Beruflich Dokumente
Kultur Dokumente
SERVICE MANUAL
Introduction
CONTENTS
9 Working Hydraulic System.................................................................................9-1
91 System Principle Description..............................................................................9-1
92 Description, Disassembly and Assembly of Hydraulic System Components.....9-2
921 Working Pump.............................................................................................9-2
922 Hydraulic Oil Tank......................................................................................9-8
923 Multitandem Valve....................................................................................9-15
924 Hydraulic Cylinders..................................................................................9-29
93 Service Precautions for Working Hydraulic System.........................................9-48
94 Testing and Adjusting of Working Hydraulic System Pressure........................9-51
941 Measuring and Adjusting of Main Safety Valve Pressure.........................9-51
942 Measuring and Adjusting of Overload Valve Pressure..............................9-53
95 Diagnosis and Solutions for Common Faults of Hydraulic System..................9-55
951 Unexpected Forward Tilt of Bucket..........................................................9-55
952 Boom Sinking............................................................................................9-56
953 Boom Rises Slowly...................................................................................9-58
954 Lifting Incapacity of Boom.......................................................................9-60
955 Bucket Slow Motion..................................................................................9-60
956 Working Incapacity of Bucket...................................................................9-60
Components
921
Working Pump
Technical parameters
Theoretical displacement
160ml/r
2350r/min
Rated pressure
18MPa
Connecting type
Rectangular spline
2 Retainer ring
3 Antifriction bearing
5 Front cover
6 Bearing
8 Gasket
14 Rivet
17 Bolt
15 Label
Working pump is double gear pump. It is composed of front pump cover, rotating seal shaft, seal
ring, O-shape seal ring, side plate, pump body, bearing, rear pump cover, driving gear and driven
gear.
P
A
Working principle
When pump shaft rotates as Fig. 9-3, the gear
demeshes on oil absorption chamber side, oil
9-2
2
3
4
Fault phenomenon
Cause
Elimination method
ATTENTION
Before dismantling the working pump, be sure to carefully read 93 service precautions for
working hydraulic system.
9-3
Pressure relief.
Start the machine and drive it to the flat
spacious place. Raise the boom to the highest
position. Tilt the bucket backward, and then
shut down the engine.
Push the control handle of the pilot valve
towards right slowly. Let the bucket tilt
forward gently to drain the oil in bucket
cylinder.
Fig. 9-4
Fig. 9-5
1 Mat
2.
3.
4.
plate in the cab, and then take down the plateseat assembly down.
1
Fig. 9-6
1 Maintenance cover plate
9-4
5.
1
Fig. 9-7
1 Working pump oil absorption steel pipe
6.
1
Fig. 9-8
1 Working pump oil outlet steel pipe
7.
1 2
Fig. 9-9
1 Pump sealing gasket
2 Nut
9-5
755 Nm
ATTENTION
1
Fig. 9-11
1 Working pump oil outlet steel pipe
3.
1
Fig. 9-12
1 Working pump oil absorption steel pipe
9-6
4.
Install
the
maintenance
cover
plate-seat
1
Fig. 9-13
1 Maintenance cover plate
8.
Fig. 9-14
1 Mat
922
It is used to provide oil to the whole hydraulic system. An oil return filter is designed in the tank to
ensure the cleanliness of hydraulic oil. Hydraulic oil filters should be replaced periodically
according to requirements in related manual.
9-7
To breather
ATTENTION
Before dismantling the hydraulic oil tank, be sure to carefully read the 93 Service Precautions
for Working Hydraulic System in this chapter.
Disassembly of hydraulic oil tank
9-8
Pressure relief.
Start the machine and drive it to the flat
spacious place. Raise the boom to the highest
position. Tilt the bucket backward, and then
shut down the engine.
Push the control handle of the pilot valve
towards right slowly. Let the bucket tilt
forward gently to drain the oil in bucket
cylinder.
Fig. 9-16
3.
1
1
Fig. 9-17
1 Oil drain plug
4.
1
Fig. 9-18
1 Left platform
1
9-9
1
Fig. 9-19
1 Left platform
5.
6.
