or slip.
• The blade shall be close to ground while driving on hills, embankments or slopes, and be
about 20~30 cm above the ground. The blade shall be lowered to ground rapidly in case
of emergency, to help stop the machine or to prevent rollover.
• Do not turn on a slope or cross a slope, and do this kind of operation at a flat place. Put
the heavy end of the machine on the upper slope side while working on a slope.
• Rocks and wetlands will seriously affect the traction and stability of the machine. Uneven
rock surfaces may cause sliding at one end of the machine.
• Do not cross grasslands, leaves or wet steel plates, which may lead to slip of the machine.
A very low speed shall be maintained while driving along slope edges.
• Slow down while driving downslope.
• Lower the blade immediately if the engine stalls on a slope and use the parking brake.
• Prohibit downsloping under the effect of dead load or inertia.
• If the machine is idle for a long term, the cut-off switch of the battery shall be turned to
“OFF” with the rear shield being locked, to prevent battery discharge due to short circuit,
damage to some elements and artificial reasons.
Engine Stop
• If the machine is idle for a long term, the cut-off switch of the battery shall be turned to
“OFF” with the rear shield being locked, to prevent battery discharge due to short circuit,
damage to some elements and artificial reasons.
• The engine is allowed to run for 5 min at a low speed before stop, so that hot positions on
the engine can cool down gradually.
Transportation
Shipment
• The provisions concerning length, width and height of cargoes in various countries and
regions as well as all applicable laws shall be followed during shipment of the bulldozer.
• The length, width and height of cargoes shall be considered while determining the
shipment route, to prevent off-limit.
Dragging
• The ropes can only be used for dragging when the machine is started, or otherwise
hydraulic components of the machine will be damaged.
• The ropes of sufficient strength must be used while dragging this vehicle with other
machines.
• Do not drag the machine on a slope.
• Do not use curved or twisted pulling ropes.
• Do not cross or get close to the pulling rope.
• Do not let any person stand between the tractor and the pulled vehicle while bonding the
pulled machine.
• Make the axes of the tractor and the pulled part locate on the same axis, to guarantee
that it is at a correct position.
• The machine not started shall be moved by lifting.
Before Service
Suitable Tools
• Use high-quality reliable tools only. Use of damaged, low-quality, defective or temporary
tools may bring injuries to you.
During Service
Personnel
Only the authorized personnel can be engaged in service and maintenance. Additional safety
measures shall be taken during grinding, welding and hammering.
Fittings
The parts removed from the machine shall be placed at a safe area, to avoid severe personal
injuries due to falling.
Use of Lighting
Explosion-proof lamps must be used while checking fuel, engine oil, coolant or battery
Foreword
Overview
This Manual is prepared to help maintenance personnel better understand this product, show
them correct methods of repair and judgment, so as to improve maintenance quality. The
contents in this Manual must be clearly known, to realize the optimal effect.
This Manual mainly includes the technical materials required to complete operations in the
maintenance workshop. To facilitate better understanding, this Manual is classified into the
followings based on components: engine auxiliary devices, undercarriage system,
transmission and control systems, work tools and control system, frame and balance beam
and electrical system. Each part is elaborated respectively as per structure and functions, test
and adjustment, disassembling and assembling, maintenance standards.
Fault Diagnosis
Common troubleshooting and fault eliminating methods are given.
Safety
Caution
Weight
Tightening torque
Applying
Oil, water
Drainage
Lifting Instructions
Lifting
If parts and components cannot be lifted from the machine stably via a crane, the followings
shall be checked:
• Check all fastening bolts fixing this component onto relevant components to see whether
they are removed;
• Check for parts interfering with the parts to be removed.
mm kN t
10 9.8 1.0
11.5 13.7 1.4
The allowable load shall be calculated as per 1/6 or 1/7 of breaking strength of the steel wire
ropes used.
• Hang steel wire ropes in the middle of the hook.
Steel wire ropes may fall from the hook during lifting if the steel wire ropes are too close to the
hook edge, causing severe accidents. The maximum strength of the hook lies in the middle.
1) Do not lift heavy objects with a single steel wire rope, and two or more steel wire ropes
should be wrapped on the heavy objects in a symmetric manner.
The lifted objects may move during lifting if heavy objects are lifted with a single rope,
loosening steel wire ropes, or leading to slip from the original wrapping position on the load,
causing accidents.
2) Do not lift heavy objects when a large hanging angle is formed between the steel wire
rope and the hook.
If heavy objects are lifted with two or above steel wire ropes, the bearing capacity of each
rope increases with the increase in hanging angle. The table below shows the variation of
allowable load at different angles when heavy objects are lifted with two steel wire ropes (the
allowable vertical lifting weight of each piece is 9.8 kN {1,000 kg}).
If two steel wire ropes are used for vertical lifting, the total lifting weight is 19.6 kN {2,000 kg}.
Such figure becomes 9.8 kN {1,000 kg} if an angle of 120° is formed for two steel wire ropes.
On the other hand, if 19.6 kN {2,000 kg} load is lifted at 150°, two steel wire ropes will bear a
force up to 39.2 kN {4,000 kg}.
Fig 0.34 Relationship Between Different Lifting Angles (°) and Load
Conversion Table
Use Methods
The Conversion Table in this Chapter may be used for simple numerical conversion. See the
28 Shantui Construction Machinery Co., Ltd.
Foreword
example below for detailed use methods of this table:
Example: Use this conversion table to convert millimeters into inches.
1. Converting 55 mm into inches
(1) Find out 50 in the left column and take this point as A
○, and draw a traverse line from A
○.
(2) Find out 5 in the top row and take this point as B
○, and draw a vertical line from B
○.
(3) Take the intersection point of both lines as C
○. C
○ is the value converting millimeters into
inches. Therefore, 55 mm = 2.165 in.
2. Converting 550 mm into inches
(1) There is no number 550 in this table, so it is divided by 10 (one decimal point shifted to
the left) to obtain 55 mm.
(2) Convert 55 mm into 2.165 in. as per the procedures above.
(3) Because the original value (550 mm) has been divided by 10, the 2.165 in. shall be
multiplied by 10 (one decimal point shifted to the right) to restore the original value. The
result is 550 mm = 21.65 in.
Tab 0.5 Conversion Table (1 mm=0.03937 in)
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
50 110.23 112.43 114.64 116.84 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.794 15.058 15.322 15.586
60 15.850 16.114 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
50 10.998 11.218 11.438 11.658 11.878 12.098 12.318 12.538 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.6 1048.8 1056.0 1063.3 1070.5 1077.7
150 1085.0 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1229.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.2 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2133 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2390 2404
170 2418 2432 2446 2461 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2774 2788 2802 2816 2830
200 2845 2859 2873 2887 2902 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3342 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Unit
In this Manual, measuring units are expressed in SI.
The conventional gravity system unit is expressed in { } as references.
Chapter 1 Overview
1.1 General Information and Technical Specifications of Machines
1.1.1 General Information of Complete Machine
1.1.2 Engine
Tab 1.2 Engine Information
Engine Model WD12
In-line, direct-injection, water-cooled, four-stroke,
Type
turbocharged & non-intercooled
Overall length (mm) 1404.6
Dimensions
Overall width (mm) 900
Final drive Three-stage deceleration, one-stage spur gear + two-stage planetary deceleration
● The engine cooling system mainly includes a water radiator, an oil radiator, a fan etc.;
● The water radiator cools engine coolant, while the oil radiator cools the hydraulic oil;
5) Separate the pipe clamps at both ends of hoses 7, 8 and 9 and remove the hoses.
Remove the bolts 10 and 4 and remove the expansion tank 11.
6) Remove the upper shield. See the removal process of the hood for details.
7) Remove the engine coolant inlet and outlet pipes 12 and 14, loosen the fan belt tensioner
pulley, and remove the fan belt 13.
11) Close the fuel inlet and return valves of the fuel system and separate the fuel inlet and
return pipelines.
12) Remove the gantry 18. See the removal process of the hood for details.
Note: While removing the engine, check whether all pipelines and wires are disconnected.
Installation:
● Install in the reverse order of removal.
Do not distort or affect each other while installing hoses.
Avoid entry of dirts, dust or water in the host while installing A/C hose.
● Refill coolant.
Shantui Construction Machinery Co., Ltd. 43
Chapter 2 Power System
Fill the coolant to the specified level, start the engine to circulate the coolant in the system,
and then check the coolant again.
● Fill the A/C refrigerant.
Fill the A/C refrigerant into the A/C pipelines with a tool.
(3) Disconnect the water radiator pipelines 3 and 8, and the expansion tank pipelines 4, 5
and 7 respectively,
Remove the expansion tank 6.
(5) Install the lifting lugs on both sides (M12 threaded holes) of the water radiator at the
installation point 11 (left and right) and lift them properly.
(6) Remove the mounting bolts 13 and 4 of the upper bracket of the water radiator, and
disconnect the upper mounting bracket.
(7) Remove the bolts 15 and 2 and remove the plate 16.
(8) Remove the fixing bolt 17 of the shock absorber at the bottom of the water radiator.
(9) Lift and remove the water radiator, the weight of which is 85 kg.
(10) Remove the 55 kg oil radiator in the same way as the water radiator.
Installation: Install in the reverse order of removal.
Refill the coolant: Fill the coolant to the specified level, start the engine to circulate the coolant
in the system, and then check the coolant again after parking.
(4) Operate the rear valve 3 of the bulldozer to empty the fuel in the fuel tank, remove the
rear hose clamp of the valve, and release the hose.
(5) Close the fuel tank valve 4, remove the fuel inlet pipe joint in front of the fuel tank and
separate the fuel inlet pipelines.
(6) Close the valve 5 and separate the fuel return pipelines.
(7) Remove the bolt 6 and the cover plate 7.
(9) Remove the mounting bolt 9 at the bottom of the fuel tank (6 on the left and right).
(10) Lift the fuel tank assembly, the weight of which is about 280 Kg (no-load) and 680 Kg
(full-load).
Installation: Install in the reverse order of removal.
1-Front idler 2-tensioning device 3-carrier roller 4-track roller guard 5-trolley frame 6-single-side track
roller 7-double-side track roller 8-sprocket 9-track
1-seat 2-piston rod 3-lifting lug 4-base 5-tensioning spring 6-cylinder block 7-spring box 8-big nut
9-grease cup
Width of roller
5 51.6 ---
surface (double)
Width of roller edge
6 21 ---
(single)
Width of roller edge
(outer side,
7 21 ---
double-side track
roller)
Width of roller edge
(inner side,
8 21 ---
double-side track
roller)
9 Total width 251.2 ---
Standard Tolerance
Clearance between Standard clearance
dimensions Axle Hole Replace the
10 the shaft and the
bushing
bushing -0.210 +0.13 0.270-
φ70
-0.260 +0.06 0.390
Standard Tolerance
Interference fit Standard interference
dimensions Axle Hole Replace the
11 between the bushing
bushing
and the track roller +0.094 0.013-
φ115 ±0.027
+0.040 0.121
5 2 1
3 4
Outer diameter of
2 roller edge (inner φ185 φ162 Repair or
side) replace
Width of roller
3 57 -
path surface
Width of roller
4 19 -
edge
Standard Tolerance
Clearance Standard clearance
dimensions Axle Hole
5 between the shaft
and the bracket 0 +0.30
φ58 0-0.50
-0.200 0.
