ACY-2H MANUAL

Foreword This manual provides users with a generalized overview and theory of

operation of various components and systems on the ACY-2 scooptram. It

also covers all routine service by service hour maintenance interval .By

using this manual you will be able to understand how complex systems

work, how to troubleshoot problems in operation, and how to remove

safely and effectively and how to replace worn or damaged components.

This manual content maybe different from the products improved in

future because of product’s improvement and enhancement. Since many

reasons restrain, we cannot inform every user about it, please every user

understand.

To give you better service, if you find any question, you can feedback

to us with it and its improvement advice when you use this manual. We

will be gratitude very much!

If there is any mistake or shortcoming, please criticize and conduct. . Anchises corporate in Beijing 2007.3

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Catalog

Chapter one summary....................................................................................6

1.1 Entire Vehicle Mainly Configuration..................................................................................6

1.1.1 Engine........................................................................................................................6

1.1.2 Hydraulic Torque Converter ..........................................................................6

1.1.3 Kinetic Change Gear Case ..............................................................................6

1.1.4 Axle ............................................................................................................................6

1.1.5 Brake System.........................................................................................................7

1.1.6 Hydraulic System ................................................................................................7

1.2 Entire Vehicle Mainly Capacity Parameter........................................................................7

1.2.1 Entire Dimension.................................................................................................7

1.2.2 Vehicle Weight And Axle Load.....................................................................8

1.2.3 Running Capacity ................................................................................................8

1.2.4 Hydraulic System ................................................................................................8

1.2.5 Oil Tank....................................................................................................................8

1.2.6 Electric System .....................................................................................................9

1.2.7 Operator’s Arrangement...................................................................................9

1.2.8 Steering.....................................................................................................................9

Chapter two Scooptram Operating.........................................9

2.1 Safety Regulation ..................................................................................................................9

2.2 Pre-Startup Check And Maintenance ...............................................................................10

2.3 Pre-Startup Check Term....................................................................................................11

2.4 Poststart Check And Maintainment..................................................................................11

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2.5 Engine Startup.....................................................................................................................11

2.6 Engine Choke.......................................................................................................................12

2.7 Poststart Operating.............................................................................................................12

2.8 Engine Malfunction Diagnosement And Eliminatement .................................................13

2.9 Scooptram Operating..........................................................................................................15

2.10 Scooptram Shutup.............................................................................................................15

Chapter three every mainly part structure and

maintenance....................................................................................................................16

3.1 Transmission System...........................................................................................................16

3.1.1 Axle...........................................................................................................................17

3.1.2 Transmission Shaft............................................................................................18

3.1.3 Tire, Rim ................................................................................................................19

3.2 Hydraulic Systems...............................................................................................................20

3.2.1 Hydraulic System Component ....................................................................20

3.2.2Fluid That The System Uses..........................................................................22

3.2.3 Fuel Tank Of The Hydraulic Pressure .....................................................23

3.2.4The Changing Of Hydraulic Oil ..................................................................24

3.2.5the System Exhausts ..........................................................................................24

3.2.6Systematic Accident Analysis Of The Hydraulic Pressure And

Safeguarding ....................................................................................................................25

3.3Electric system......................................................................................................................27

3.3.1Power system ........................................................................................................27

3.3.2Start system............................................................................................................27

3.3.3Lighting system....................................................................................................27

3.3.4Signal system ........................................................................................................27

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3.3.5Instrument system...............................................................................................27

3.3.6Electric circuit.......................................................................................................28

3.3.7Precautions of using of the regulator of the current alternating

generator ............................................................................................................................28

3.3.8The trouble preventing .....................................................................................29

3.3.9Accident analysis and Remedial method.................................................29

Chapter four Maintenance and maintenance of the

scraper....................................................................................................................................31

4.1 Generally safeguard the step and method of maintaining the work regularly:.............31

4.1.1Wash the machine ...............................................................................................31

4.1.2 Put lubricating oil ..............................................................................................31

4.1.3Antirust and protect............................................................................................31

4.1.4Change the part ....................................................................................................31

4.1.5The circuit maintaining ....................................................................................32

4.1.6check the oil level ...............................................................................................32

4.1.7Change the oil .......................................................................................................32

4.1.8Check the seal and its surface .......................................................................32

4.1.9Check and lock the component ....................................................................32

4.2 General unscheduled maintenance and project maintained ...........................................32

4.3 Safeguard and maintain tabulating regularly ..................................................................33

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Chapter one summary The ACY-2 Scooptram consists of a Power Frame and a Load Frame connected by

an articulating joint that permits 40-degree turns, in combination with an oscillating joint that permits the units to tilt relative to each other to accommodate uneven surfaces. The Power Frame includes the diesel engine and a power shift transmission.

The boom, the bucket, and the front axle are mounted on the load frame. The bucket may be either of a standard design or an eject-o-dump design consisting of a push plate assembly controlled by the operator. The entire vehicle is designed for maximum durability and easy maintenance.

1.1 Entire Vehicle Mainly Configuration

1.1.1 Engine

Production Factory DEUTZ corporate in Germany Model BF4M1013C Type 2-stage combustion water cooling diesel

Power Rating 63kw

Maximum Torque 275Nm

1.1.2 Hydraulic Torque Converter

Production Factory DANA corporate in American Model C272-300 Type with hydraulic pump

1.1.3 Kinetic Change Gear Case

Production Factory DANA corporate in American Model R32366 Type KINETIC CHANGE GEAR Number 6(forward 3 backward 3)

1.1.4 Axle

Production Factory Xuzhoumeichi-Beijing Anchises

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Model NO-SPIN against sliding differential planetary transmission axle

1.1.5 Brake System

Component Working Brake Stopping Brake

Note Spring-Applied, Hydraulically Released;

Fully Enclosed, Force Cooled Multiple Wet

Discs at Each Wheel End Parking and

Emergency shutdown.