1 2
3 4
5
Fig. 9-20
1 Radiator oil return steel pipe
2 Working pump oil absorption hose
3 Steering pump oil absorption hose
4 Breather hose5 Pipe clamp
9.
1 2
Fig. 9-21
1 Oil return block2 Bolt
9-10
Fig. 9-22
11. Remove
the
connecting
bolts
between
Fig. 9-23
1 Bolt
1
Fig. 9-24
1 Bolt
9-11
2.
Fig. 9-25
1
Fig. 9-26
1 Bolt
Fig. 9-27
1 Bolt
3.
1 2
3 4
5
Fig. 9-28
1 Radiator oil return steel pipe
2 Working pump oil absorption hose
3 Steering pump oil absorption hose
4 Breather hose5 Pipe clamp
9-12
6.
1 2
Fig. 9-29
1 Oil return block2 Bolt
7.
1
Fig. 9-30
1 Left platform
Fig. 9-31
1 Left platform
1
9-13
8.
Fig. 9-32
923
Multitandem Valve
The multiandem valve adopts unitary double-slide-valve structure, which is mainly composed of
boom part reversing valve, bucket part reversing valve, safety valve, overload oil supplementary
valve and check valves. Oil circuits of the two reversing valves are in series.
9-14
A2
B2
Component
Connected with working pump oil
outlet port
Back to oil tank after cooling in
radiator
Connected with piston-side chamber
of bucket cylinder
Connected with rod-side chamber of
bucket cylinder
Connected with piston-side chamber
of boom cylinder
Connected with rod-side chamber of
boom cylinder
9-15
2 Gasket
3 Round-shoulder pin
7 Gasket
9 O-ring
8 O-ring
12 O-ring
14 Check valve
15 O-ring
16 O-ring
20 Spring seat
21 Spring
22 Steel ball
23 Sealing gasket
24 End cover
25 Gasket
26 Bolt
27 Rubber plug
28 Rubber plug
29 End cover
30 Bolt
31 Sealing gasket
35 Safety valve
38 Screw plug
43 O-ring
17 Screw plug
18 Valve body
33 Return spring
40 Bolt
41 Gasket
19 Base plate
34 Spring seat
Bucket part reversing valve is a 6/3 valve, which can control the forward tilt, backward tilt and
holding of the bucket.
Boom part reversing valve is a 6/4 valve, which can control the lifting, holding, lowering and
floating of boom. Spring in the boom return sleeve can press the steel ball to the two ends and keep
the ball stuck in the V-groove of locating sleeve inwall, so the boom part slide valve element can be
fixed in any action position of the four movements.
A check valve is designed in inlet port of bucket part reversing valve and boom part reversing valve
respectively, the check valves are pressed against the valve seat by spring. Check valve can prevent
9-16
3 Pilot valve
2 Slide valve
3 Cone valve
6 O-ring
7 Poppet valve
valve seat
4 Spring
5 Cone valve
9 O-ring
10 Poppet
12 Lock nut
In the process of the boom lifting, overload oil supplementary valve can conduct oil discharging and
supplementing automatically. For instance, when the boom is lifted to a certain position, the piston
rod of bucket cylinder will be forced to extend outward, which will make the oil pressure in the
bucket cylinder rod-side chamber rise up sharply, the oil cylinder or hydraulic pipe can be damaged
under such circumstance. However, because overload valve is designed in the system, it can make
the oil trapped in the oil cylinder rod-side chamber return back to the hydraulic oil tank through the
overload valve. The volume of oil cylinder rod-side chamber decreases, meanwhile, the volume of
oil cylinder piston-side chamber increases and partial vacuum will be formed. At this moment the
oil supplementary valve opens to add hydraulic oil into the bucket cylinder piston-side chamber, in
order to eliminate the partial vacuum.