Replace
Standard Tolerance Standard
Interference
dimensions Axle Hole interference
6 between the shaft
and the ring +0.035 -0.1
φ68 0.065-0.2
0 -0.2
Oil filling level 260ml(SAE85W-140)
Standard Tolerance
Interference between Standard interference
dimensions Axle Hole
5 the bushing and the
Steer or
link +0.4 +0.12
71 0.23-0.4 replace
+0.35 0
Interference between +0.25 +0.1
6 47.32 0.12-0.25
the master pin and the +0.22 0
Interference between
+0.4 +0.1
7 the common pin and 47.32 0.25-0.4
+0.35 0
the link
8 Bushing extension 9
Adjust
9 Pin extension 3
Test
1. Drive the machine forward and stop it on a flat ground.
★ Stop the machine without using the brake.
2. Place the straight steel plate ① between the front idler and the front carrier roller, and
measure the clearance a between the bottom of the steel plate and the track shoe
grouser.
● Standard clearance a: 15-20 mm
Adjust
★ If the tension of the track shoe is abnormal, adjust as per the following requirements.
1. Remove the cover ②.
The plug may fly out under the HP effect of the internal grease, so it shall not be loosened
for above 1 circle.
3. If the tension is too small:
Pump grease in via the grease cup ④.
★ If the track has a poor tension, move the machine backward or forward slowly.
★ Repeat the above steps to check the tension again after adjustment.
8. Remove mounting bolts and the covers ⑤⑦from the trolley frame.
3. Lift the front idler assembly and pull it out and then remove the mounting bolts of
the bracket ⑤ and the base ⑥.
Installation
2. Remove the bolt ②, and separate the front idler ③ from the tensioning device④.
Installation
After jacking the machine, install a cushion block on the top of the track shoe and lock the
work tool control lever and the braking lock lever.
Installation
1. Open the track frame cover, and loosen the grease cup ① to release the track
shoe tension.
Do not loosen the grease cup ① more than one turn. If the track shoe tension is not
released when the grease cup is loosened, move the machine back and forth.
3. Remove bolt ②.
Pass the wire rope through the hole of the track link and fix it on the support bypassing the
carrier roller ③, then gradually loosen the wire rope and pull out the carrier roller ③ from the
bracket ④.
Carrier roller: 39 kg
Installation
The tension spring cylinder is subjected to a considerable internal force. Do not loosen the
grease cup ① more than one turn. If the track shoe tension is not released when the grease
cup is loosened, move the machine back and forth until the track is completely released.
Drive forward slowly to allow the track shoe at the front idler end to contact the large cushion
block or wall (If there is another bulldozer with the same power, contact its blade). When the
tensioning spring is bent and the track shoe is bent, stop the machine and apply the brake.
Now set the master link between the front idler and the front carrier roller. For safety reasons,
install a lever block between the carrier roller bracket and the track link.
Installation
The final drive employs a deceleration system with a first-stage spur gear and a second-stage
planetary gear.
The final drive can be removed and installed as a separate component.
Lubrication method: splash lubrication that facilitates gear rotation.
The floating oil seal is installed in the rotating and sliding part of the sprocket to prevent the
entry of soil or sand and the leakage of lubricating oil.
Power is transferred from the travel motor to the first-stage pinion 6 and then to the sun gear 1
via the driven gear 8 that engages with the first-stage pinion. The sun gear 1 rotates so that
the power is transferred to the planetary gear 12 and eventually output through the planetary
carrier (sprocket).
16
5) Remove the travel motor, and separate the travel motor from the final drive assembly
※ Brake Assembly
1) Remove the mounting bolt 18 of the brake, and take out the brake assembly 19, brake
gear ring 20, friction disc 21, polished plate 22 and spline housing 23 in sequence.
18
20
23
22 21
19
24
25
12
26
13
27
28
30
Fig. 4.11 Removal of the Gear Ring and the Fixed Support
31
10
Gently knock the connecting plate 9 with a copper bar, and press the driven gear bearing
Shantui Construction Machinery Co., Ltd. 73
Chapter 4 Final Drive and Transfer Case
34 downward until the end face of the connecting plate fits the end face of the inner case.
Note: The driven gear bearing 34 must be pressed downward, otherwise the driven gear ring
cannot be removed.
Remove bolt 32. Remove the driven gear ring 8 from the connecting plate with a lifting
eye, and take out the connecting plate 9.
Remove the pinion assembly
Loosen the fixing bolt, and remove the pinion shaft 6 with a special tooling. Remove the
bearing from the pinion shaft.
8
6
9
34
32
Standard Tolerance
dimensions Axle Hole
Standard Tolerance
dimensions Axle Hole
4
Fit clearance of the pump -0.006
Φ120 -----
drive gear shaft -0.028
+0.021
Φ65 +0.002 -----
2
1
(2) Remove the connecting bolt and washer 4, and separate the transfer case assembly 5
from the engine;
(3) Remove the bolt and washer 6, and separate the shock absorber assembly 7 from the
engine;
(2) Lift the transfer case assembly 5, install the connecting bolt and washer 4 between the
engine and the transfer case body, and tighten the bolt;
(3) Install right travel pump 1, left travel pump 2 and implement pump 3.
2
1
10
11
12
(2) Remove the connecting bolt and washer 16, and take off the bearing pedestal assembly
15
15
15
16
16
(3) Place the bearing pedestal assembly 15 on the platform, remove the O-ring 17, and
remove the bearing outer ring 18 with the tooling
17 18
19
19
(5) Place gear assembly 19 on the platform, and remove the bearing inner ring 20 from gear
21 with the tooling.
20
21
20
(6) Remove the bolt and washer 22, and lift out the bearing pedestal assembly 23
22
23
27
26
28
(9) Place the spline shaft assembly 28 on the platform, remove the O-ring 29, and remove
the bearing inner ring 30 with tooling;
29
30
(10) Reverse the spline shaft assembly 28, remove the bolt and washer 32, separate the
spline shaft 33 from the gear 34, and remove the bearing inner ring 31 with the tooling
34
31
32
33
35
(12) Remove the cotter pin 36, bolt and nut 37 and plate 38. Remove the bearing outer rings
46 and 47 from case 49 with the tooling. Remove the screw plug 48;
38 46
36 37
47
46 49 48
39
ii. Remove the plate 40, shock absorber inner case 41, plug and safety valve 42, and rubber
block 43 from the shock absorber outer case 44 in sequence;
iii. Lift the shock absorber outer case 44, and separate it from the plate 45;
40
41
42
43
44
45
42
41
43
41
vi. Install the plate 40, the bolt and washer 39, and tighten the bolt;
39
40
38 46
36 37
47
46 49 48
35
i. Install the plate 38 on the case 49, then install the bolt 36, tighten the nut, and install the
cotter pin 37;
ii. Cool the bearing outer rings 46 and 47, and press-fit them into the mounting holes of the
case 49;
iii. Install plug screw 48;
iv. Install the retaining ring 35
(3) Assemble the spline shaft assembly 28:
i. Place the spline shaft 33 on the platform;
ii. Install gear 34 and align threaded holes;
iii. Install the bolt and washer 32 and tighten them;
iv. Heat the bearing out ring 31, and press-fit it on the spline shaft 33;
34
31
32
33
v. Heat the bearing out ring 30, and press-fit it on the spline shaft 33
vi. Install the O-ring 29
29
30
24 25
27
26
20
21
20
17 18
50
28
(8) Lift the bearing pedestal assembly 23, install the bolt and washer 22, and tighten the bolt;
22
23
19
19
(10) Lift the bearing pedestal assembly 15, install the connecting bolt and washer 16, and
tighten the bolt;
15
15
16
16
(11) Install the O-ring 51 into the groove of the refueling hard pipe 8
51
10
11
12
10
1 Blade 2 Trunnion
Tolerance
Standard Standard Clearance
Clearance between dimensions clearance limit
Axle Hole
1 the ball joint and
seat surface
0 +0.5
100 0.2-0.6 1
-0.1 +0.2
Replace
2 Clearance between 100 0 +0.5 0.2-0.6 1
Clearance between
-0.5 +0.5
3 trunnion cover and 160 0.5- 1.5 5
-1.0 0
trunnion sphere
Clearance between
-0.2 +0.5
4 the push arm seat 120 0.5-1.2 5
-0.7 +0.3
and the blade seat
Clearance between
-0.3 +0.3
5 blade pin and 60 0.3-0.8 3 Replace
-0.5 0
bearing
Clearance between
the push arm seat -0.2 +0.5
6 120 0.5-1.2 5
and the connecting -0.7 +0.3
block
Clearance between
the push arm pin -0.3 +0.3
7 60 0.3-0.8 3
and the joint -0.5 0
Clearance between
the support pin and -0.3 +0.5
8 60 0.6-1.0 2
the push arm -0.5 +0.3
Clearance between
the support pin and -0.3 +0.5
9 60 0.5-1.0 2
the bracket -0.5 +0.2
Clearance between
the middle pin of the -0.3 +0.1
10 85 0.2-0.6 1
blade and -0.5 -0.1
the bracket
Clearance between
the middle pin of the -0.3 +0.3
11 85 0.3-0.8 3
blade and -0.5 0
the seat
Clearance between
the ball joint of the
0 +0.5
12 right diagonal 100 0.2-0.6 1
-0.1 +0.2
support and
the bracket
Clearance between
the ball joint of the
0 +0.5
13 left diagonal support 100 0.2-0.6 1
-0.1 +0.2
and
the bracket
Clearance between
-0.1 +0.087
14 arm cover and arm 120 0.1-0.287 Adjust it
-0.2 0
seat or
replace
Clearance between gaskets
-0.1 +0.087
15 arm cover and arm 120 0.1-0.287
-0.2 0
seat
2. Temporarily hang the lift cylinder assembly (2). Run the engine and fully retract the
cylinder.
3. Install the lift cylinder assembly (2) to the radiator cover using the seat (3).
★ Bind the plunger rod with wires to prevent it from coming out.
4. Disconnect the lift cylinder assembly from the other side of the blade.
Installation
● Install in the reverse order of removal.
★ Adjust the clearance a of the fitting surface of the cover with a gasket to the following
values and check whether the pivot rotates smoothly.
• Standard clearance a: 0.2-0.5 mm
• Standard gasket thickness: 4 mm
★ After installing the blade, adjust the tilting distance of the blade.
★ Adjust the height b and width c of the two push arms using cushion blocks [1] to the
following values.
• Pivot height b: 460 mm
• Frame width c: 2772 mm
⑧
⑨
[1]
5. Hang the connecting rod (4), remove the pins (3) (on the left and right sides), and lift the
left and right connecting rods (4) away from the machine.
Connecting rod: 85 Kg
6. Disconnect the four lift cylinder hoses (5), hang the lift cylinder, remove the pins (6) (on
the left and right sides), and
lift the lift cylinder (7) away from the machine.
4 5
7
6
3
7. Place the bracket [2] under the connecting frame, remove the pins (8) (on the left and
right sides), and lift the cross beam (9) away from the machine.