1.1.6 Hydraulic System

Component Working Steering Brake

Chang Gear Supply Oil

Note Mainly Sections From Abroad

1.2 Entire Vehicle Mainly Capacity Parameter

1.2.1 Entire Dimension

Load Rating 4000kg

Entire Dimension Figure See Figure 1

Entire Long (Bucket Lay Down) 6820mm

Entire Width 1770mm

Entire Height 2100mm

Bucket Volume (Nominal Heaped) 2m3

Bucket boom Raise Time 5.6s

Bucket dump Time 6.4s

Maximum Raised Height 4218mm

Maximum dump HEIGHT 1743mm

Dump Distance 900mm

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Dump ANGLE 40°

Axle Distance 2525mm

Tread 1373mm

Minimum gap away field ≥250mm

away angle 15°

1.2.2 Vehicle Weight And Axle Load

Empty 12500kg

Front Axle Load (empty) 5625kg

Rear Axle Load (empty) 6875kg

Full Loaded 16500kg

1.2.3 Running Capacity

Processing Speed

1st Gear Forward/Reverse 0～4.76km/h

2nd Gear Forward/Reverse 0～9.4km/h

3rd Gear Forward/Reverse 0～18.4km/h

Gradeability 34%（1st Gear 1.2km/h）

1.2.4 Hydraulic System

Working System See Figure 2 Pressure rating14mp

Steering System See Figure 2 Pressure rating 14mp

Braking System See Figure 3 Pressure rating 12.5mp

Chang Gear Supply Oil System See Figure 4

1.2.5 Oil Tank

Fuel Tank (L) 100

Hydraulic Tank 132

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1.2.6 Electric System

System Voltage 24 Volt Starting, 24-Volt Accessories

Electric Theory See Figure 5

1.2.7 Operator’s Arrangement

Side Seated Operator For Bi-Directional Operation Maximum Visibility

1.2.8 Steering

Central Joint Hydraulic Kinetic Steering

Steering Angle ±42 Degree

Minimum Volv Radius Inside 2500±150mm

Outside 4800±250mm

Chapter two Scooptram Operating Operating scooptram in safety and norm is good to ensure its lifetime and reduce its

broken-down, please users operate comply with manual.

2.1 Safety Regulation

2.1.1 before you start the engine and operate this vehicle make sure you have read and

understood the operation of the vehicle. Make sure you have read and understand all

the safety messages in the operator’s manual, safety manual and the safety decals on

the vehicle. It is your responsibility to understand and follow the manufacturer’s

instructions on vehicle operation, service, and safety.

2.1.2 implement special person to drive scooptram, forbid anonymous person to operate.

2.1.3Never drive with illness; every section should be retained clean and prevented

from leakage.

2.1.4 never operate an engine with explosion and combustion easily such as dynamite.

2.1.5 tool and working place should be clean.

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2.1.6 make sure depress park brake knob when parking; if the engine is parked on the

ramp the tire should be used plate against.

2.1.7 never smoke when fill oil.

2.1.8 stand on safe space when inflating the tires.

Forbid to stand here

2.2 Pre-Startup Check And Maintenance

2.2.1 Check oil level in diesel and change gear case basin; check oil level in diesel case and hydraulic oil case; check oil level in electricity flask, supply immediately if its level is below the add mark on the dipstick and change it if it is polluted. 2.2.2 Check the seal about the oil pipe and joint and other sections, deal if there is any trouble. 2.2.3 Check whether the operating, steering and brake system can operate smartly and safely, make sure no any potential danger. Move the steering linkage lever to the NEUTRAL position. 2.2.4 Check bolt and nut in every section especially in change gear case, diesel, drive shaft, drive axle, tyre and so on. Wrench tightly or change immediately if they are loose or crack. 2.2.5 check the diesel fan and the engine belt loose degree. 2.2.6 Check hydraulic hose, wires that are located firmly and cannot lie on the exhaust pipe or drive shaft. 2.2.7 check whether there are unwelty or crack in welt section. Especially pay

attention to the joint, axle bracket and beam welt section.

2.2.8 Check whether there is any damage about oil nozzle in lubrication mark, and

regulate to fill lubricating oil.

2.2.9 Check the pressure in tires, fill air until arrive to the regulated value (front wheel:

0.68 Mpa rear wheel:0. 414Mpa).

2.2.10 Pre-Startup in first time, manipulate the hand pump and excel air in the fuel

system.

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2.3 Pre-Startup Check Term

2.3.1 Fuel oil level

2.3.2 Engine oil level

2.3.3 Change gear case oil level

2.3.4 Cooling fluid level

2.3.5 all parts tightening

2.3.6 Pressure in tire

2.3.7 Operating in brake

2.3.8 Steering operating

2.3.9 Lighten system

2.3.10 all operating parts and control apparatus function

2.4 Poststart Check And Maintainment

2.4.1 check the working parts near to floor.

2.4.2 Park on dry and plane floor. Don’t allow the drive cab to face the material side

on ramp.

2.4.3 depress the switch off.

2.4.4 move the entire operating column to NEUTRAL position.

2.4.5 disconnect the Electricity Switch.

2.4.6 clean the Machine.

2.4.7 check whether the machine figure damage and whether any bolt and nut is loose.

2.5 Engine Startup

2.5.1 shut the Switch

2.5.2 Move The Change Gear Handle to Neutral Position.

2.5.3 Insert Key and turn Startup Switch to “1” Position.

2.5.4 If need Pre-heat, turn startup switch to “2” position for several seconds (pay

attention to the pre-heat lamp lighting). When the pre-warm lamp is extinguish, at the

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same time turn the startup switch to “3” position for 2-3 seconds and turn the startup

switch to “1” position immediately. If the engine hasn’t been started, start it following

the above steps 1 second later.

2.5.5 as soon as the engine starts, release the pedal lightly to make the engine run

smoothly in medium speed. Warning: don’t allow overpass 10 seconds once starting,

if need repeat the starting process. Before starting again, make 1-minute interval.

2.5.6 after the engine start, please check whether the instructor light is on

2.5.6.1 instrument lamp

2.5.6.2 brake oil pressure

2.5.6.3 engine oil pressure

2.5.6.4 torque converter oil pressure

2.6 Engine Choke

2.6.1 depress “chock button”. When engine stops working, filling electrical instructor

lamp will relight.