When the loader is unloading, it can help to make the bucket tip down quickly under the action its
own weight, and hits the stop block freely to dump all the materials inside the bucket. During this
process, after the bucket barycenter crosses the lower hinge point, the bucket will turn increasingly
under the action of gravity; but the movement velocity of bucket cylinder is limited by the oil
supply rate of the hydraulic pump. In this case, oil supplementary valve can make the bucket
cylinder piston-side chamber overflow timely and at the same time refills oil to the bucket cylinder
9-21
ATTENTION
Before dismantling multitandem valve, be sure to carefully read the 93 Service Precautions for
Working Hydraulic System in this chapter.
Disassembly of the multitandem valve
1
Fig 9-40
1
Fig 9-41
1 Front cover plate
1 2
Fig 9-42
1 Boom part piston-side steel pipe
2 Boom part rod-side steel pipe
piston-side/rod-side
steel
pipes
and
multiandem valve, take down the bolts and Orings, disconnect the steel pipes.
9-22
1 2
Fig 9-43
1 Bolt
2 Oil inlet block
piston-side/rod-side
steel
pipes
and
multiandem valve, take down the bolts and Orings, disconnect the steel pipes.
7
1 2
3
Fig 9-44
1 Bucket part piston-side steel pipe
2 Bucket part rod-side steel pipe
3 Multiandem valve oil return steel pipe
1
Fig 9-45
1 Pipe fixing clamp
9-23
1
Fig 9-46
1 Pipe fixing clamp
1
Fig 9-47
1 U-shape fixing bolt
1 2
Fig. 9-48
1 Shield2 Bolt
9-24
1
Fig. 9-49
1 Operating flexible shaft
1.
1
Fig. 9-50
1 Bolt
ATTENTION
Do not tighten the bolts in this step, note that
big gasket is used here.
9015Nm
1
Fig. 9-51
1 Bolt
9-25
1
Fig 9-52
1 Multiandem valve oil return steel pipe
3.
ATTENTION
Keep the boom slide valve element in floating
position (refer to Fig. 9-35), adjust the flexible
shafts
until
they
are
coaxial
to
the
4.
1 2
Fig. 9-54
1 Shield2 Bolt
5.
9-26
1 2
3
Fig 9-55
1 Bucket part piston-side steel pipe
2 Bucket part rod-side steel pipe
3 Multiandem valve oil return steel pipe
6.
1 2
Fig 9-56
1 Bolt
2 Oil inlet block
7.
1 2
Fig 9-57
1 Boom part piston-side steel pipe
2 Boom part rod-side steel pipe
8.
1
Fig 9-58
1 Pipe fixing clamp
9-27
1
Fig 9-59
1 Pipe fixing clamp
1
Fig 9-60
1 U-shape fixing bolt
9.
1
Fig 9-61
1 Front cover plate
924
Hydraulic Cylinders
9-28
2 Piston rod
3 Dust ring
5 Bearing ring
8 Cylinder cover
9 O-ring
10 Cylinder block
12 O-ring
13 Bearing ring
11 Piston
16 Bolt
17 Gasket
4 Guide ring
7 O-ring
8 O-ring
9 Retainer ring
10 Cylinder cover
11 Cylinder block
12 O-ring
13 Guide ring
14 Combination seal
15 Steel ball
16 Screw
17 Contamination ring
20 Sleeve
21 Gasket
22 Screw
18 Piston
23 Grease cup
24 Sleeve
Before installing a dust ring, crimp the ring in the way as shown in , install it in the way
will very difficult and more likely to fall off after assembly.
When installing piston seals, the opening position of two neighboring seal should be more than
90o different.
Fig. 9-64
Maintenance method
Comply to the following procedures to correct the piston rod problem: Planish the axial scratch
with oilstone. If the scratch is too depth that can embed a nail, replace the rod immediately. If
there is smooth dent, planish the protrudent around with oilstone to adjust; if the dent is too
big, replace or re-plate the rod immediately.
Important! Repolish the rod after re-plating, the re-plating thickness should be at least
0.25mm.
Attention! If the base metal is hurt during planishing, then the rod must be re-plated.
Maintenance guides
ATTENTION
Before dismantling the boom cylinder, be sure to carefully read the 93 Service Precautions for
Working Hydraulic System in this chapter.
Disassembly of the boom cylinder
1.
Fig. 9-65
2.