9
10
8 11
[2]
5.4.2 Assembling
1. Hang the connecting frame (11) and place it in the installation position, then install the pin
shafts (10) on the left and right sides and fix them with bolts.
9
10
11 8
[2]
[1]
3. Hang the lift cylinder assembly (7) and place it in the installation position. Start the engine,
extend the piston rod and align it with the pin hole. Install the pin shaft (6) and fix it with
bolts. Connect the four lift cylinder hoses (5).
Connecting rod: 85 Kg
5 4
7
6
3
5. Place the machine on the ground and lower the blade to the ground.
! Lock the brake firmly.
6. Operate to lift the ripper slightly to remove the bracket [1].
7. Lift the ripper completely, and hang the ripper shank (1) with a hook. Slowly lift the ripper
shank (1), align the pin hole, and install the upper pin shaft (2).
[1]
Drop 1-3
Working
Blade Quick drop s 1-2
cycle time of
the Left tilt 1-3
hydraulic Right tilt 1-3
cylinder
Lift 1-3
Ripper s
Drop 1-3
1 - implement pump 2 - working valve 3 - hydraulic tank 4 - quick drop valve 5 - oil cooler 6 - right lift
cylinder 7 - left lift cylinder 8 - tilt cylinder 9 - ripper cylinder
1 - blade handle 2 - ripper handle 3 - working valve 4 - pilot valve block 5 - accumulator 6 - pilot filter
element
1 - hydraulic tank 2 - two-way implement pump 3 - oil returning filter element 4 - pilot valve block 5 -
accumulator 6 - oil cooler 7 - working valve 8 - blade handle 9 - ripper handle 10 - tilt cylinder 11 - quick
Working Principle
The hydraulic system of the work tools is a quantitative hydraulic pilot control system,
consisting of the implement pump, working valve, handle, oil tank and cylinder.
The front pump of the two-way implement pump 2 is the implement pump, and the rear pump
is the pilot pump. The implement pump sucks oil from hydraulic tank 1 and supplies oil to the
working valve 7. Working valve 7 includes the blade lift control valve, the blade tilt control
valve, and the ripper control valve. When the operating handle is in the neutral position, the oil
will return to hydraulic tank 1 through port T of the working valve 7 and the oil return filter 3. If
the blade handle 8 is operated, the blade cylinder acts to lift, drop, hold, float the blade and tilt
it left or right. If the ripper handle 9 is operated, the ripper cylinder acts to lift or drop the ripper.
Each way of working valve 7 is equipped with an in-line check valve. The in-line check valve
prevents oil from flowing backward. If the engine shuts down suddenly when the blade is lifted,
the hydraulic pump stops supplying oil, and the in-line check valve locks the cylinder. The
blade can be maintained in the lifted position. The lifting way is equipped with a make-up
check valve to prevent cavitation in the hydraulic system. When the blade falls, the oil inlet
chamber of the cylinder will be vacuumized due to gravity. At this time, the make-up check
valve acts to allow oil to enter the cylinder from the oil tank, thus preventing cavitation.
The ripper way is equipped with an overload valve to prevent the ripper from overloading and
thus damaging the hydraulic components. When the oil pressure exceeds the set value of the
overload valve, the valve will overflow to unload.
In the pilot control hydraulic system, the pilot oil source is provided by the pilot pump of the
travel system. The oil is filtered by the pilot valve block and then sent to the pilot chamber of
the working valve through the ball valve 15, so as to control the movement of the main valve
core and enable the action of the blade and ripper.
The pilot valve block 4 integrates the check valve, filter element, sequence valve and
accumulator. When the whole machine cannot be started, the blade and ripper can be
dropped using the pressure oil stored in the accumulator.
The blade handle 8 is with a spider, and it can be controlled to lift, drop and tilt the blade;
The ripper handle 9 is with a slot-type shaft, and it can be controlled to lift and drop the ripper;
The ball valve 15 is used to lock the pilot oil source. When ball valve 15 is closed, the work
tools do not act no matter which handle is operated. Only when the ball valve 16 is connected
can each work tool acts;
If the load is too large during operation, the system pressure will temporarily exceed the set
pressure of 21 Mpa. At this time, the overflow valve inside the main valve is opened, and the
working oil returns to the oil tank through the overflow valve to protect the system.
The working valve is installed on the right fender of the machine using a bracket. According to
different work tools, the working valves can be of 2 pieces (with traction frame) or 3 pieces (for
the ripper). The valve core of the working way moves in the valve body, changes the on-off
relationship of different oil lines, and controls various actions of the blade and ripper
respectively. Both ends of the valve are equipped with centering springs. The centering spring
can provide a pre-tightening force to keep the reversing valve core in the neutral position.
The blade lifting way is equipped with a 6/4 valve. It controls the pilot handle to lift, drop,
neutralize and float the blade, and the other ways are equipped with 6/3 valves to lift, drop and
neutralize the ripper;
In the floating position, the two chambers of the blade lift cylinder communicate with the oil
inlet and oil return lines. The blade is free to stand on the ground and its height changes with
the terrain;
1 - blade lifting 2 - blade left tilting 3 - blade drop 4 - blade right tilting 5 - ripper lifting 6 - ripper drop
The hydraulic pilot oil is supplied by the pilot pump. The oil goes to the working handle or
ripper handle through the pilot valve block. When the work tool needs to be operated, the
handle shall be deflected to enable the pilot fluid to reach the pilot chamber of the main valve
core and push the main valve core into action. The output pressure of the pilot oil port is
proportional to the stroke of the handle and the stiffness of the working spring, and the
blade/ripper can act at the corresponding speed and direction. When the handle returns to the
neutral position, the handle oil inlet port is closed under the force of the reset spring, and the
working oil port and the oil return port are connected.
1 - filter 2 - accumulator 3 - sequence valve 4 - pressure measuring connector P - to oil outlet pipe of
pilot pump P1-to oil inlet of handle T/T1 - to oil tank
The pilot valve block is located on the right fender and consists of a sequence valve, an
accumulator, a filter and a check valve. Filter 1 cleans the oil in the pilot circuit, accumulator 2
stabilizes the pressure and lowers the work tools to the ground in case of engine flameout due
to failure. Sequence valve 3 limits the pressure in the pilot circuit. Pressure measuring
connector 4 tests the pressure in the pilot circuit. Port P is connected to the oil outlet of the
pilot pump, port P1 is connected to the oil inlet of the handle, and port T1/T is connected to the
oil return tank.
When the working handle is operated after the startup, the oil in the pilot pump travels from
port P to the filter element for filtering. Part of the oil is then filled into the accumulator, and the
rest enters the pilot chamber of the working valve through the handle to drive the main valve
core to move. When the handle is in the neutral position, the oil of the pilot pump overflows to
the oil tank through the sequence valve. At this time, the oil in the spring chamber of the pilot
valve returns to the oil tank through port T1.
bushing
1 - right lift cylinder 2 - quick drop valve 3 - to rod chamber of lifting cylinder 4 - to lift cylinder chamber
1 - valve body 2 - check valve 3 - slide valve 4 - spring A - to cylinder chamber without rod B - to cylinder
chamber with rod
The quick drop valve is located on the side of the front engine hood and is installed in the
blade lift pipeline to increase the blade drop speed and prevent vacuum on the bottom side of
the cylinder, and to shorten the hysteresis at the beginning of work. The quick drop valve
consists of the valve body, check valve, slide valve, and spring.
Operation:
1) Blade rise
When the blade is in the rising position, the pump oil from the working valve enters the
cylinder chamber with rod from orifice 1. Part of the pump oil acts on the lower end of the slide
valve through orifice 2. Under the action of oil pressure and spring, the check valve closes the
channel of the cylinder chambers with rod and without rod, and the oil in the cylinder chamber
without rod returns to the oil tank through the quick drop valve.
1) Quick drop of blade
Fig. 6.15 Operation of Quick Drop Valve during Quick Drop of Blade
When there is no external load on the blade and the working valve opens wide to drop the
blade, the pumping oil from the working valve goes to the cylinder chamber without rod
Model DH24
Settlement
for blade 150
lift Hydraulic oil temperature: within the
operating range
Engine flameout
Raise the blade to the maximum height and
measure the reduction of the blade bottom
height h within 15 minutes
Settlement mm/min
Settlement
for blade Hydraulic oil temperature: within the 50
tilt operating range
Engine flameout
Tilt the blade to the maximum extent to jack
the track on either side, and then measure
the reduction in track shoe height h within 5
minutes
Settlement
of blade
50
supporting
the vehicle
Settlement
for ripper Hydraulic oil temperature: within the 80
lift operating range
Engine flameout
Raise ripper to the highest position, and
measure the reduction of ripper height h in 15
minutes
Settlement
of ripper
supporting
the vehicle
Hydraulic oil temperature: within the
operating range 30
Engine flameout
Jack up the rear of the machine with the
ripper, and measure the reduction of the
height h of the final drive center within 5
minutes
Testing Tools
Mechanical or digital pressure A: Mechanical
Stress testing tools
tester pressure tester
Sensor range (bar) 0-60 0-600 B: Pressure
measuring wire
C: Digital
Pressure measuring wire 5m pressure tester
D: Sensor
a. Install a 0 - 60 bar pressure tester or digital pressure tester at the centralized pressure
measuring port A, and increase the oil temperature to the specified range before testing;
b. Run the engine at high and low idle speeds, place the blade and ripper handles in the
neutral position, and start the testing;
c. If the pressure is not the specified design value, adjust the sequence valve 3 on the pilot
valve block
1) Loosen the nut and adjust the screw;
2) Rotate it clockwise to increase the pressure, rotate it counterclockwise to decrease the
pressure;
3) Tighten the nut after adjustment.
Remove the testing tools.
1) Install a 0 - 60 bar pressure tester or digital pressure tester at the centralized pressure
measuring port B, and increase the oil temperature to the specified range before testing;
2) Run the engine at high idle speed, place the blade handle to the left or right tilt position,
and start the testing;
3) If the pressure is not the specified design value, adjust the overflow valve C on the
2) The blade tilt cylinder retracts the tilt cylinder to the end of the stroke and supports the
blade to jack up the right side of the body.
3) The ripper lift cylinder supports the ripper to jack the rear of the body.
2. Extend the cylinder to be measured with the corresponding control lever and check its
movement.
• If the lowering speed increases, the cylinder seal is faulty.
• If the lowering speed does not change, the control valve is faulty.
★ If the pressure in the accumulator is lost, run the engine for about 10s to increase the
pressure in the accumulator.
[Reference]
When the cylinder seal causes hydraulic drift,
Reasons for increased lowering speed are:
1 - left and right two-way travel pump 2 - make-up pump 3 - make-up filter 4 - oil return valve block 5 -
manifold 6- left and right travel motor 7 - radiator
1 - left travel pump 2 - right travel pump 3 - makeup pump 4 - oil return valve block 5 - manifold 6 -
makeup filter 7 - left travel motor 8 - right travel motor
The left and right travel pumps are connected to the engine through the gear transfer case,
and the engine drives the travel pump to rotate through the transfer case. The left and right
travel pumps are connected to the left and right travel motors 7/8 through high-pressure
pipelines. The variable pump converts the torque provided by the engine into high-pressure oil
flow, and the high-pressure oil flow transfers energy to the left and right travel motors. The
motors convert hydraulic energy into mechanical energy to drive the sprockets, making the
tracks travel.