2.6.2 depress “stop button”.

2.6.3 disconnect the outlet. If the temperature is lower than –30 degree outside, carry

the battery inside in case of freezing.

2.6.4 without emergency, not allow engine stop suddenly from full loads. Cool engine

first then stop.

2.6.5 Stop engine immediately and make sure the reason if “the filling instructor

lamp” or “engine pressure” lamp is on. If “bucket temperature” beacon is light,

stop the scooptram working and make the engine come to cool, make the engine idle for

minutes then stop.

2.7 Poststart Operating

2.7.1 Never turn the ignite key to disconnect position after the engine start.

2.7.2 make the engine run in situation after the engine starts and drive in gear until the

pressure and temperature arrive to the criterion.

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2.7.3 Pre-heat the engine to 30~40 degree starts the engine in low temperature zone or

in winter.

2.7.4 See the detail operating and manipulate: random “engine manual”.

2.8 Engine Malfunction Diagnosement And

Eliminatement

Reefing to the following chart to diagnose the usual malfunction except checking

whether the fuel tank and fuel pipe is leakage.

The malfunction-contrasting chart:

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trouble Remedial measureengine fails to start

runs unevenly or stall check CHengine becomes too hot, temperature monitor gives warnadjust A

Renew Rclean CLtop up TU

engine oil consumption exessive lower level LLengine smoke -blue

-white -blackcause section

★ not declutched(where possibleoperation CH★ ★ below start limit temperature CH★ ★ engine shut-down level still in stop positio CH

★ ★ oil level too low TU★ ★ ★ ★ oil level too high LL

★ ★ ★ excessive inclination of engine CH★ ★ ★ wrong SAE-grade of engine o op.Media R★ ★ ★ ★ fuel quality grade not as specified in operaR

★ ★ ★ air cleaner contaminated combustion R★ ★ ★ indicator/switch defective R★ cooling fins soiled cooling syst CL★ cooling air temperature rise /hot air recircuCH/R★ cool wind temperature is too high/intake hCH★ oil cooler soiled Ch/Cl

★ bettery defective/flat electrics CH★ loose or oxidized CH★ starter faulty or pinion does not engage CH★ ★ ★ ★ ★ valve clearances incorrect engine A

★ ★ ★ injectionline leaky CH★ ★ ★ ★ ★ ★ ★ injector defective CH/R★ ★ ★ air in fuel system CH★ ★ ★ ★ diesel filter/start filter is choked ch/cl/r

★ oil in combustion case Ch/Cl

engine give poor performanceengine not working on all cylinders

engine has little/no oil pressure

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2.9 Scooptram Operating

2.9.1 Sound the horn to warn all persons that you are going to start the engine.

2.9.2 Release the park break before startup.

2.9.3 drive the scooptram to stop away the material pile for 1 meter about, make the

bucket toward the material pile. Operate the change gear handle to move the change

gear case toⅠgear.

2.9.4 operate the liter oil tank handle to descend the big boom to the lowest position.

2.9.5 move the handle to place the bucket to the insert position toward material pile.

2.9.6 Press the accelerate pedal to the floor, drive machine toward mineral (or rock

pipe), insert the bucket to the material pile until the wheel slither. The dump and hoist

lever controls the bucket and boom. Moving the lever toward the operator raises the

boom. Move the hoist lever away from the operator to lower the boom. Make the

bucket insert and dump until the bucket fills.

2.9.7 Drive the scooptram to the dump skip, raise the boom to the demand height

(toward ore car, mobile or well), and align to the container receiving the ore. Move

the handle to make the bucket turn down to pour ore.

2.9.8 Retreat the scooptram and lay down the boom, make the bucket to the

transportation situation, then drive the machine to the mineral pipe.

2.9.9 Never suspend the front wheel when bucket insert to the mineral pipe. If find the

front wheel is suspended, raise the bucket properly in order to touch well between the

front wheel and floor, to ensure the enough insert press.

2.9.10 Change gear when driving, needn’t stop and press brake pedal. If change from

the high speed to low gear then release the oil pedal and then change gear. If change

the driving direction (forward to reverse or reverse to forward), then move the change

gear handle to neutral position and then change gear latter.

2.10 Scooptram Shutup

2.10.1 Scooptram should park on entire plate and dry horizontal floor. If park on the

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ramp, make triangle mood to tighten the wheel and close the hand brake.

2.10.2 the park steps:

①lay down the boom and bucket

②move the change gear handle to the neutral position

③engine shutup and pull out the ignite key

④disconnect the outlet

2.10.3 implement the following work if the scooptram parks for a long time:

①move the operating handle to the neutral position

②retract all hydraulic oil tank

③cover the machine cap with white or lucent cloths and efface (butter) to the

exposure of piston stick and the joint.

④unfasten the battery and store it in a dry room about 20 degree.

Chapter three every mainly part structure and

maintenance ACY-2 includes 6 sections: engine system, transmission system, front engine

mount assembly, rear engine mount assembly, hydraulic system and electric system.

This chapter mainly introduces the structure and maintenance in transmission,

hydraulic and electric system. Please consult the <<operation and maintenance

manual>> the factory supply about the detail structure and common maintenance in

buying parts such as engine, change gear case, torque converter and drive axle,

hydraulic pump and valve. This chapter will not give any instruction.

3.1 Transmission System

Transmission system mainly consists of torque converter, change gear case and

drive axle, transmission shaft. Torque converter connects with pump wheel by the

engine flywheel, then output gear output by 2-turbo and connect the change gear case

output drive gear by transmission axle, then change gear case put the emotion to the

rear and front axle by transmission axle.

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3.1.1 Axle

To increase the drive force and improve the working capacity, ACY-2 scooptram

adopts double drive axle and four-drive wheel. Front axle equips NO-SPIN against

sliding differential .In order to fit for the hardship environment, both rear and front

axle equip brake system with Spring-Applied, Hydraulically Released; Fully Enclosed,

Force Cooled Multiple Wet Discs at Each Wheel.

