Sie sind auf Seite 1von 31

Service

S Maanual of Wh
heel Loader

Coonten
nts
9  W m ......................................................................................................................... 1 
Working hydrraulic system
91 Oveerview of working hydraulic system ....................................................................................................... 1 
92 Meaasurement an
nd adjustmeent of workin
ng hydraulic system .................................................................... 4 
4
9221 Measurem
ment of system pressure ................................................ ...................................... 4 
m working p 4
ucket cavity .................... ...................................... 6 
9222 Overload pressure meeasurement oof rotating bu 6
9223 Primary pressure
p asuring of pillot control ............................................ ...................................... 7 
mea 7
9224 Secondaryy pressure measuring
m of pilot controll ......................................... ...................................... 8 
8
o cylinder ... .............................................................. ...................................... 9 
9225 Settlement detection of 9
9226 Pressure adjustment
a o safety valvve ........................................................... .................................... 100 
of
ng the hydraaulic system .......................................... .....................................11 
933 Precautionss for repairin
94 Intrroduction to hydraulic co
omponents....................................................................................................... 122 
9441 Hydraulicc oil tank ........................... .............................................................. .................................... 122 
9442 Working pump
p ................................ .............................................................. .................................... 122 
9443 Multiway valve
v ................................. .............................................................. .................................... 13 
9444 Pilot contrrol valve ........................... .............................................................. .................................... 177 
9445 Pressure selector
s valvee ................... .............................................................. .................................... 199 
95 Fau
ult diagnosis and troublesshooting of h
hydraulic sysstem ....................................................................... 200 
9661 Bucket fallling .................................. .............................................................. .................................... 200 
9662 Boom setttlement .............................. .............................................................. .................................... 222 
o the boom ....................... .............................................................. .................................... 23 
9663 Slow lift of
o boom lift ....................... .............................................................. .................................... 266 
9664 Inability of
9665 Blow buck nt ................. .............................................................. .................................... 277 
ket movemen
9666 Inability bucket
b movement ........... .............................................................. .................................... 277 

I
Service Maanual of Wheel
W Loadeer

9 Worki
W ing hydrraulicc
systtem
91 Overview
O w of worrking hy
ydraulicc
system
m
Workin
ng hydraulicc system haas two typees includingg
mechannical controol type annd pilot co
ontrol type..
Workin
ng pressuree of the syystem is 16Mpa.
1 Itss
schemaatic diagram
m is as follow
ws:

转向油缸
STEERING CYLINNDER
动臂油缸 缸
LIFTING CYLINDER

L R
B2
A2 4

B1

A1
120bar 180bar

转斗油缸 缸
TILT CYLINNDER

160bar 转向器 器
STEERINGG UNIT
T P
T Ls P

Ls CF EF

140bbar
回油滤芯
FILTER INSERT 优先阀 P
PRRIORITY VALVE
齿轮泵
GEAR PUMP

图 9-1 L9366Hydraulic schematic


s diagram
d (meechanical)C
China market

1
动臂油缸
LIFTING CYLINDER
K 2C
A2
转向油缸
B2 STEERING CYLINDER
2a
2A
2B
转斗油缸 2b 1A L R
TILT CYLINDER 1B

A1

B1

d
1
1a

180bar 120bar 1b

图 9-2 L9366Hydraulic sschematic diagram


先导阀
160bar PILOT VAVLE
P T

2
T 多路阀 P
CONTROL VALVE
滤油器
W

m
转向器
FILTER
STEERING UNIT
T Ls P
Service Maanual of Wheel

(pillot) China market


Ls CF EF
Loadeer

T T
P3
140bar

压力选择阀 P1 优先阀 P
PRESSURE SELECTOR VALVE PRIORITY VALVE

齿轮泵
GEAR PUMP

回油滤芯
FILTER INSERT
动臂油缸
LIFTING CYLINDER
K 2C
A2

B2
2a
2A
2B
转斗油缸 2b 1A
TILT CYLINDER 1B

A1 转向油缸
STEERING CYLINDER

图 9-3 L9366 L938 Hydra


B1
1a
L R
180bar 120bar 1b

aulic schem
A3
先导阀
B3 PILOT VALVE
3a
P T

3b

matic diagram
3
160bar

m (pilot)
滤油器
T 多路阀 P FILTER 转向器
W

CONTROL VALVE STEERING UNIT


Service Maanual of Wheel

油缸
CYLINDER
T Ls P

except Chin
Loadeer

Ls CF EF

液压锁
T T

na market
HYDRAULIC LOCK
P3
120bar
电磁阀
SOLENOID VALVE 压力选择阀 P1 优先阀 P
PRESSURE SELECTOR VALVE PRIORITY VALVE

回油滤芯
齿轮泵 FILTER INSERT
GEAR PUMP 齿轮泵
回油滤芯 GEAR PUMP
FILTER INSERT
Service Maanual of Wheel
W Loadeer