1
2
Fig. 9-66
1 Boom cylinder rod-side rubber hose
2 Boom cylinder piston-side rubber hose
3.
Fig. 9-67
4.
1 2
Fig 9-68
1 Pin2 Bolt
5.
1
Fig 9-69
1 Pin
6.
to
assembling
make
of
the
boom
disassembling
and
cylinder
pin
rear
convenient.
Fig 9-70
1 Pin
7.
1
Fig 9-71
1 Pin
8.
1
Fig 9-72
1 Pin
9-33
9.
10. Remove the fixing bolts of boom cylinder rodside pipe clamp, take down the bolts, steel pipe
and O-ring.
1
2
3
Fig 9-73
1 Pipe clamp
2 Boom cylinder rod-side steel pipe
3 Bolt
11. Remove the fixing bolts of boom cylinder rodside steel pipe, take down the bolts, steel pipe
and O-ring.
1
2
3
Fig 9-74
1 Bolt
2 Boom cylinder piston-side steel pipe
3 Bolt
9-34
2.
1
2
3
Fig 9-75
1 Pipe clamp
2 Boom cylinder rod-side steel pipe
3 Bolt
3.
4.
1
2
3
Fig 9-76
1 Bolt
2 Boom cylinder piston-side steel pipe
3 Bolt
5.
Fig. 9-77
9-35
6.
ATTENTION
1) Note that piston-side pipes should be on
the outside, do not make mistakes.
2) Do not damage the grease cup when
knocking the pin.
1
Fig 9-78
1 Pin
7.
1
Fig 9-79
1 Pin
8.
ATTENTION
Be
1
Fig 9-80
1 Pin
careful
when
assembling
the
boom
1
Fig 9-81
1 Pin
ATTENTION
1
2
Fig. 9-82
1 Boom cylinder rod-side rubber hose
2 Boom cylinder piston-side rubber hose
Fig 9-83
1 Pin
Fig 9-84
Fig 9-85
ATTENTION
Before dismantling the bucket cylinder, be sure to carefully read the 93 Service Precautions
for Working Hydraulic System in this chapter.
Disassembly of the bucket cylinder
1
9-38
Fig 9-86
Pressure relief.
1.
1
Fig 9-87
1 Flat fender
2.
disassembling
the
hydraulic
3.
1
Fig 9-89
1 Bucket cylinder rod-side rubber hose
4.
1
Fig. 9-90
1 Bucket cylinder
5.
1
Fig. 9-91
1 Pin
9-40
6.
ATTENTION
Avoid scratching the pin during the operation
1
Fig. 9-92
1 Pin
7.
1
Fig. 9-93
1 Pin
8.
1 2
Fig. 9-94
1 Pin2 Grease pipe
9-41
1
Fig 9-95
1 Steel pipe
2.
1
Fig 9-96
1 Steel pipe
3.
Fig 9-97
4.
9-42
Fig 9-98
ATTENTION
Put gaskets on connecting end faces, ensure the
fitting clearance between two end faces is within
0.5~1.5mm by using different type and number
of gaskets.
5.
1
Fig. 9-99
1 Pin
1 2
Fig. 9-100
1 Pin2 Grease pipe
6.
7.
9-43
Fig 9-101
8.
Fig. 9-102
1 Pin
9.
ATTENTION
Do not distort the hose.
5210Nm
1
Fig. 9-103
1 Bucket cylinder piston-side rubber hose
ATTENTION
Do not distort the hose.
5210Nm
1
Fig. 9-104
1 Bucket cylinder rod-side rubber hose
9-44
1
Fig 9-105
1 Flat fender
1
Fig 9-106
1 Grease nozzle
1
Fig 9-107
1 Grease nozzle
9-45
Removing
and
servicing
machine
on
outdoor site.
Chances are that fouling will enter the
equipment if removal and service are done on
outdoor site; moreover, it is difficult to
Fig. 9-108
appraise
equipments
performance
after
Fig. 9-109
9-46
Fig. 9-110
Rinsing oil
Flushing operation.
The fouling, oil sludge and old oil in the
hydraulic oil circuit should be flushed away
Fig. 9-111
9-47
secondary
flushing
with
specified
hydraulic oil.