Power from the diesel engine is transmitted directly from the engine flywheel to

the torque converter. The converter output shaft transmits the power via driveline to

the transmission input shaft. The transmission output shafts transmit power via

drivelines to the front and rear differentials. The bevel gear and bevel pinion of each

differential transmits power through the differential to the free-floating axles. The

planetary final drive sun gears are splined to the axles. As the axles rotate, planet

gears mounted in the carrier are forced to walk around the stationary gear, imparting

rotation to the hub and wheel, which is attached to it. 3.1.1.1Decelerator by the wheel

The decelerator is one planet gear transmission organization by the wheel,

enclose and link one and fix on the axis of supporting by the wheel through a gear

wheel with interior tooth. Planetary shelf and rim are fixing and rotating together. Its

sport was got through the semi-axis and the sun wheel. Task of it is to increase

transmission torsion of department and reduce transmission rotational speed of

department further, in order to obtain the suitable speed of wheel. 3.1.1.2Multiple Wet Discs brake 3.1.1.2.1Advantage of this brake:

① This brake is not affected by external temperature and dust, working

performance is steady, it is very little to wear and tear, needn't generally change

while using.

② The annular work areas is large, have bigger making motive force torque.

③ Heat dissipation is effectual in cooling, it is reliable to apply the brake steadily

and its working temperature is low. It has long performance life generally for

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3-5 times of the dry type brake.

3.1.1.2.2 the maintenance of the brake is checked

① Whether check the brake shell and overlay have crack, nick and whether spline

that are worn and torn excessively, change it if necessary.

② Checking the regular one of brake, pressing one, thrust one, rubbing one etc.,

they should totally level and have no burr, crack, nick, shave wounded，fritting

etc., change it if necessary.

③ As rub disc of thickness is smaller than 4mm, or surface cannelure depth is

smaller than 0.2mm,and locating disc of thickness is lighter than 2.5mm, should

change it.

3.1.2 Transmission Shaft

The ACY-2 scooptram has five drive shafts: the changing speed drive shaft link

torque converter and gearbox; rear axle drive shaft link the gearbox fronts output

flange and rear drive axle; middle drive shafts link gearbox back and transaxle

bracket; the front axle drive shaft link the transaxle and front axle flange.

When the scooptram runs, the drive shaft should bear very big torsion and

impact, in addition, the condition of work is very abominable, so must carry on

serious maintenance and maintenance to the drive shaft, please pay attention to the

following several points while installing and using:

① Assign at horizontal plane drive shaft per section. There is a certain skew

angle between the change speed transmission shaft and rear front axle

transmission shaft at horizontal plane. Must guarantee installation that the

universal joint of both ends of each drive shaft lies in the same level

② When spline axle works, frequently slipping fork does the axial motion.

The cross axle is that the high speed and heavily loaded moveable piece in

addition, must lubricate regularly according to the regulation. Spline axle

oil seal prevents lubricating oil from overflowing and soaking with muddy

water, dust, must keep it intact.

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③ To dispel unequally transmission to final drive and prevent drive shaft

producing additional vibration and impact the gear wheel in drive axle.

Drive shaft joint yoke of both ends lay the same level. Carry on dynamic

equilibrium test and have arrow indicated already. While unpicking and

washing and repairing, pay attention to not destroying balance.

④ The apt and limit measurement of wearing and tearing the position of the

drive shaft is: the biggest interval between the spline axle and sliding fork

spline tooth side is 0.03mm; the biggest interval of the bearing underport

and cardan bearing is 0. 052mm; the biggest interval of cross axle and

bearing underport is 0.052mm.

⑤ The drive shaft must be overhauled while wearing and tearing allays to the

size of above-mentioned limit or change.

3.1.3 Tire, Rim

Tire, rim main walking part of machine. Tires in that machine use 12.00-24, 20

level smooth plane with inner tyre. Section size is heavy and elasticity fine, little than

pigeonhole earth have and has good wear-resisting performance

Dismantlement and resolving of the tire, rim:

① Support the frame with the jack or the support; make the transaxle leave the

ground. Unscrew the oil screw plug in the decelerator and brake by turning on

final drive, wheel and the net to let out lubricating oil among them.

② Put atmospheric pressure of tire to the same as environmental atmospheric

pressure, back out rim nut of bolt, pull down the tire and rim from transaxle.

Choose and open the lock ring, unload block enclosing and outer fringe then pull

down the tire, thus can resolve it.

③ Back out the planetary shelf and set bolt of the rim, carry the planetary shelf

from hub to loose with the top cover screw (M12) and hang and put a shelf of

planet to become always.

④ Take the sun wheel and semi-axis out.

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⑤ Unscrew the interior wheel lock bolt and take down the lock plate then take

down interior tooth enclose.

⑥ Fasten and open the nut, take down the tooth and enclose locating one.

⑦ Rock and hang and put down the hub gently

⑧ After the tire and rim are assembled, guarantee safely inflates.

3.2 Hydraulic Systems

3.2.1 Hydraulic System Component

ACY-2 scooptram consists of working hydraulic system, steering hydraulic

system, braking hydraulic system and change gear supplying oil hydraulic system.

3.2.1.1 steering and working hydraulic system

Hydraulic oil is supplied by the dump/hoist pump on the converter directly to the

dump/hoist main control valve. The system also receives additional flow from the

steering system. With monostick steering, oil flows through the Steering Control

valve from the high-pressure carry over (HCPO) port and through the Priority valve

from the excess flow (EF) port to the dump/hoist Main Control valve. With orbital

(Wheel) steering, oil flows from the power beyond (PB) port of the Steering Control

valve to the dump/hoist Main Control valve. The Pilot Control valve, located in the

operators cab, using 14MPa pressure supplied from the Pilot Pressure valve,

hydraulically operates the Main Control valve. The operator control lever directly

operates the Pilot Control valve. Oil travels from the Main Control valve to the boom

and dump cylinders. 3.2.1.2 braking hydraulic system

Braking hydraulic system includes Brake pump, SAFIM filling fluid Uncharging

valve, SAFIM foot brake valve .The above-mentioned components belong to the

international advanced products. In order to maintain the systematic pressure and

guarantee that the completed car can be dragged away from the job place when the

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engine breaks down, set up three device of holding energy which pressure is keeping

by the unload valve and its pressure range is 13-15MPa.