The make-up pump of the travel pump is a single pump. The make-up pump sucks oil from
the oil tank, and the respective oil outlets pass through filter 6 to the make-up systems of the
left/right closed travel systems, ensuring the cleanliness of oil in the closed system. Make-up
pump 3 also provides control oil for the brake system and the travel motor.
The oil return valve block 4 integrates an overflow valve and a solenoid valve to limit the
pressure of the make-up system and release the travel brake.
The flow and direction of the travel pump are adjusted through two proportional solenoid
valves. The travel motor is adjusted through one proportional solenoid valve. The speed of the
pump and motor can be adjusted in a stepless manner:
Low speed and large torque: travel pump: small angle and small flow travel motor; large
angle and large consumption
High speed and low torque: travel pump: large angle and large flow travel motor: small
angle and small consumption
S/P: HP and LP working oil ports of the pump MS/MP: pressure measuring oil ports of
HP and LP oil ports
F: Make-up pressure oil port T: pump control oil drain port
L/U/: oil drain port of pump housing Z/Y: pressure measuring oil port of servo
pressure
MY/MZ: travel pump solenoid valve
1 - travel pump 2 - HP overflow valve 3 - makeup overflow valve 4 - variable piston 5 - variable
mechanism 6 - electric proportional reducing valve
The travel pump is a swash plate type close circuit axial piston variable displacement pump.
2 - swash plate 6/7 - variable displacement piston 14 - electro-hydraulic control valve block 18 -
feedback rod 21 - shaft 22 - pilot piston 23 - variable cylinder 24 - valve plate 25 - holder 26 - fixing plate
27 - PTO port 28 - feedback rod 29 - locating pin (control device E1 centering) 40 - seal ring 42 - seal
ring 43 - oil pipe
3 - pilot piston 5 - pilot valve core 15 - spring 16 - proportional valve 18 - position feedback rod 30 -
housing 31 - spring seat 32 - adjusting plug 33 - lock plate 34 - adjusting stud for maximum
displacement 35 - nut (tightening torque 23n.m) 36 - lock plate 37 - hollow screw to adjust hydraulic
neutral position
1 - pilot valve 2 - proportional electromagnet 3 - flushing valve 4 - flushing overflow valve A/B - pressure
oil port L/U/L1/L2 - oil drain port E - control oil port Ss - speed sensor Lmin: adjusting screw for
minimum displacement of motor Lmax: adjusting screw for maximum displacement of motor Ma/Mb -
pressure measuring port
The travel motor is a swash plate type axial piston variable displacement pump. The hydraulic
pump provides high-pressure oil for the high-pressure oil port A/B of the motor. The oil flows
through the swash plate and the variable cylinder and acts on the end face of the piston and
pushes the piston to realize the rotary movement of the motor. The left-hand rotation
(counterclockwise) or right-hand rotation (clockwise) depends on whether the high-pressure
oil inlet is A or B.
The travel motor is installed on the final drive brake housing through bolts in the main frame.
Solenoid valve 2 adjusts the displacement of the motor. The maximum displacement of the
motor at the initial position is the maximum displacement. The control oil at port E comes from
the make-up pump.
(1) Pressure
The maximum working pressure of the travel motor is 450 bar, the peak pressure is 500 bar,
and the continuous working pressure is 250 bar.
(2) Composition
The travel motor has a variable structure (regulating piston of the motor), a flushing overflow
valve, a flushing valve and a speed sensor.
(3) Electric proportional reversing valve
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Chapter 6 Hydraulic System
It is a 4/2 solenoid valve with a voltage of 24V. The control oil source is provided by the
make-up system through the motor E port. The motor displacement is inversely proportional
to the input current of the solenoid valve. When the current is the maximum, the displacement
is minimum; when the current is minimum, the displacement is maximum.
When the proportional solenoid valve 2 is not energized, the pilot valve core 1 does not act,
and the motor is at the maximum displacement.
When the proportional solenoid valve 2 is energized, the pilot valve core 1 opens, which
pushes the piston to move and changes the swash plate angle, thus changing the motor
displacement.
(4) Flushing system
The flushing system can sufficiently reduce the temperature in the closed system. The
low-pressure side of the motor is connected to overflow valve 4 through flushing valve 3. After
the flushing oil is cooled, it returns to the system to cool the whole closed circuit through the
make-up circuit (installed on the travel pump).
The flushing system can quantitatively supply flushing oil to the housing through overflow
valve 3. After flushing the housing, the flushing oil will be discharged out of the housing with
the oil drainage of the housing. The oil drainage of the housing will flow back to the oil tank
through L/U/L1/L2 via the brake oil return valve block and the radiator (hot oil) or directly (cold
oil).
Function of the flushing valve: As shown in the figure below, when the pressure at ports A and
B of the motor is equal (The travel pump is at zero displacement, and the pressure at ports A
and B of the main oil line is at make-up pressure), the two valve cores of flushing valve 4 are
in the neutral position under the action of spring force, and the flushing overflow valve 3 has
no flow
When the system starts to work, as shown in the figure below, pressure is established on the
high-pressure side of the main oil line. If port A is HP and port B is LP, A1 and B1 are pushed
to the right. Part of the LP flow is pushed through the groove at B1 to open flushing overflow
valve 3, and enters the motor housing. Then it returns to the oil tank through the oil return pipe
of the housing. The flushing flow of this part is 10 L/min. The taper C of A1 limits the maximum
stroke of A1 while closing the flow channel from HP to flushing overflow valve 4.
Variable displacement process of the motor:
When the proportional solenoid valve 10 is not energized, the pilot valve core 1 is in the upper
position under the action of the feedback spring 16. The oil of port E (from the make-up pump)
enters the oil chambers of pistons 13 and 14 through the oil channel, and returns to the oil
return tank through the housing. At this time, the motor is at the maximum displacement.
When the proportional solenoid valve 10 is energized, the current reaches the opening value
of the pilot valve core 1. Pilot valve core 1 overcomes the thrust of feedback spring 16 under
the action of the electromagnetic force and moves downwards, opening the channel from port
E to the oil chamber of piston 14. The pressure in the oil chamber of piston 14 gradually
increases until the swash plate 3 swings back. Under the action of feedback rod 15, the
electromagnetic force and feedback spring 16 establish a new force balance, so that pilot
valve core 1 is in a new balance position. The motor will maintain the displacement under the
current until the current changes.
1 - pilot valve core 2 - shaft 3 - swash plate 7 - piston 8 - cylinder barrel 9 - valve plate 10 - proportional
solenoid valve 13 - piston 14 - piston 15 - feedback rod 16 - feedback spring 17 - pilot valve housing 18
- oil pipe 19 - rear end cover 20 - speed sensor 21 - tonewheel
The make-up pump is a gear pump, connected in series behind the right travel pump. 2 is the
oil suction port, and 1 is the oil outlet which is connected with the oil inlet of the make-up filter.
1 - alarm 2 - oil inlet (to make-up pump outlet) 3 - oil outlet (to port p of manifold)
The make-up oil filter is located on the left side of the machine. Port 2 is the oil inlet, which is
connected to the outlet of the make-up pump. Port 3 is the oil outlet, which is connected to
port P of the manifold. 1 is the filter with pressure alarm, the alarm pressure is 2.4 bar, and the
bypass pressure is 3.4 bar.
Make-up pressure
26±0.3
(bar)
a. Jack up the machine, and lower the work tools. The tracks on both sides can operate
freely;
b. Install a 0 - 60 bar pressure tester or digital pressure tester at port G of the manifold, and
increase the oil temperature to the specified range before testing;
c. With the working handle and traveling handle in the locked positions, run the engine at
high idle speed, start the test and record the value of G;
d. If the pressure is not the specified value, adjust the makeup overflow valve;
e. Loosen the corresponding nut with a 14 wrench, and screw the adjusting screw with an
Allen wrench. Rotate it clockwise to increase the pressure and counterclockwise to
decrease the pressure;
f. If the pressure cannot reach the design value, repair or replace the overflow valve;
g. Put down the traveling lock lever, move the traveling handle forward or backward, and
observe the pressure of G. When the handle is pushed forward or backward, the pressure
drops by about 2 bar. If the pressure is abnormal, check the pressure of the overflow
valves of the left and right travel motors;
h. Remove the testing tools.
Whether the hydraulic zero point is aligned is determined by the position of part 1 on the travel
pump. When the zero point is aligned, the dimension here shall be 14.75 mm.
When the travel pump is repaired or the hydraulic zero point of the travel pump is misaligned,
the hydraulic zero point shall be adjusted.
a. Jack up the machine, and lower the work tools. The tracks on both sides can operate
freely;
b. Install a 0 - 60 bar pressure tester or digital pressure tester at centralized pressure
measurement ports MS1 and MP1 or MS2 and MP2 (Use a pressure tester of 0 - 600 bar
if abnormal pressure is suspected), and increase the oil temperature to the specified
range before testing;
c. When the working handle and traveling handle are in the locked positions, run the engine
at a high idle speed. Observe whether the pressure values of the 2 pressure measuring
ports are equal to the make-up pressure, and the maximum difference is about ±1 bar;
d. If the pressure is abnormal, adjust the hydraulic zero point alignment;
e. Refer to position ①. Remove the paint film, loosen the screw, remove the base plate,
adjust part ① so that the distance is 14.75 mm, and then restore;
f. Test the pressures of MS1 and MP1 or MS2 and MP2 again.
Before the test, make sure that nothing is on the track to prevent personal injury due to
unexpected operation of the track.
6. Lift the two-way pump (5), remove the mounting bolt (6) and remove the two-way pump.
Two-way pump: 35 kg
7. Plug the oil port of the hose.
Installation
Installation shall be in the reverse order of removal.
Refill (the hydraulic tank)
Fill the oil to the specified level through the oil filler, and run the engine to circulate the oil
through the system. Check the oil level again.
3. Disconnect 6 pilot hoses (4), (5), (6), (7) (8) and (9).
4. Disconnect 1 hose (10) and 7 hard pipes (11), (12), (13), (14), (15), (16), (17).
5. Hang the working valve (19), remove 3 bolts (18), and remove the working valve (19).
Working valve assembly: 86KG.
6. Plug the hose and oil port with the plug and the flange plate.
Installation
Install in the reverse order of removal.
Refill (the hydraulic tank)
Fill the oil to the specified level through the oil filler, and run the engine to circulate the oil
through the system. Check the oil level again.
5. Disconnect oil return hoses (4), (5), (6), (7) and (8).
Installation
Install in the reverse order of removal.
Refill (the hydraulic tank)
Fill the oil to the specified level through the oil filler, and run the engine to circulate the oil
through the system. Check the oil level again.
Fig. 6.23 Removal and Installation of Relevant Components of the Two-way Travel Pump
S/N Description S/N Description S/N Description
Main pipeline between Two-way implement
1 2 Make-up pump 3
pump and motor pump
Oil return hose of the Make-up hose of
Oil return hose of the right
4 control mechanism of 5 6 the right travel
travel pump housing
the right travel pump pump
Oil return hose of the
Oil return hose of the Make-up hose of
7 8 control mechanism of the 9
left travel pump housing the left travel pump
left travel pump
Centralized pressure 12 Left travel pump
10 11 Transfer case
measuring hose
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Chapter 6 Hydraulic System
Removal
Drop the work tools to the ground and shut down the engine. Release the residual pressure in
the hydraulic line.