Cleaning operation.
Get rid of the sludge and fouling in the
hydraulic oil circuit with oil cleaning device
after repairing the hydraulic device (pump,
control valve, etc.) or when the machine is
operating. The oil cleaning device is used to
remove the ultrafine granule that cannot be
removed by the filter in the hydraulic device,
which is a very effective cleaning tool.
Fig.8 9-112
Torque requirements.
The securing operation should be conducted in strict accordance with the torque required in this
manual during the process of removal, refitting and service of the hydraulic system. Excessive or
insufficient torque will lead to hydraulic oil leakage.
ATTENTION
For the torque that is not indicated, please refer to relevant requirements in chapter 0
General of this manual.
1.
1
Fig 9-113
1 Pressure measuring port
Fig. 9-114
Start the engine, and operate the pilot operating handle to retract the bucket. After the bucket
gets to its extreme position, increase the accelerator to the maximum size (2200r/min)
gradually. Observe the pressure gauge and record the steady pressure value, and that is the
current working pressure for working hydraulic system.
9-49
To get more accurate result, put the boom in other positions and repeat the measurement.
ATTENTION
After the measurement, disassemble the measurement tools and wipe them clean.
Adjusting method
Multiandem valve of LG953N wheel loader is installed on front frame and the main safety valve is
on the side of oil inlet port, covered with lead seal. Remove the lead seal and loose the lock nut,
rotate the adjusting screw to change main safety valve set pressure.
2 Lead seal
3Adjusting screw
9-50
1
Fig 9-116
1 Pressure measuring port
Fig. 9-117
Start the engine, and operate the pilot operating handle to retract the bucket. After the bucket
gets to its extreme position, increase the accelerator to the maximum size (2200r/min)
gradually. Observe the pressure gauge and record the steady pressure value, and that is the
current working pressure for working hydraulic system.
To get more accurate result, put the boom in other positions and repeat the measurement.
ATTENTION
After the measurement, disassemble the measurement tools and clean them up.
Adjusting method
Multiandem valve of LG953N wheel loader is installed on front frame. Bucket piston-side and rod9-51
2 Lead seal
3Adjusting screw
ATTENTION
Because set pressure of bucket cylinder piston-side overload valve is higher than that of
main safety valve, so its pressure must be adjusted on specialized test-bed other than on
the machine directly.
Pressure of rod-side overload valve cannot be adjusted for now.
Unexpected
9-52
Forward
Tilt
of
Bucket
Fault phenomena: When operating handle of pilot valve is in neutral position, the bucket tilt
forward unexpectedly.
Fault analysis: Because link mechanisms are used in working device, when the bucket is under
retract state and operating handle of pilot valve is in neutral position, the bucket cylinder piston-side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston-side
chamber, it will result in unexpected forward tilt of bucket.
Six situations can cause the leakage in piston-side chamber of bucket cylinder:
1
Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve.
Multitandem valve bucket slide vale part fails to go back to neutral position (because valve
element gets stuck, valve element of pilot valve cannot reset or there are faults exist in the
valve body, such as sand holes and grooves that connect to piston-side chamber).
While inner leakage exists in bucket cylinder, leakage also exists from rod-side chamber to oil
outlet port.
Low overload pressure for bucket cylinder piston-side overload valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, dirt exists in the conical fitting
surface between valve element and valve body, or there are defects exist in the valve body, such
as sand holes and grooves that connect to piston-side chamber).
Leakage exists in bucket cylinder piston-side oil compensation valve (may caused by damaged
reset spring, valve element stuck in open position, dirt exists in the conical fitting surface
between valve element and valve body, or there are defects exist in the valve body, such as sand
holes and grooves that connect to piston-side chamber)
Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
Six situations that cause leakage are listed above and the simplest and easiest to diagnose is the
first one: Start the machine and lift the boom to a certain height, retract the bucket to its
extreme position, and then observe the pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve to find out whether there are obvious external leakage
phenomena exist.