The characteristic of this system is the hydraulic pressure applies the brake and the

spring is released when driving a vehicle. If apply the brake, step on the brake pedal.

Then the pressure oil that the valve outputs is transmitted to the wet DISC brake, thus

realize brake. Oil pressure that output in direct radio journey under with pedal valve.

When all step on, the oil pressure that the pedal valve outputs reaches the maximum

designed, the complete machine is in the state of totally applying the brake.

In order to guarantee it while driving a vehicle park and apply the brake to totally

release, set up the pressure relay. When lower than the pressure of releasing in

pressure, the indicator lamp in the cab will give warning. 3.2.1.3 Change speed and mend the system of hydraulic pressure of oil

Mend oil hydraulic pressure system consists of mend oil pump, pressure regulating

valve, direction choose valve, gear choose valve, oil filter and cooler etc., main

hydraulic pressure component except the cooler is offered by DEUTZ Company, the

others are offered by DANA Company. Maintenance and maintenance working

content of system see former factory offer " the use safeguard manual ".

3.2.1.3.1 the pressure oil supplied device

Torque converter support oil gear wheel pump is installed in Torque converter,

driven by the diesel engine. The suction oil pipe links with oil bottom shell of gearbox,

output oil pipe connect with torque converter by 10um precision oil filter.

3.2.1.3.2 torque converter Control and mend the oil in oil pressure

The pressure of oil the pump output is control 1.76~1.96Mpa by the pilot valve

installed in the torque converter. The pressure is the need of gearbox rub clutch work.

Gear wheel oil that pumps discharges mend oil is mainly to the gearbox lubrication

and the gearbox to handle. It is extremely essential to go on to cool because of hot

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load the torque converter device produce. Pump wheel and turbine use the aluminium

alloy to make, and a relief valve prevents the inside pressure from being too high.

Leakage oil from the torque converter concentrate to oil bottom shell, and through one

hose flow back to the gearbox. In attention, the oil from the spray nozzle to lubricate

the gear in torque case flow back into oil bottom then back to gearbox.

3.2.1.3.3Directional control of the gearbox

Gearbox changes gear by many slice rub clutch. Oil consumption is low and

invariable. Multi-plate clutch doesn’t clench at ordinary times. The pressure oil that

the valve supplies flow through the valve out of supply of the clutch at first, and then

enter clutch. After carrying on brake, this valve cut of the pressure oil to reach the

clutch and make the clutch unclamp. Scooptram go advance or go backwards through

manual choose valve move position to control. Because of the function of the pressure

oil, after the clutch of a direction clenches, the other clutches are uncoupled because

of there is no pressure oil.

3.2.1.3.4Cooling of the oil and lubrication of the gearbox

The oil from the torque converter is too high and need to cool by cooler in order to

prevent oil from excessively high to making oil wear out and damage bearing too

early. The oil cooled flows and lubricates gear wheel and bearing to gather the shell of

oil bottom of gearbox. Every oil pipe, Cooler and lubricate distributor obstruction

make oil produce sure pressure lower, prevent the torque converter from air corrosion

phenomenon

3.2.2Fluid That The System Uses

3.2.2.1 Hydraulic oil

Machine adopts L-HM46 symbol or L-HV46 hydraulic oil; the complete machine

uses about 132 liters of oil. While using other oil to replace, need to meet the

following technical indicator:

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When the 50 degree, sport viscidity then 40 lics

Glue temperature index≥95

Condensation point is lower than - 20 degrees Centigrade

Clean and spend more than 10 grades (NAS1638)

3.2.2.2Hydraulic transmission oil

Hydraulic transmission oil No. 8

3.2.3 Fuel Tank Of The Hydraulic Pressure

The fuel tank of the hydraulic pressure is the oil storage device offering the

hydraulic oil for hydraulic pressure system. It is made up of several following parts

mainly: Case body, go back oil filter, air filter (and concurrently fuel-injection mouth),

wash oil mouth, liquid location instruction count, put oil mouth, suction oil pipe

package, etc. 3.2.3.1 the oil level checking

Is it should check oil level every 100-150 hour to work each time, for this reason,

all hydraulic pressure jar should withdrawal and engine stops working. Observing

liquid location height to count by location from liquid, in time the hydraulic oil should

be supplemented originally when being insufficient. 3.2.3.2 Oil filter

Containing two kinds of oil filter in the fuel tank, one is oil filter back to the oil

mounted on apron on the fuel tank; another kind of suction oil filter installed in the oil

device mouthing.

After the 20 hours to work and first change filter core. Work the second change

filter core after 100-150 hour work. Work each time after this to change and strain the

core in 400-500 hours and change and strain the core while changing hydraulic oil

each time. While straining the oil device seriously polluted, send news device to send

out signal point out and change and strain the core in time at this moment.

The method Strain and change the core:

A: the returns oil filter: Back out top cover and take out old filter core then change the

new core.

23

B: the sucks oil filter: Put off oil of fuel tank first, lift hand hole apron off, loose suck

oil the connect bolt to unclamp and back out the old one change the new one.

Before putting and covering, check hand hole cover and suck oil O-ring. If

damage, change it immediately. While enclosing O-ring to put, the surface should

apply some butter. 3.2.3.3Air filter

To keep hydraulic pressure normal pressure of fuel tank and clean degree, change

the core of the air filter in 400-500 hours to work each time. Before packing into and

straining the core newly, should check whether the sealed cushion is intact and wash it.

If sealed cushion is damaged, should change immediately. 3.2.3.4 the fuel tank washing

When work for 3000 hours and change oil, wash wall and bottom in the all fuel

tank with cleaner completely each time; While washing, not use the washing cloth

fluffing, must remove the cleaner clean finally. Before covering put hand hole, check

O-enclose intact and the ones that damaged should change immediately.