Refer to "Testing and Adjustment" about the release of residual pressure in the hydraulic oil
line for details.
Then slowly loosen the filler cap to relieve the pressure in the hydraulic tank.
Disconnect the cable from the battery negative (-) terminal.
1. Drain the hydraulic tank.
2. Remove the cab, the engine guard assembly, engine accessories and pipelines
connecting the engine and the radiator, so as to lift the engine and transfer case pump
assembly as a whole. Refer to the removal and installation process of the cab, guard
assembly and engine for details.
3. Remove the main line (1) from the motor end that connects the travel pump to the travel
motor. The oil port and hose connector shall be protected.
4. Remove the pipeline connecting the make-up pump (2). Refer to the disassembly
process of make-up pump for details.
5. Remove the pipeline connecting the two-way implement pump (3). Refer to the
disassembly process of the implement pump for details.
6. Remove the hose connecting the travel pump, and protect each oil port with plastic bags.
The hoses to be removed include oil drain pipe (7) of the left travel pump housing, oil
drain pipe (5) of the right travel pump housing, oil return hose of the control mechanism of
the right travel pump (4), oil make-up hose of the right travel pump (6), oil return hose of
the control mechanism of the left travel pump (8), oil make-up hose of the left travel pump
(9) and centralized pressure measuring hose (10).
7. Remove the cooling pipeline of transfer case (12) and relevant brackets. Refer to the
removal process of the transfer case for details.
8. Unplug the 4 electrical plugs on the left and right travel pump solenoid valves, the oil
temperature sensor plug of the transfer case, etc. and relevant engine harnesses.
Disconnect all relevant connecting harnesses from the frame.
9. After confirming that the pump, transfer case and engine are not connected with other
components, use lifting equipment to lift the engine, transfer case (12), pump assembly
and main travel pipeline (1) as a whole. Refer to the engine disassembly and assembly
process for the specific lifting positions.
10. Lift the engine, transfer case and pump assembly as a whole and place them in safe
positions.
11. Remove the make-up pump (2) and the two-way implement pump (3) as a whole. Refer to
the disassembly and assembly process of make-up pump and the implement pump for
details. Protect the rear oil outlet of the right travel pump with a cover plate
12. Disconnect the traveling main pipeline hose (1) from the left travel pump (12) and the right
travel pump (13) and protect the hose joint from the pump oil port with a plastic plug or
cover plate.
13. Lift the left travel pump (12) or right travel pump (13) with the lifting equipment.
14. Remove the mounting bolts for the lifting of the travel pump, slowly pull out the travel
pump with lifting equipment and place it in a safe position.
15. Protect the transfer case mounting port with a cover plate.
■ Installation of the Travel Pump
1. Lift the left travel pump (12) or right travel pump (13) with lifting equipment, engage the
travel pump spline shaft with the transfer case spline sleeve, and then push the mounting
flange rabbet of the travel pump to fit with the transfer case groove.
2. Install the left travel pump (12) or right travel pump (13) on the corresponding mounting
flanges with mounting bolts, with tightening torque of 540 N*m respectively.
3. Install the main travel pipeline (1) at the port of the left travel pump (12) or the right travel
pump (13) as marked.
4. Install the two-way implement pump (3) and the make-up pump (2) at the rear flanges of
the transfer case and the right travel pump respectively. Refer to the disassembly and
assembly process of the implement pump (3) and the make-up pump (2) for details.
5. Install the engine, transfer case and pump assembly into the frame as a whole with lifting
equipment. Refer to the disassembly and assembly process of the engine for details.
6. Restore pipeline connections as marked.
6. Detach the track. Refer to the disassembly and assembly process of the track for details.
7. Remove fixing bolt (7) between final drive (8) and the frame, and lift out the final drive
together with the motor.
Removal
Drop the work tools to the ground and shut down the engine. Release the residual pressure in
the hydraulic line.
Refer to "Testing and Adjustment" about the release of residual pressure in the hydraulic oil
line for details.
Then slowly loosen the filler cap to relieve the pressure in the hydraulic tank.
Disconnect the cable from the battery negative (-) terminal.
1. Remove the cab. Refer to the specification of cab removal operation for details.
2. Remove the pipeline connecting the make-up pump, and make corresponding marks.
Protect all oil ports (including hose ports, connectors, oil inlet and outlet of the pump, etc.)
with plastic bags and plugs. Remove hoses including hose clamp (1), jointless hose (2),
oil suction hard pipe of the make-up pump (4) and oil outlet hose of the make-up pump
(3).
Removal
Drop the work tools to the ground and shut down the engine. Release the residual pressure in
the hydraulic line.
Refer to "Testing and Adjustment" about the release of residual pressure in the hydraulic oil
line for details.
Then slowly loosen the filler cap to relieve the pressure in the hydraulic tank.
Disconnect the cable from the battery negative (-) terminal.
1. Drain the hydraulic tank.
2. Remove the cab. Refer to the cab removal procedure.
3. Mark the pipeline and electrical connectors for easy subsequent assembly.
4. Remove the pipe fittings (2) - (12) on the valve block, and plug all oil ports to prevent
contamination.
5. Remove the electrical connector of the brake solenoid valve (13) on the valve block.
As shown in the figure, the main frame is the most critical structural part of the complete
machine and is used for fixing and installation of components, such as hood, radiator, engine,
balance beam, cab, fuel tank, hydraulic fuel tank, final transmission. The machining accuracy
of each installation position on the main frame determines the operating performance and
appearance coordination of the whole machine.
The bottom of the front hood and the front side of the main frame are installed on the main
frame through the pin shaft; the front grille is fixed on the front hood through bolts; the gantry
is installed on the main frame through bolts; the upper hood of engine is fixed on the front
hood and the gantry through bolts; the side shield upper cover of engine is fixed on the upper
hood and the side shield lower cover of engine through bolts; and the side shield lower cover
of engine is fixed on the main frame and flange plate through bolts. After removing the 4 bolts,
the front grille can be opened sideways to observe the operating conditions of the fan and
radiator inside. The engine side shield can be opened directly to facilitate the inspection and
replacement of the filter element.
Note: The bottom guard plate is heavy, and shall be removed with proper tools to avoid
crushing.
1. Remove the front bottom guard plate(7), middle bottom guard plate(10), and rear bottom
guard plate(13).
2. Clean the dust, soil and other sundries left on the bottom plate of the main frame.
3. Install the front bottom guard plate(7), middle bottom guard plate(10), and rear bottom
guard plate(13).
4. When observing the oil drain port, only remove the plate (4).
Specification:
Shantui Construction Machinery Co., Ltd. 163
Chapter 7 Frame and Hood
Weight of front bottom guard plate: 24.7kg
Weight of middle bottom guard plate: 37.5kg
Weight of rear bottom guard plate: 14.3kg/piece
4 Washer 4
Note: The front grille is heavy, and shall be removed with proper tools to avoid injury.
1. Remove the cover (2), bolt (3), and washer (4), and the front grille (1) can be opened by
rotation;
2. Fix the front grille (1), mounting cover (2), bolt (3) and washer (4).
Specification:
Weight of front grille: 76.7kg
Note: The front hood is heavy, and shall be removed with proper tools to avoid injury. During
removal, keep the shock pad to prevent loss.
1. Remove the bolt (2), washer (3) and shock pad (4), and remove the front upper hood (1);
2. Install the front hood (1), and install the bolt (2), washer (3) and shock pad (4).
Specification:
Weight of front hood: 33.7 kg
Note: The upper hood is heavy, and shall be removed with proper tools to avoid injury. During
removal and installation, pay attention to protecting the transition channel under the pre-filter.
1. Remove the bolt (6) and washer (7), and take away the plate (8) and exhaust pipe (5).
Remove bolt (17), washer (18), and take away the plate (16), plate (11), plate (12) and
pre-filter (13). Remove bolt (9) and washer (10). Remove bolt (2), washer (3), washer (4),
bolt (14) and washer (15), and finally remove the upper hood (1) of engine.
2. Install the upper hood (1), and install the bolt (2), washer (3) and washer (4), bolt (14) and
washer (15). Install the exhaust pipe (5), plate (8), bolt (6) and washer (7). Install the bolt
(9) and washer (10). And install the pre-filter (13), plate (11), plate (12), (16), bolt (17) and
washer (18).
Specification:
Weight of upper hood: 79.7 kg
Fig. 6.7 Engine Side Shield and Its Removal and Installation
S/N Description Qty. S/N Description Qty. S/N Description Qty.
Side shield
1 1 2 Washer 4 3 Bolt 12*30 4
upper cover
Side shield
4 1 5 Cover 3 6 Bolt 12*30 3
lower cover
7 Washer 3 8 Pin 1
Note: The engine side shield is heavy. To avoid injury, please remove the upper half before
the lower half with a proper tool.
1. Remove the bolt (3) and washer (2), remove the upper cover (1) of the engine side shield,
remove the cover (5), bolt (6) and washer (7), move the lower cover of the engine side
shield backward to disengage the pin shaft (8), and then remove the lower cover (4) of
side shield.
2. Connect the pin shaft (8) with the corresponding hole, install the side shield lower cover
(4), install the cover (5), bolt (6) and washer (7), install the side shield upper cover (1),
and install the bolt (3) and washer (2).
Specification:
Total weight of engine side shield: 129kg
Note: The gantry is heavy, and shall be removed with proper tools to avoid injury.
1. Remove the bolt (2) and washer (3), and take down the gantry (1);
2. Install the gantry (1), and fix the washer (3) and the bolt (2).
Specification:
Weight of gantry: 44.5kg
10 Bolt 12*30 2
Note: The rear side shield is heavy, and shall be removed with proper tools to avoid injury.
1. Remove bolts (3), (4) and washers (2), (5), and take down the left rear hood (1). Remove
bolts (7), (10) and washers (8), (9), and take down the right rear hood (6).
2. Install the left rear hood (1), and fix the bolts (3), (4) and washers (2), (5). Install the right
rear hood (6) and fix the bolts (7), (10) and washers (8), (9).
Specification:
Weight of left rear hood: 62kg
W10/CN10——to display
W10/CN11——A/C panel
W10/CN15——to pedal controlling both throttle and brake
W10/CN16——to engine wiring harness W11/CN16
W10/CN17——to floor rack wiring harness W1/CN17
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Chapter 8 Electrical system
W10/CN19——to floor rack wiring harness W1/CN19
W10/CN20——to engine wiring harness W11/CN2
W10/CL1——to starting switch G2
W10/CL2——to starting switch B2
W10/CL3——to starting switch M
W10/CL4——instrument box wiring harness GND
D31——display
D33——starting switch
W10——instrument box wiring harness
W10/CN10——to display
W10/CN11——A/C panel
W10/CN15——to pedal controlling both throttle and brake
W10/CN16——to engine wiring harness W11/CN16
W10/CN17——to floor rack wiring harness W1/CN17
W10/CN19——to floor rack wiring harness W1/CN19
W10/CN20——to engine wiring harness W11/CN2
W10/CL1——to starting switch G2
W10/CL2——to starting switch B2
W10/CL3——to starting switch M
W10/CL4——instrument box wiring harness GND
D31——display
D33——starting switch
W10——instrument box wiring harness
After starting the software, enter the account and password according to the prompt, select
the offline login mode, and click "Login" to enter the software page:
Click the [System Configuration] button in the lower left corner to enter the system
configuration interface, and select the adapter type according to the current version of
Diagsmart hardware.