If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multitandem valve bucket slide vale part. At this point, if the
9-53
For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lower the boom to lowest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect bucket cylinder piston-side rubber hose and diver it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to backward tilt the
bucket, observe whether there is oil comes out from piston-side oil port continually. If there is,
which means server inner leakage exists in bucket cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth and fifth situations.
For the fourth and fifth situations, method of pressure detection can be used: Connect a 0250Bar pressure gauge to gauge port of bucket cylinder piston-side chamber. Start the machine
and operate pilot valve handle to extend the bucket to its extreme position; step on the gas and
operate pilot valve handle to lift the boom, at the same time, check whether the reading on the
gauge reach the design value when the boom is lifting. If not, either situation mentioned in the
first place is possible, the overload valve or oil compensation valve for bucket cylinder pistonside chamber need to be checked and cleaned.
If situation 1 to situation 5 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multitandem valve bucket slide
valve part, look through the valve element, valve opening and their fitting situation.
Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
952
Boom Sinking
Fault phenomena: When operating handle of pilot valve is in neutral position, the boom sinks
automatically and exceeds allowed range.
Fault analysis: When the boom is lifted and stays in a certain height, the boom cylinder piston-side
chamber will suffer extra force caused by self-weight. At this point, if there is leakage in piston-side
chamber, the boom will fall automatically.
Four situations can cause the leakage in piston-side chamber of boom cylinder:
1
Obvious external leakage exists in pipelines, joints and fitting surfaces from the piston-side
chamber to multitandem valve.
Multitandem valve boom slide vale part fails to go back to neutral position (because valve
element gets stuck, valve element of pilot valve cannot reset or there are defects exist in the
9-54
While inner leakage exists in boom cylinder, leakage also exists from rod-side chamber to oil
outlet port.
Excessive wear of selector valve body or element, which result in fit clearance between valve
body and valve element is far more than design value.
Four situations that cause leakage are listed above and the simplest and easiest to diagnose is
the first one: Start the machine and lift the boom to highest height, and then observe the
pipelines, joints and fitting surfaces from the piston-side chamber to multitandem valve to find
out whether there are obvious external leakage phenomena exist.
If the first situation is being excluded, consider the second situation: Start the machine and
operate pilot valve handle to lift the boom to highest position, and retract the bucket to its
extreme position, and then shut down the engine, disassemble the two pilot pipes that
connected to two ends of multitandem valve bucket slide vale part. At this point, if the boom
sinking phenomenon disappeared, then we can come to a conclusion that the fault is caused by
pilot valve, which causes multitandem valve boom slide vale part fails to go back to neutral
position. Disassemble and clean the pilot valve or replace it. Otherwise, check the third
situation.
For the third situation, we can do some simple check: Start the machine and operate pilot valve
handle to lift the boom to highest position, and retract the bucket to its extreme position, and
then shut down the engine, disconnect boom cylinder piston-side rubber hose and divert it to
hydraulic oil tank. Start the machine again, operate the pilot valve handle to lower the boom,
observe whether there is oil comes out from piston-side oil port continually. If there is, which
means server inner leakage exists in boom cylinder, the cylinder needs to be repaired or
replaced. Otherwise, check the fourth situation.
If situation 1 to situation 3 have been excluded and the fault still exists, then stop the machine,
low boom and bucker to lowest positions and disassemble multitandem valve boom slide valve
part, look through the valve element, valve opening and their fitting situation.
953
Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom from lowest to highest position, the time it needed exceeds full load lifting time.
Fault analysis: Consider the characteristics of Hydraulic power units, the reason for boom lifting
slowly: insufficient flow from hydraulic pump to cylinder.
Nine situations are listed below that may cause insufficient flow from hydraulic pump to
9-55
Severe external leakage exists in joints, pipelines, valves and fitting surfaces from pump to
boom cylinder piston-side chamber.
The hydraulic oil contain a lot of bubble or turns black, or goes bad, and its viscosity has been
changed.
Blocked oil absorption filter or oil absorption pipe, which make the working pump hard to suck
oil.
Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element).
Low adjusting pressure of multitandem valve main safety valve (may caused by damaged
pressure adjusting spring, valve element stuck in open position, or there are defects exist in the
valve body, such as sand holes and grooves that connect to oil return chamber).