3.2.4The Changing Of Hydraulic Oil

3.2.4.1 put oil

Change hydraulic oil in 3000 hour to work each time, system should change the oil

at appearing great troubling in hydraulic pressure. When the hydraulic oil used queues

up and varies change the oil. While changing the oil, cylinder should all withdrawal.

Insert the funnel under the oil plug then loose open oil screw plug and puts all the

hydraulic oil in the fuel tank neatly. 3.2.4.1 irrigate oil

Turn on empty filter cover; pour into hydraulic oil to fuel tank. After pouring,

check the situation of the strain core pollute, change if necessary. Forbid sucking the

oil from the bottom of the barrel while irritating the oil.

3.2.5the System Exhausts

Carry on system exhaust after refueling. Start engine dally for 5-10 minute and

24

make every cylinder unloaded and flexible for several times in order to get rid of the

air in the system. Then make the oil level of final inspection and supplements in case

of necessity.

3.2.6Systematic Accident Analysis Of The Hydraulic Pressure And

Safeguarding

The accident analysis systematic in hydraulic pressure is the focal point of the

repair work of completed car and difficult point, need relevant maintenance personals

to deal with the scene, On the basis of consult relevant materials or ask about

maintenance engineers and technician to go to the accident analysis arranged forms

and deal with the measure, some experience summarized and summing up is as

follows:

The accident analysis systematic in hydraulic pressure and Remedial

method

Steering system

Trouble Cause Remedial method

The steering core of the valve

is blocked

① The fluid is polluted ②

There is booty or the valve core

that is damaged in the valve ③

Damage to hitting the spring

① Wash the valve body, change

the fluid ② Wash the valve body,

change the core of the valve ③

Change the spring Operation of changing direction

is ineffective ① The handle is not flexible ②

There is air in the system ① Repair or reinstallation ②

Exhaust systematically

The systematic pressure is too

low

① The steering pump breaks

down ② The systematic relief

valve sets the pressure low ③

The overload valve sets the

pressure low

① Repair or reinstallation ②

Adjust the systematic pressure

again ③ Revitalize

The systematic pressure

fluctuates

① There is air in the system ②

Hydraulic oil viscidity is abnormal

③ The fluid is polluted ④ The

work of the valve is unstable

① Exhaust systematically ②

Adopt the qualified hydraulic oil ③

Change the fluid ④ Repair or

change

25

Brake system

Trouble Cause Remedial method

the brakes do not have

pressure or the pressure is low

① The systematic pressure is

adjusted too low ② The pump

is out of order to apply the brake

③ hold the device out of order

④Hold device low to fill pressure

in advance

① Readjust the pressure ②

Repair or change ③ Repair or

change ④ Fill and press it to

7MPa

The foot a brake valve does not

work

① The foot brake valve body is

connected with footboard and

the bolt in the place becomes

flexible ② Hold the device low

to fill pressure in advance

① Revitalize ② Fill and press it to

7MPa

Park and brake does not work

① The systematic pressure is

adjusted too low ② The

electromagnetic valve is out of

order

① Revitalize the pressure ②

Repair or change

The pressure of the device is

unstable that can hold

① hold the device serve as the

pressure in advance low ②

hold the device leak the vapor

① Fill and press it to 7MPa ②

Repair or change

Job system

Trouble Cause Remedial method

The cylinder does not act ① the fuel tank liquid is low ②

The systematic pressure is low

③ Exceed load work

① Mend the oil ② Revitalize the

pressure ③ Reduce load

Movements of the cylinder are

slow

① The cylinder is out of order

② The systematic pressure is

too low ③ Mixed with the air in

the system

① Repair the cylinder ②

Revitalize the pressure ③ The

system exhausts

The hydraulic oil is warm and

too high

① Repair the cylinder ②

Revitalize the pressure ③ The

system exhausts

① Change and strain the core ②

Fill the hydraulic oil ③ Carry on

the hydraulic pressure system and

exhaust

The hydraulic pressure system

shakes the noise

① The oil level is too low ②

Mixed with the air in the system

③ suction oil pipe to stop up ④

Hydraulic oil emulsification goes

bad ⑤main overflow valve is

tremble.

① Check the oil level, fill the

hydraulic oil ② Carry on the

hydraulic pressure system and

exhaust ③ Check and suck the

oil and strain the core, change in

case of necessity ④ Change the

hydraulic oil ⑤Check the overflow

26

valve, change in case of necessity

rise jar is unable to lift

① The hydraulic pressure

pipeline is let out ② the

pressure is too low in the main

overflow valve ③The reversing

valve blocking

① Check the pipeline to let out ②

Adjust the overflow valve ③

Overhaul the reversing valve

3.3Electric system

3.3.1Power system

Battery 6-Q (A-165) 12V 2

Generator 28V 35A take the regulator

3.3.2Start system

· Starter 24V 4.8KW enclose the relay

· Key switch

· Resistance that preheat

3.3.3Lighting system

Light from beginning to end; Cab light

3.3.4Signal system

Include signal lamp and chime

3.3.5Instrument system

Engine oil manometer (number 1788)

Engine oil thermometer (number 3425)

The rotational speed hour instrument

27

Voltmeter –30~+30

3.3.6Electric circuit

Electric equipment connect in arallel, 24V is made one-way, negative pole put

up irons.

Consider the job electric current as well as consider the mechanical intensity in

choice of the circuit wire. To guarantee starter power give play, require circuit

every 100A electric current voltage produced lower exceeding 0.1-0.15V, so

this circuit adopts 50mm2 wire. Electrical wiring harness can't be played tight

very much, especially move round the acute angle in the corner.

3.3.7Precautions of using of the regulator of the current alternating

generator

Polarity cannot link by mistake unless discharge will pass and will burn out other

electronic elements of the regulator.