3
1
For the software version as shown in the figure above, select [Diagsmart V2-USB] for the
adapter type , and [No] for the message collection default. Click the [Configuration] button,
and click the arrow at the upper left corner to return to the main interface after successful
configuration.
For the software version as shown in the figure above, select [Standard
Version-WIFI/USB-Normal Mode] for the adapter type, and [No] for the message collection
default. Click the [Configuration] button, and click the arrow at the upper left corner to return to
the main interface after successful configuration.
After the configuration is completed, return to the main interface, and click the [Power System]
button on the right side and select [Weichai Hydraulic] to enter the service interface.
Then click the [Connect Controller] button. When [Controller Connected] is prompted, it
indicates that the connection between software and controller has been established.
Note: The operation interfaces shown in the above two figures are for the second
generation of Diagsmart hardware, and are slightly different from those of the standard
version of Diagsmart, but the operations of the two versions are basically the same.
Note: The fault information will not be automatically updated in real time, and the fault list will
be updated by manually clicking the [DTC] button. The fault with the DTC status of [Current
Fault] is the fault reported by the current system.
Data flow
Select the [Data Flow] module to enter the data flow observation page, select the data
information to be observed, and click [Start Monitoring] to observe the real-time information of
the selected data. To add or reduce the data to be observed, click [Stop Monitoring] first.
Coefficient calibration
Select the [Parameter Calibration] module to enter the parameter calibration page. There is a
column of "CalibrateEnable" for each type of calibration, and "Default" is selected as default,
indicating that calibration is not allowed. When requiring calibration, click "Yes",and the
corresponding calibration quantity will be lighted, indicating that calibration can be performed.
When calibration is required, click the [Read] button in the lower right corner to read the
current system parameters, and then modify relevant parameters as required.
When the modification is completed, there are two methods to write the modified
parameters into the controller:
1. [Download], parameters can be modified and written to the controller during the current
power-on cycle, but the modified value will change back to the original value after the
controller is powered off.
2. [Direct flashing], in this method, the modified value is still valid after the controller is
powered off, but during flashing, the controller will be temporarily disconnected from the
vehicle. Therefore, it is recommended not to flash when the engine is started, or under
the driving state. At the same time, it is not recommended to operate the handle and hand
throttle after clicking [Direct flashing], so as to avoid affecting communication and causing
flashing failure.
Self-learning
Select the [Self-learning] module to enter the self-learning page.
Note: As the key to synchronization function, the self-learning is a critical function for the
hydraulic system. It needs to be performed in the vehicle supporting state, and the engine
speed is not less than 1500rpm.
The self-learning process is relatively simple. Click the [Start] button and operate according to
the prompt information.
Note: After self-learning, the system will automatically save the learning data and
writes it to the controller.
002 2031 12 Current of left pump forward solenoid valve cannot return to zero
005 2021 12 Current of left pump reversing solenoid valve cannot return to zero
008 2001 12 Current of right pump forward solenoid valve cannot return to zero
014 2051 12 Current of left motor solenoid valve cannot return to zero
017 2041 12 Current of right motor solenoid valve cannot return to zero
023 9005 2 Solenoid valve live error under stop demand of inching pedal
024 9006 2 Solenoid valve live error under travel locking switch
036 9012 3 Left pump forward solenoid valve short-circuited to power supply
039 9013 3 Left pump reversing solenoid valve short-circuited to power supply
042 9010 3 Right pump forward solenoid valve short-circuited to power supply.
062 9038 4 Closed pump solenoid valve high side short-circuited to ground
Closed pump solenoid valve high side short-circuited to power
063 9038 3
supply
064 9038 5 Closed pump solenoid valve high side open-circuited
066 9038 25 Closed pump solenoid valve high side voltage out of limit
068 9039 3 Motor solenoid valve high side short-circuited to power supply
071 9039 25 Motor solenoid valve high side voltage out of limit
092 2104 3 Handle driving main signal voltage above upper limit
093 2104 4 Handle driving main signal voltage below lower limit
Shantui Construction Machinery Co., Ltd. 235
Chapter 8 Electrical system
094 2105 3 Handle driving check signal voltage above upper limit
095 2105 4 Handle running check signal voltage below lower limit
097 2084 3 Handle steering main signal voltage above upper limit
098 2084 4 Handle steering main signal voltage below lower limit
099 2085 3 Handle steering check signal voltage above upper limit
100 2085 4 Handle steering check signal voltage below lower limit
104 2094 3 Inching pedal main signal voltage above upper limit
105 2094 4 Inching pedal main signal voltage below lower limit
106 2095 3 Inching pedal check signal voltage above upper limit
107 2095 4 Inch pedal check signal voltage below upper limit
135 9179 3 Shovel blade left tilt solenoid valve short-circuited to power supply
136 9179 4 Shovel blade left tilt solenoid valve short-circuited to ground
141 9181 3 Shovel blade lifting solenoid valve short-circuited to power supply
154 9186 3 Shovel blade left/right tilt signal voltage above upper limit
155 9187 4 Shovel blade lifting/lowering signal voltage below lower limit
156 9187 3 Shovel blade lifting/lowering signal voltage above upper limit
157 9188 4 Shovel blade left/right slewing signal voltage below lower limit
158 9188 3 Shovel blade left/right slewing signal voltage above upper limit
167 9192 14 Message length error of CAN handle in the shovel blade X/Y axis
168 9193 14 Message length error of CAN handle in the shovel blade Z axis
169 9194 19 Message timeout of CAN handle in the shovel blade X/Y axis
170 9195 19 Message timeout of CAN handle in the shovel blade Z axis
174 9199 1 Forced reverse switch of fan being pressed too long
175 9200 3 Work tool temperature sensor voltage above upper limit
176 9201 4 Work tool temperature sensor voltage below lower limit
179 9204 4 Throttle foot pedal main signal sensor voltage below lower limit
180 9205 3 Throttle foot pedal main signal sensor voltage above upper limit
181 9206 4 Throttle foot pedal check signal sensor voltage below lower limit
182 9207 3 Throttle foot pedal check signal sensor voltage above upper limit
1. Hook the pressed plate with the small barb at the end of the removal tool. 2. Pull the
removal tool with force to take out the pressed plate.
3. Use the end of the removal tool to open the clip of the connector and take out the terminal.
4. Replace the connector or terminal if necessary.
5. Push the terminal vertically into the connector and hear a clear "click" sound, indicating
that the terminal is connected in place.
6. Clamp the pressed plate with tweezers, and align the small end of the pressed plate with
the slot in the middle of the connector. After the pressed plate is completely inserted, a "click"
sound of cell clearing can be heard.
Note: The pressed plate of the 2-pin connector is not symmetrical, and the latch position shall
be close to the terminal side.
240 Shantui Construction Machinery Co., Ltd.
Chapter 8 Electrical system
Replacement of DEUTSCH series circular connector
1. Cover the external wire with a suitable 2 Insert the tool into the hole in the rear of
removal tool. the connector until resistance is felt.
4. Hold the core wire, and align the terminal with the corresponding hole of the connector.
5. Push the terminal vertically into the connector. When resistance is felt, pull it back slightly
to make sure that the terminal is locked.
The tool:
ATRT-100
1. Cab assembly 2.Main frame 3.Flange plate assembly 4.Shock absorber 5.Bolt
6.Washer 7.Washer 8.Nut
The cab assembly is connected to the flange plate assembly and the main frame through two
supports respectively at the front and rear, and the shock absorber is used for vibration
reduction. The cab and floor rack is an integrated assembly. During assembly, it is fixed by 8
shock absorbers and 8 bolts (M20X155, S30, with a tightening torque of 460Nm) at 4 shock
absorption points.
9. Floor bracket 10.Travel locking lever 11.Anti-skid plate 12.Floor pad 13.Pedal
14.Instrument box
The travel locking lever (10), pedal (13) and instrument box (14) are fixed on the floor rack (9)
by bolts, and the anti-skid plate (11) is fixed on the floor pad (12). Pedal (13) is fixed by 2 bolts
(M12X55, S18, tightening torque: 89Nm), and the instrument box (14) is fixed by 4 bolts
(M12X30, S18, with a tightening torque of 89Nm).
1. Square tuyere 2.Rubber plate 3.Instrument box 4.Plate 5.Plate 6.Bolt (01010-51230)
7.Bracket 8.Square tuyere 9.Round tuyere 10.Bracket
The instrument box is assembled together with cab assembly by bolt (6) (SW18).
The seat assembly includes main structures such as seat and seat bracket, as shown
in the figure below.
Fig9.5 Seat
System composition
1-Condenser and fan
2-Control pane 3-Evaporator 4-Compressor
assembly
5-Refrigerant pipe 6-Liquid storage tank 7-Warm water pipe 8-belt
Loosen the bolts shown in the figure, and remove the armrest and its fixing ring in sequence.
Remove the 4 fixing bolts shown in the figure, and remove the armrest bracket from the lower
part of the cab.
Repeat the above operations to remove the left and right armrests.
Installation of seat:
The seat assembly is installed in the opposite direction of its removal.
Remove the instrument box and its connecting pipeline harness and other accessories.
Remove the refrigerant pipe and warm water pipe connected to the evaporator.
Removal/installation of condenser
Remove the shield above the condenser and its mounting bolts.
Disconnect the harness connecting the condenser, and remove the condenser.
Installation
Install the condenser in the reverse order of its removal.
9.5 Precautions
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Chapter 9 Driving System
Before installation, the plugs at both ends of the hose shall not be removed. The installation
environment shall be clean and moisture-proof. Dirt and moisture shall not enter the cooling
medium circuit.
The bending radius of the installation pipeline shall be greater than 90mm, the hose shall not
be twisted, and the middle of the pipeline shall be fixed with clamps to prevent vibration and
wear.
The inspection shall be carried out before installation, to ensure that the O-ring is installed at
the joint, and then cooling oil shall be applied. The threaded part of the hot water circuit shall
be coated with sealant LS3 or wrapped with raw material tape.
The condenser shall be handled gently without damaging its surface, and the installed inlet
and outlet shall not be inverted.
The hot water pipe valve shall be placed in the open position when discharging water in
winter.
The voltage required by A/C shall be distinguished from the power supply, and shall not be
mixed. The heat sources, sharp objects, and movable objects shall not appear in the wiring
space.
The absolute pressure shall be maintained at -0.1Mpa for half an hour during vacuuming. And
the refrigerant shall only be filled when there is no leakage. During removal and installation,
the engine must not be started to prevent damage to the compressor due to liquid impact.
Whether the air conditioner is used or not, periodical inspection and maintenance shall be
carried out for its pipeline and other devices.
In winter, the heating system must be filled with antifreeze to keep the core from frost cracks.
The refrigerant shall be R134a and shall not be mixed, with the filling amount of 1000g.