Severe inner leakage exists between oil inlet channel an oil return channel of multitandem
valve body (caused by sand hole or breakage of valve body).
Excessive wear of selector valve element or valve opening of multitandem valve boom slide
valve part, which result in fit clearance between valve body and valve element is far more than
design value.
Insufficient opening of multitandem valve (because selector valve element gets stuck, valve
element of boom cylinder piston-side pilot valve cannot reset or there are sand holes and
grooves exist in the valve body, or low setting pressure of combination valve that result in
insufficient pilot pressure).
For all situations mentioned above, firstly, we should start the machine and lift the boom, check
out whether there is obvious external leakage exists in pipelines, joints and fitting surfaces from
working pump to boom cylinder piston-side chamber.
If there is no severe external leakage, then basic inspection should be done: Whether the
hydraulic oil level is above LOW level, whether there is too much bubble in hydraulic oil or
the oil turns black. Add hydraulic oil if necessary; if the oil turns bad, clean the tank and the
whole hydraulic system, and then replace the oil.
If the hydraulic oil is good, then start the machine and operate pilot handle to retract the bucket,
at the same time, listen carefully and check whether there is screaming in working pump. If
there is, which means the pump have severe oil absorption problem, check and clean oil
absorption filter and rubber hoses.
9-56
If there is no screaming phenomenon, check the forth situation: Start the machine, operate the
pilot valve to load the pump for 1-2 minutes, then shut down the engine; carefully touch the
shell of working pump, if it feels too hot, then we can come to a conclusion that severe inner
leakage exist in working pump, which causes the oil shortage problem.
For the fifth to ninth situations, we need to do some simple tests first: Connect a 0-40MPa
pressure gauge to gauge port of multitandem valve P port. Start the machine and operate pilot
valve handle to pressurize the hydraulic system, at the same time, check whether the reading on
the gauge reach the design value. If not, check situation 5 to 8 one by one.
For the fifth situation, start the machine and operate pilot valve handle to lower the boom to
lowest position, and retract the bucket to its extreme position, and then shut down the engine,
disconnect boom cylinder piston-side rubber hose and divert it to hydraulic oil tank. Start the
machine again, operate the pilot valve handle to lower the boom, observe whether there is oil
comes out from piston-side oil port continually. If there is, which means server inner leakage
exists in boom cylinder, the cylinder needs to be repaired or replaced.
For situation 6: Check and clean main safety valve, if there is irreparable damage for valve
element or valve body, please replace the safety valve.
If situation 6 and 7 are being excluded and the system pressure still fails to reach design value,
then focus on situation 7 and 8. Disassemble multitandem valve boom slide valve part, look
through the valve element, valve opening and their fitting situation.
If the hydraulic system pressure reaches design value but the boom still lifting slow, check the
ninth situation: Operate pilot valve handle to lower the boom and bucket to their lowest
positions, and then open the spring-free end cover (the one with short axial dimension) of
multitandem valve boom slide valve part, force the valve element to do axial movement, check
whether the rod can get to the right positions, whether it can return to neutral position smoothly.
954
Fault phenomena: When the diesel engine is running under rated speed, operate pilot valve handle
to lift the boom under full load, the boom fails to be lifted.
Fault analysis: The most direct reason for lifting incapacity of boom is low pressure of boom
cylinder piston chamber.
Primary reasons for low pressure in boom cylinder piston chamber:
1
Low overload pressure for main safety valve of multitandem valve (may be caused by damaged
pressure adjusting spring, valve element stuck in open position, or there are defects exist in the
valve body, such as sand holes and grooves that connect to oil return chamber).
9-57
Severe inner leakage of working pump, because that the system cannot build up pressure or the
system pressure cannot reach design value.
Severe inner leakage exists in boom cylinder (caused by cylinder scoring or damaged sealing
element ).
Severe inner leakage exists between oil inlet channel an oil return channel of multitandem
valve body (caused by sand hole or breakage of valve body), because that the system cannot
build up pressure or the system pressure cannot reach design value.
955
956
9-58