Battery has electric capacity function. It protect transistor. So the line of

generator"+" receive by battery" + " lead must be firm. The battery can absorb the

instantaneous over voltage to a certain extent, as follows:

Add the instantaneous over voltage on the generator and regulator

Cause Voltage value （V） Lasting time

The battery is connected

inside out

-12V 或－24V －

The battery contacting in

series

+24V －

Switch key disconnection ＋20～＋40V Several ms

The regulator Work ＋50～＋100V Several 100us

All load disconnection ＋50～＋150V 0.1～0.5s

Battery disconnection ＋50～＋100V 0.1～0.5s

28

Transistor regulator and generator wiring is the correct," F " of regulator and "-

" binding post separately with " F " of generator and "- "binding post meet, and

the two specification should be matched.

Do not promise the insulation of checking generator and regulator by exchange

voltmeter of Europe's form or 220V handily

While changing the diode, the power of the electric iron can't be greater than

45W

The generator ceases fire, disconnect the starting switch in time

At the time of the normal running of the generator, electric apparatus line is

removable

3.3.8The trouble preventing

If QF1 circuit breaker trip, engine preheat circuit and start control break down

If QF2 circuit breaker trips, the generator circuit breaks down.

If QF3 circuit breaker trips, the previous light circuit breaks down.

If QF4 circuit breaker trips, the back light circuit breaks down.

If QF5 circuit breaker trips, energy storage pressure switch or its signal lamp and

brake, stop working to stop, horn circuit break down.

If QF6 circuit breaker trips, jarhead thermometer and sensor, engine oil

manometer and sensor, rotational speed form, voltmeter, jarhead temperature

switch and engine oil signal lamp circuit break down.

Battery fuse wire fuses start cable electromechanical circuit break down.

Connecting wire unwell causes the resistance to increase, thus generate heat. Pull

down the terminal box to check and connect electrically.

3.3.9Accident analysis and Remedial method

Electric system accident analysis needs specialized electric engineers and

technicians to measure and deal with, the following are some common trouble, reason

and measure.

29

Lighting system and indicator lamp circuit part

Trouble Cause Remedial mention

The headlight and taillight

go out

① The bulb is out of order ②

The circuit takes off broken

circuit loose ③ QF3, QF4

circuit breaker trip ④ The

switch damaging

① Change the bulb ② Change

the bulb or tighten the connect ③

Change the wire, check whether

short out or not ④ Change the

switch

All indicator lamps are not

bright

① Battery switch disconnection

② Power shortage of the

battery

① Open the switch ② Charge

Some indicator lamps are

not bright

① The specific sensor is out of

order ② The specific indicator

lamp damaging

① Change the sensor ②

Change the indicator lamp

Incorrect indication

① Power shortage of the

battery ② The specific

indicator lamp damaging ③

The specific sensor is out of

order

① Charge ② Change the

indicator lamp ③ Change the

sensor

Alternating current generator section

Trouble Cause Remedial mention

The battery is charged

excessively

① It is high to charge the voltage

② Binding post earth of electric

brush ③ regulate the resistance

too big

① Change the voltage regulator

②Correct installation alternating

current generator ③ Check

and maintain The battery is too big in

power consumption ① It is excessive to charge ②

The shell of the battery is let out ① Check the alternating current

generator ②Change the battery

The battery can't keep

charging the state

① Connect and damage with the

wire ② The alternating current

generator damaging ③ The

battery damaging

① Wash , maintain or change

30

Chapter four Maintenance and maintenance of

the scraper Fixed maintenance and maintenance work depend on the operation of the vehicle

operates the number hour; it according to maintain regularly to go on hour to serve.

Because the driver's skilled degree of operation and maintaining the difference of

the situation to the scooptram, some spare parts of the machine can not be damaged

according to the same regulation, observe and maintain some spare parts irregularly.

4.1 Generally safeguard the step and method of

maintaining the work regularly:

4.1.1Wash the machine

Before beginning any work, wash the spare part lying in relevant working ranges.

Selecting cleaner and wash medium correctly depends on material of spare part. For

example rubber or electric apparatus part should wash to spray with benzene or steam.

4.1.2 Put lubricating oil

After the machine is washed, put the lubricating oil in all movable-bearing places. After lubricating oil, removing the excessive lubricating oil.

4.1.3Antirust and protect

Mend lacquer destroyed and surface damaged frequently.

4.1.4Change the part

Change the spare part damaged in order to prevent greater trouble from taking place

in time

31

4.1.5The circuit maintaining

The dangerous wire is joined well with the tool; go on in close down the switch cases

4.1.6check the oil level

After the machine operates for 15 minutes, check the oil level. While checking and

mobilizing the engine oil location. Suspend the machine on a smooth ground and go

on after the engine stop working for about 10 minutes.

4.1.7Change the oil

Only under hot car state, put oil from oil mouth and not remove the filter screen from

the fuel-injection mouth when refueling

4.1.8Check the seal and its surface

Check the damaged condition of the sealed component. If need changing, change the

sealed component damaged at once. Before reinstallation, wash the whole seal surface

and check install-sealed situation.

4.1.9Check and lock the component

When dismantle the part, pay attention to lock component (lock washer, the flat pin

etc.)

4.2 General unscheduled maintenance and project

maintained

⑴ Check the hydraulic pressure and oil level of the fuel tank.

⑵ Check all points lubricated situations.

⑶ Check case , lid , covering , plug , pipeline etc..

32

⑷ Check the tightening torque of the rim bolt.

⑸ Check the atmospheric pressure of the tire.

⑹ Check the function of the electric system.

⑺ Check the operate component and control the function of the instrument.

⑻ Check the function of the brake system.

⑼ Check the unload / raise the function promoted and turn to the hydraulic pressure

system.

4.3 Safeguard and maintain tabulating regularly

According to server time to maintain regularly figure 1:

Engine Safeguard the work

Measurement

Observation

Consult each other The hours of Operate Opinion

The eye depend on that

checks seepage 10 50 150 300 600 1200

Check and mobilize the

engine oil location

Check with the dipstick

by eye, need to add

fuel-injection /

Check firm junction, tube

and hose If need to tighten /

Check transferring speed

organization and

footboard stopping

device

/

Plan to carry on the

maintenance of the

engine according to the

maintenance of engine

manufacturers

Use the meaning of the symbol in the form: /: Real; X: need match.