Step 1
Step 2
Step 8
Identify possible positions of causes
1) Refer to the Fault Diagnosis in the Repair on site
Installation and Maintenance Manual to find
out where the fault causes might be.
OK!
It's fixed.
Step 3
Mechanical Step 6
Manual
Reproduction of faults
·
Start and operate the machine, confirm the faults of machine and
Installation and judge whether there is a fault.
Maintenance
Manual
Step 5
Step 4
Poor
chimerism
3) Wire breakage
If you hold the wire with your hand and pull out the plug or lift the component that is still
connected to the wire with a crane or there is a heavy object hitting the wire, it may cause the
crimping part to be disengaged or the welding spot to be damaged or the wire to be broken.
Although the connector is waterproof (immersion proof), if high pressure water is sprayed
directly into the connector, water may enter the connector in the direction of spraying. Since
the connector is waterproof, it is difficult for water to enter and also difficult to be drained.
Therefore, if water enters the connector, the pin will be short-circuited by water. Therefore, if
water enters the connector, dry the connector immediately before connecting the power
supply, or take other effective measures.
5) There is oil or dirt on the connector
If there is oil or grease on the connector, an oil film will be formed on the contact surface of the
plug or socket, which will cause poor contact because oil is not conductive.
If there is oil or grease on the connector, wipe it off with a dry cloth or dry it with compressed
3. Calibration of bulge of rubber sleeve and misalignment of wire harness. For connectors
with rubber sleeves, the bulge of the rubber sleeve must be calibrated. In addition, if the
wire harness or clamp is not in the correct position, it must be calibrated to the correct
position.
★ If the connector is not easy to be calibrated, remove the clamp and adjust its position.
4. If the connector clamp has been removed, be sure to install it back in place. Also check
for loose clamps.
Harness drying
If there is oil or dirt on the harness, wipe it off with a dry cloth. Do not clean it with water or
steam. If the connector must be cleaned with water, the high-pressure water or steam shall
not directly face the harness.
If water enters the connector directly, the following work must be done:
1) Disconnect the connector and wipe off the water with a dry cloth.
★ It is dangerous to dry the connector with compressed air, because oil in the air may cause
poor contact. Therefore, we shall dry the connector with compressed air free of water and
oil.
2) Dry the inside of the connector with a dryer.
If water enters the connector, dry the connector with a dryer.
★ Although it is good to use a dryer for drying, the connector and its accessories are easy to
be deformed and damaged by heat. Please pay attention to adjusting the drying time.
III. Connection and Precautions of Controller (ECU, VCU) and Harness Connector
Connection of controller and harness connector
ECU and wiring harness are connected reliably and ECU connector is provided with locking
and booster mechanism. Therefore, do not plug or unplug ECU connector forcibly. Please
plug or unplug the connector as required.
1. ECU connector booster and locking mechanism:
If the booster mechanism is damaged, pull out the locking mechanism with force until it cannot
be moved, so that the locking mechanism can fully extend, as shown in the following figure:
3) Align the connector with the ECU connector, push it in, and try to pull back the booster
mechanism (without too much force to avoid damage). If it cannot be moved, it may not
be aligned with the ECU connector. Move it up and down and left and right and try to pull
back the booster mechanism. If it still cannot be moved, the locking mechanism may not
be completely withdrawn. Repeat steps 2 and 3 until the booster mechanism can be
easily retracted.
If the booster mechanism is damaged, please directly push the locking mechanism. If it
cannot be pushed or can be pushed but the ECU connector is not pressed with the ECU,
please repeat steps 2 and 3 until it can be pushed and pressed with the ECU.
1) After pulling the locking mechanism to the end (until "click" for some mechanism and
others cannot be moved) as shown in the figure, the ECU connector will be reliably locked
through the locking mechanism. If the connector booster mechanism is damaged, please
push the locking mechanism until the ECU connector is reliably locked through the
locking mechanism.
7) Cleaning operations
After repairing the hydraulic device (pumps, control valves, etc.) or when the machine is
running, clean the hydraulic oil to remove oil sludge or impurities in the hydraulic pipeline.
※ On-site Safety
• Check surroundings for abnormalities which may trigger danger before starting.
• Check the landform and soil texture and select the optimal working methods, and do not
work in the area susceptible to falling objects.
• When working on the highway, special personnel shall be assigned to direct traffic and set
up roadblocks to ensure the safety of traffic and pedestrians.
• If working at the place with buried facilities such as water pipes, gas pipelines, HV cables
etc., contact relevant departments first, to determine the position of pipelines, so as to
prevent damage to them during construction.
• If working in water or passing through a sandbank, check ground mass, water depth and
flow velocity first, and do not work in a water area beyond the allowable water depth.
※ Fire Protection
• Remove garbage such as leaves, deadwood, waste paper and waste materials
accumulated at the engine and other hot parts of the machine to avoid fire caused by
270 Shantui Construction Machinery Co., Ltd.
Chapter 10 Fault Diagnosis
thermal combustion.
• Check the fuel, lubricating oil and the hydraulic system for leakage, and repair any leak.
Clear all surplus oil, fuel or other flammable liquids.
• Guarantee that a reliable fire extinguisher is provided.
• Do not operate the machine around open fire.
※ Getting on/off
• Do not jump up and down while getting on/off the machine. Getting on/off of the machine
running is prohibited, or otherwise accidental injuries will be triggered.
• Face the machine while getting on/off the machine, and always maintain three-point
contact (feet and a single hand, or hands and a single foot) among the human body,
handrails and the ladder, to guarantee safety.
• Do not grasp any control lever while getting on/off the machine.
• Check handrails and ladders while getting on/off the machine. Wipe any oil stains or
sludge found on the handrail or ladders immediately. Timely repair the damaged parts,
and tighten the loose bolts.
• For the machine installed with a reversing alarm bell and a buzzer, guarantee that the
alarm can work normally.
• Firmly buckle the seat belt during driving.
Buckle
seat belt
100V-200V >2m
6600V >2m
22000V >3m
66000V >4m
154000V >5m
187000V >6m
275000V >7m
500000V > 11 m
※ Driving on Slopes
• When driving on steep hills, embankments or slopes, the vehicle may roll over or slip.
• The blade shall be close to ground while driving on hills, embankments or slopes, and be
about 20~30 cm above the ground. The blade shall be lowered to ground rapidly in case
of emergency, to help stop the machine or to prevent rollover.
• Do not turn on a slope or cross a slope, and do this kind of operation at a flat place. Put
the heavy end of the machine on the upper slope side while working on a slope.
• Rocks and wetlands will seriously affect the traction and stability of the machine. Uneven
rock surfaces may cause sliding at one end of the machine.
• Do not cross grasslands, leaves or wet steel plates, which may lead to slip of the machine.
A very low speed shall be maintained while driving along slope edges.
• Slow down while driving downslope.
• Lower the blade immediately if the engine stalls on a slope and use the parking brake.
• If the machine is idle for a long term, the cut-off switch of the battery shall be turned to
“OFF” with the rear shield being locked, to prevent battery discharge due to short circuit,
damage to some elements and artificial reasons.
10.2.7 Dragging
• The ropes can only be used for dragging when the machine is started, or otherwise
hydraulic components of the machine will be damaged.
• The ropes of sufficient strength must be used while dragging this vehicle with other
machines.
• Do not drag the machine on a slope.
• Do not use curved or twisted pulling ropes.
• Do not cross or get close to the pulling rope.
• Do not let any person stand between the tractor and the pulled vehicle while bonding the
pulled machine.
Relevant
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
information
Causes Standard value under normal state/fault diagnosis record
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
Before fault diagnosis, check and confirm that the hydraulic system pipeline is free of oil
Relevant
leakage.
information
If the hydraulic drift of work tool is serious, implement the fault diagnosis for "hydraulic
drift of work tool".
Possible Standard value under normal state/fault diagnosis record
Causes
causes
Hydraulic oil temperature If the oil temperature is low, preheat the oil temperature to
low 50-60°C
Check the engine speed. The minimum idle speed is
Engine speed low
750rpm
It is possible that the air enters the oil suction pipeline of the
Presumed Air enters suction pipeline
implement pump. Directly check the pipeline.
causes and
Too high or too low viscosity of hydraulic oil will lead to
standard Whether the viscosity of
insufficient oil suction of pump or incorrect control and
value under hydraulic oil exceeds the
adjustment, so we shall choose hydraulic oil with proper
normal state limit
viscosity.
Pilot control pressure low Pilot pressure 3MPa
Damage of implement
pump (implement pump Check pump flow Flow: 300L/min
cannot work normally due
Relevant
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
information
Causes Standard value under normal state/fault diagnosis
record
1 Air enters suction
Check connection at pump inlet side
pipeline
Presumed 2 Improper viscosity of
causes and Direct inspection
hydraulic oil
standard
3 Pump rotary assembly Check pump flow Flow: 196L/min
value under
fault
normal state
4 Air in hydraulic circuit Check the oil for foam
5 Contact between
Check whether the hydraulic pipeline resonates with the
pipeline and structural
main frame and engine
parts
Relevant
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
information
Standard value under normal state/fault diagnosis
Causes
record
1 Air flow in the blocked
radiator or passing
Check the radiator, clean or replace it.
through the radiator is
low.
2 Radiator bypass valve
Check bypass valve, repair or replace it.
stuck
Presumed 3 Improper viscosity of
Direct inspection, use recommended hydraulic oil.
causes and hydraulic oil
standard 4 Observe whether the oil is turbid through the oil
There is a lot of gas in
value under window, and check whether there is leakage at the
the hydraulic system
normal state pipeline and cylinder head
5 Low pressure of oil Oil replenishing pressure: 26bar. Refer to the low oil
replenishment replenishing pressure for troubleshooting
6 Check the pressure at the low pressure side of the
traveling system. If it is low, block the valve core with a
Inside the motor flush valve and shield the flush valve. If there is no flush
valve, observe the oil return volume of the motor
housing. If the flow is too large, replace the motor.
7 Working system LS LS pressure: 230 bar, too low, repair or replace LS
Relevant Before fault diagnosis, check and confirm that there is no oil leakage in the work tool
information pipeline
Standard value under normal state/fault diagnosis
Causes
record
1 Check the internal leakage of oil cylinder, and refer to
Internal leakage of
Presumed the detection and standard of internal leakage of oil
hydraulic cylinder
causes and cylinder
standard 2 Blockage or leakage of
Repair or replace the safety valves
value under pipeline safety valve
normal state 3 Blockage or leakage of
Repair or replace the anti-suction check valve
anti-suction check valve
4 Working contact internal
Repair or replace the spool
leakage of working valve
Relevant Before fault diagnosis, check and confirm that there is no oil leakage in the work tool
information pipeline
Standard value under normal state/fault diagnosis
Causes
record
1 Check the internal leakage of oil cylinder, and refer to
Internal leakage of
the detection and standard of internal leakage of oil
Presumed hydraulic cylinder
cylinder
causes and 2 Blockage or leakage of
standard Repair or replace the safety valves
pipeline safety valve
value under
3 Blockage or leakage of
normal state Repair or replace the anti-suction check valve
anti-suction check valve
4 Working contact internal
Repair or replace the spool
leakage of working valve
2 Faults inside pull pin There may be faults inside pull pin cylinder, and directly
3 Abnormal double-tilt
There may be faults in double-tilt switching valve 2 of
switching valve of dozer
dozer blade, and directly check it.
blade
4 Abnormal function of
There may be faults in double-tilt cylinder of dozer
double-tilt cylinder of
blade, and directly check it.
dozer blade
Before fault diagnosis, check and confirm the oil level of hydraulic oil tank and check
Relevant
the pipeline for leakage.
information
Perform troubleshooting according to the DTC information if any.
Causes Standard value under normal state/fault diagnosis record
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
Relevant
Perform troubleshooting according to the DTC information if any.
information
Check whether the input signal of control module is normal.
No. Causes Standard value under normal state/fault diagnosis record
Low left and right oil Low oil replenishing pressure, brake not released, oil replenishing
1
replenishing pressure pressure detected, standard value 26±0.3bar
Oil replenishing If the test oil replenishing pressure is low, there may be faults inside the
2
pump fails. oil replenishing pump.
Brake solenoid valve Brake Brake pedal not
3 Brake pressure 26±0.3bar
fault solenoid depressed
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Chapter 10 Fault Diagnosis
valve Depress the brake
Brake pressure 0 bar
energized pedal
If the pressure is abnormal, check the resistance of the brake solenoid
valve. The standard value is 28-36Ω. Repair or replace it,
Check the brake solenoid valve harness and repair or replace it.
4 Power output fault Check whether the work tool and fan work normally.
5 Brake component Disassemble the brake and check the seal, spline, friction plate and
fault brake plate, etc., and repair or replace them.
Travel pump electric Control valve High idle Handle forward Min 4bar
1 proportional relief valve outlet speed of Handle in neutral
fault pressure engine 0
position
Relevant Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal.
information Check the pipeline for leakage and air intake
No. Causes Standard value under normal state/fault diagnosis record
1 Travel pump with gas The gas in the servo valve of the travel pump needs to be exhausted.
Preheat the oil, ensure the temperature reaches the green area on the
2 Low oil temperature
instrument.
Travel pump servo There is a problem during maintenance and adjustment of travel
3
valve adjustment fault pump. Adjust and calibrate the valve again
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
Relevant
Check the pipeline for leakage and air intake
information
Perform troubleshooting according to the DTC information if any.
No. Causes Standard value under normal state/fault diagnosis record
Traveling handle not in
1 Is the traveling handle in the neutral position
neutral position
Abnormal motor speed
2 Check whether the motor speed sensor is normal
sensor
Abnormal control of Whether the control current of travel pump and control servo valve are
3
travel pump normal
Incomplete exhaust of
4 Exhaust the servo valve
travel pump
Travel pump
Check the output pressure of proportional relief valve, standard:
5 proportional relief valve
4-16bar
fault
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Chapter 10 Fault Diagnosis
Handle in
26±0.3bar
Traveling High idle speed neutral position
system pressure of engine Handle forward
Internal abnormality of 420±10bar
6 or backward
travel pump
If the forward and backward deviation is the same and the pressure on
the slow side is low, the pump will loosen the oil drain port of the pump
housing for personnel to observe whether there are contaminants.
Oil Traveling handle
High idle speed of
replenishing forward or 26±0.3bar
One-side motor flushing engine
7 pressure backward
overflow valve
If the pressure cannot be adjusted to normal, the motor flushing
overflow valve fails.
If it is steered in place, the speed on one side is slow and brakes on
8 One-side brake fault
some sides are stuck.
Faults inside travel
9 If the above is normal, there may be faults inside travel motor.
motor
Before fault diagnosis, check whether the oil level of hydraulic oil tank is normal
Relevant
Check the pipeline for leakage and air intake
information
Perform troubleshooting according to the DTC information if any.
No. Causes Standard value under normal state/fault diagnosis record
Incorrect use of
1 Confirm whether the oil used meets the requirements
hydraulic oil
Poor sealing of oil
2 suction port of oil Check the sealing of oil suction pipeline
replenishing pump
Loose pipeline between
3 Inspection and repair of pipelines
travel pump and motor
The oil replenishing
4 Check whether the filter element of the oil replenishing filter is blocked.
filter is blocked
Oil Traveling handle
High idle speed of
Abnormal oil replenishing in neutral 26±0.3bar
engine
5 replenishing overflow pressure position
valve If the pressure cannot be adjusted to normal, the oil replenishing
overflow valve fails.
Oil
High idle speed of Handle forward
replenishing 26±0.3bar
Motor flushing overflow engine or backward
6 pressure
valve fault
If the pressure cannot be adjusted to normal, the motor flushing oil
overflow valve fails
7 Gas in the travel pump The gas in the servo valve of the travel pump needs to be exhausted.
Faults inside travel
8 If the above is normal, there may be faults inside travel pump.
pump
2.
Drain off the air, check the sealing of the connector
Air entered into the fuel system
and repair it
3.
Check plunger, fuel outlet valve and repair or
Injection pump damaged
replace the broken parts
4.
Injector damaged Check the atomization of injector, and repair it
5.
Initial angles of valve gear or fuel delivery is wrong Cheek and adjust it
6.
High pressure line damaged or leaked Repair or replace
7.
Check the sealing of the valve and cylinder gasket
Insufficient pressure in cylinder
and the wear of the piston ring. Repair or replace
them
1. ( )
Check the air cleaner and air intake pipe, clean or
Air intake clogged (air cleaner choked)
replace filter element
2.
Check the valve-timing and exhaust pipe, adjust
Exhaust back pressure is too high
and repair
3.
Insufficient pressure in supercharging system Check and block up the leakage of pipeline
4.
Faults in turbocharger Replace the turbocharger assembly
4.1.
Compressor and turbine streets choked up Clean or replace
4.2.
Floating bearing cease to be in effect Replace
4.3. , ,
Carbon deposit or greasy filth in clearance of
Clean
turbine and compressor back
5.
Intercooler damaged Replace or repair
6.
Check the sealing of fuel pipe and connector, fuel
Leakage or choke of fuel line
filter and fuel line, repair, clean or replace the filter
element
7.
Clean the fuel tank, filter parts and fuel pipe.
Poor quality of fuel
Renew the fuel
8.
Excessive wear for injection pump or governor Repair or replace
9.
Smoke-limiter diaphragm of injection pump
Repair or replace
damaged
10. Replace
Air pipe of smoke-limiter damaged
11.
Check the injecting pressure, clean away the
Poor atomizing
carbon deposit in nozzle, adjust and repair in-jector
12.
Incorrect timing of valve gear or fuel delivery Check and adjust it
13.
High-speed of governor is adjusted too low Check the speed-governing and adjust
14.
17.
Overhaul the engine
Cylinder liner or piston worn, or piston scuffing
6.
Check and block up the leakage of pipeline and
Insufficient pressure in supercharging system
connector
7.
Faults in turbocharger Check and replace
8. ( )
Incorrect working point of smoke-limiter Readjust ( by manufacturer)
2.
Check working temperature of thermostat, replace
Temperature of cooling water is too low
if necessary
3.
Incorrect timing of valve gear or fuel delivery Check and adjust
4.
Poor atomizing Check and repair
5.
Incomplete combustion, scuffing and the Check piston ring,cylinder liner, cylinder gasket,
compressed pressure is too low and repair them
6.
Wear-in between the piston rings and cylinder Go on wearing-in
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Chapter 10 Fault Diagnosis
liners is not good
7.
The gaps of the piston rings are not staggered Adjust, reassembly
8.
Piston oil rings cease to be in effect Replace
9.
The fit clearance between piston and cylinder liner
Repair or replace
is too large
10.
The sealing ring of turbocharger worn Check and replace
11.
The thrust bearing of turbocharger worn Check and replace
12.
The oil return pipe of turbocharger choked. Clean or repair
3.
Strainer, oil pipes, connector gasket choked or
Check strainer and connector , check if there is
broken
any sponge in oil passage, repair
4.
Lub-oil doesn't conform to specifications Renew the lub-oil according to requirements
5.
Intake pipe of oil pump leaked Check the oil pipe and connector, repair or replace
6.
Water temperature in cooling system and oil
Check cooling system, and correct it
temperature are too high
7.
Excessive resistance of oil filter Renew the filter element
8.
Oil cooler choked Check and clean
9.
Main oil passage choked Check and clean
10. ,
The clearance of bearing is too large or bearing
Check and replace
damaged
11. , ,
Excessive wear of parts, need to over haul Check the working time of the engine, over haul
2.
Bad contact in connecting wire Check up circuit, tighten terminal
3.
Fuse broken Replace
4.
Bad contact in brush Clean brush surface or replace brush
5.
Short circuit in starting motor Check and repair it, or replace the motor assembly
4.
Clean away the dirt and furbished using
Commutator unclean or sintered
sandpaper, or replace commutator assembly
5.
Reweld
Sealing off at wire end
6.
Bad contact for switch Check and repair
7.
wore clutch slipped Adjust working moment of clutch or replace
The engine start circuit is provided with a neutral safety function and the engine cannot
be started unless the parking control lever is in the locked position.
Relevant
If there is a prompt that "display panel does not light up" or "the battery relay does not
information
make a sound of operation" when the starter switch is set to ON, the main power
system may be faulty. Therefore, check the main power system.
2 Start switch fault Open circuit inside starter switch, check harness resistance.
Alternator Voltage
Alternator fault (internal
3 Between terminal R and ground Max. 1V
short circuit)
wire
Starter motor fault When the supply voltage for charging and starting is normal, but the
4
(internal fault) starter motor does not work, the starter motor is faulty.
Harness open-circuited
Prepare with the starter switch off, and then diagnose the faults without
(open circuit of harness
5 turning on the starter switch. Judge the resistance between the main
or poor contact with
circuit of starter motor and the positive pole of battery
connector).
Alternator terminal R and starter motor terminal R wire harness
6 Harness short-circuited
short-circuited to ground
Relevant In cold environment, the engine intake preheater works automatically, and the preheat
information indicator on the display lights up, and goes out after preheating.
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Chapter 10 Fault Diagnosis
If the intake heater does not work, there will be corresponding DTC for engine.
Harness open-circuited
(open circuit of harness Electric intake heater terminal and electric intake air of heater relay.
4
or poor contact with Harness between heaters, maximum resistance is 1 Ω
connector).
10.7.3 Display Does Not Light Up When the Starter Switch is Turned ON
Faults The display does not light up when the starter switch is turned on.
Relevant
Turn on the starter switch, and the display lights up normally
information
1 Start switch fault Open circuit inside starter switch, check harness resistance.
Harness open-circuited
(open circuit of harness
2 Check the power supply voltage of the display
or poor contact with
connector).
Display fault (internal
3 Replace monitors
fault)
1 Fuel level sensor fault Check the fuel level sensor and check whether the floats are stuck.
Harness short-circuited
2 Check the connection and disconnection of relevant harness
or open-circuited.
Display fault (internal Check whether the bus communication between the display and
3
fault) vehicle controller is normal
5 Control panel fault When cooling indicator does not light up, replace control panel.
Electromag
netic clutch
2. Check the system pressure: Connect the A/C pressure gauge to the refrigerant filler of the
A/C pipeline and read the A/C system pressure. See Fig. 10.2 for the normal system pressure