According to server time to maintain regularly figure 2:

33

The hours of Operate Safeguard the job bridge,

the transmission

Measurement

Observation Consult

each other 10 50 150 300 600 1200 Opinion

The eye looks at and

checks the seepage

situation /

Axle: Changing with oil of

differential mechanism

See relevant chapters fill

the volume and technical

data with /

The changing of planet

gear oil

See relevant chapters fill

with the volume and

technical data /

Wash the air cleaner /

Check the interval that

the final drive inputs the

bearing of the gear wheel

Check the installing

flange in the drive shaft

with hands /

Transmission: Needle

bearing interval of the

Hooke’s joint Check on eye /

According to server time to maintain regularly figure 3:

The hours of Operate Maintenance Tire and wheel

Measurement

Observation Consult

each other 10 50 150 300 600 1200 Opinion

Check model and pressure

See technique date about inflating pressure

/

Check the destruction

situations of the tire and

the pattern profundity of

the tire

Check by eye /

Check the tightening torque in the rim

If need to tighten ，

tightening torque see in technique data

/

According to server time to maintain regularly figure 4:

34

The hours of Operate Maintenance Electric system

Measurement

Observation Consult

each other 10 50 150 300 600 1200 Opinion

Indictor instrument function、signal lamp、control component and illuminating system

/

Battery: check oil level. Put special battery fluid /

About the breaking-down of the cable

Check by eye /

According to server time to maintain regularly figure 5:

The hours of Operate Maintenance Working system

Measurement

Observation Consult

each other 10 50 150 300 600 1200 opinion

Check the interval of the bucket pin shaft

Check by eye

/

Check the interval of the boom pin shaft

Check by eye

/

Check the rotating joint pin shaft

Check by eye

/

Check the stabilized device/connecting stick of pin shaft interval (if have)

Check by eye

/

Unload device /

Check the bearing interval of scooptram bucket

/

Check the interval which rotates the pin joint bearing

/

Check rotator knuckle joint place fasten set bolt of device

If need to tighten，tightening torque see in technique data

/

According to server time to maintain regularly figure 6:

35

The hours of Operate Safeguard work

Steering and unload

Rise hydraulic pressure

Measurement

Observation Consult

each other 10 50 150 300 600 1200 opinion

Check the oil level of the

fuel tank

Count from liquid location

eye to check Flexible

cylinder

/

Check the seepage of

the junction, pipeline and

hose

If seepage, find out the

reason; If necessary,

would change the part

/

Check the steering

pressure

See the systematic

picture about test

pressure and

measurement

/

Changing the oil of fuel

tank See relevant chapters /

Change the returning

training core of oil filter

(strain tube)

Signal lamp is on or "

returning oil pressure "

indicator rise to 1.3 bar

most late in 300 after

operating hour. See

relevant chapters

/

According to server time to maintain regularly figure 7:

The hours of Operate Safeguard the work

torque converter and

gearbox Hydraulic part

Measurement

Observation Consult

each other 10 50 150 300 600 1200 Opinion

Check oil level

Make engine in operate

temperature to turn

round, test with oil chi or

gearbox oil spiral plug

check to look at.

/

Check the seepage

situations of the tube,

hose junction

If seepage, find out the

reason; If necessary,

would change the part /

Wash the oil cooler

Blow the tube by

compressing the air,

make it cross the tube /

Change the hydraulic oil

filter See relevant chapters /

Change oil See relevant chapters /

36

Clear up the oil filter in

the fuel tank See relevant chapters /

Check the interval of the

bearing: torque

converter output and the

gearbox output and

input

Manual on the flange of

the drive shaft /

Clear up the torque

converter to device - the

air vent hole of the

gearbox

/

Check the pressure of

the clutch

See the systematic

picture about the test

pressure /

According to server time to maintain regularly figure 8:

The hours of Operate Maintenance

Brake system

Measurement

Observation Consult

each other 10 50 150 300 600 1200

Opinion

Check the function of the

stopping brake and the

working brake

/

Check the seepage

situations of the tube,

hose junction

If seepage, find out the

reason; If necessary,

would change the part

/

Check the pressure of

the brake or check

respectively.

Daily test pressure

instrument (sensor). See

the systematic picture

about the test pressure

/

Text the brake with

recorder

The slope of car fully

loaded with the vehicle

stay: working brake

minimum 35%, park

minimum 25% of brake

/

Check the stop brake

install (installment: See the relevant chapter /

Multi-disc brake

/

Check the wearing away

situation of the brake Estimating a brake, the

minimum brake one is

lined with thickness 3mm

/

Check the wearing away The minimum thickness /

37

situation of working brake of brake slice isn’t

smaller than 3mm on

the brake disc and drum

brake

/

Change the filter input oil According to the

maintenance /

Check pressure of all

brake system

See the system picture

about test pressure /

According to server time to maintain regularly figure 9: The hours of operating Maintenance

Lubricating point Measure observe See each other 10 50 150 300 600 1200

Note

Drive shaft： converter－gearbox

Butter pump nozzle /

Drive shaft： gearbox－front axle

Butter pump nozzle（three） /

Drive shaft： gearbox－rear axle

Butter pump nozzle /

Swing rotation axis Butter pump nozzle /

Central knuckle joint

pivot Butter pump nozzle（tow）

The steering cylinder Butter pump nozzle（tow）

Rising cylinder Butter pump nozzle（tow） /

The tumble cylinder Butter pump nozzle（tow） /

Stabilization plant pole

(prop up the foot) Butter pump nozzle /

Big boom- connecting

rod Butter pump nozzle /

The big boom rotates

bearing Butter pump nozzle /

Big boom － bucket bearing

Butter pump nozzle（tow） /

Working operating shaft

Butter pump nozzle（tow） /

Steering operate shaft Butter pump nozzle /

38

Gearbox operating shaft

Butter pump nozzle（five）

Position that all joints

move about HD－engine oil /

.

39

Figure 1

40

Figure 2

41

R

R2

N

T2

T2′

T1′

T1

R1

Figure3

42

Figure 4

43

Figure 5

44