92 Measurem
M ment and d adjusttment off
work
king hydrraulic syystem
921 Measurem
M ment of system workingg
pressu
ure
Measurrement of oiil temperatuure: 45 - 55℃.
Pressurre measurinng tool: 400Mpa presssure gaugee
(403000 00370), pressure connnector (4120002945),,
piezom 40300003688).
metric tube (4
Pressurre measuring
g standard: 16 Mpa
Pressurre measuring g position: pplug screw location onn
the oil inlet
i of the multi-way
m vvalve.
Fig. 9-3 40030000370 pressure
p gauge
Pressurre measuring
g process:
1. Plaace the worrking devicee on the gro
ound. Presss
thee button off parking bbrake. Wed dge the tiree
wiith wood or stone. Turnn off the eng
gine.
2. Manipulate th he control hhandle and the
t steeringg
whheel for 10 1 times and aboutt 5 timess
resspectively to
t release reesidual presssure in thee
hy
ydraulic oil pipe. Preppare tools for
f pressuree
meeasuring.
3. Reemove the pressure
p meeasuring plu
ug screw onn
thee oil inlet off the multi-w
way valve.
4. Install the pressure
p meeasuring jo oint to thee
preessure port of the multiti-way valvee.
5. Tighten piezzometric tuube on th
he pressuree
meeasuring joiint.
Fig. 9-4 41120002945 pressure
p meeasuring joiint
6. onnect the pressure ggauge to th
Co he pressuree
meeasuring hose.
7. Staart the engin
ne and placce the contro
ol handle off
thee rotating bucket
b in the
he close possition. Afterr
thee bucket is placed in pposition andd moved too
thee limit position, graduually acceleerate to thee
maaximum (2200/rpm).
( . Observee the oill
preessure gaug ge to obtaiin the stablle pressure,,
whhich is the current woorking pressure of thee
woorking device hydrauliic system of the testedd
loaader.
No
ote: To con
nfirm measuurement acccuracy, thee
control handle off the boom
m might be moved too
lifting or falling posittions for repeatedd
measurements.
4
Service Maanual of Wheel
W Loadeer
Fig. 9-5 40030000368 pressure
p meeasuring ho se

Fig. 9-6 M
Measurementt location off system preessure Fig.

5
Service Maanual of Wheel
W Loadeer

922 Overload
O pressuree measurement off
rotatiing buckeet cavity
Note: This pressure measururing metho od is onlyy
applicable to fauult diagnoosis. Serviccemen aree
prohibited to adjust the ovverload vallve on thee
machinne.
Measurrement of oiil temperatuure: 45 - 55℃.
Pressurre measurin
ng tool: 400Mpa presssure gaugee
(403000 00370), pressure connnector (4120002945),,
metric tube (40300000368). See 921
piezom
Measurrement of sy
ystem worki
king pressure
g standard: 18 Mpa.
Pressurre measuring
Pressurre measurin ng positionn: Plug scrrew on thee
steel pip
pe of the rotating buckket cavity
Pressurre measuring
g process:
1. Plaace the worrking devicee on the gro
ound. Presss
thee button off parking bbrake. Wed dge the tiree
wiith wood or stone. Turnn off the eng
gine.
2. Manipulate th he control hhandle and the
t steeringg
whheel for 10 1 times and aboutt 5 timess
resspectively to
t release reesidual presssure in thee
hy
ydraulic oil pipe. Preppare tools for
f pressuree
meeasuring.
3. Reemove the plug
p screw of pressuree measuringg
on
n the steel piipe of the rootating buck
ket cavity.
4. Install the pressure
p meeasuring jo oint to thee
preessure port of the multiti-way valvee.
5. Tighten piezzometric tuube on th
he pressuree
meeasuring joiint.
6. Staart the engiine. Lift thee boom to the highestt
po
osition. Run n the diesell engine at idle speed..
Manipulate th he control hhandle of the
t rotatingg
bu
ucket to the maximum.. Return to the neutrall
po
osition. Opeerate the coontrol handle to lowerr
thee boom. Th he current m maximum pressure
p off
thee pressure gauge
g is thee overload pressure off
thee overload d valve off the rotatiing buckett
cy
ylinder cavitty. (The maaximum stress appearss
aftter the buck
ket reaches tthe limit position)
Note: The measu
urement mi
might be reepeated forr
confirm
mation.
Fig. 9-7 M
Measurementt position off overload vvalve pressu
ure

6
Service Maanual of Wheel
W Loadeer

923 Primary
P pressurre measu
uring off
pilot control
c
Note: This
T operation is appliccable to mo
odel of pilott
control only.
Measurrement of oiil temperatuure: 45 - 55℃.
Pressurre measurinng tool: 66Mpa presssure gaugee
(641000 03106), pressure connnector (4120001751),,
T-junctiion (41200001100) annd piezom metric tubee
(403000 00368).
Pressurre measuring
g standard: 3.5 Mpa.
Pressurre measuring
g position: O
Oil inlet of pilot filter.
Fig. 9-8 64410003106 pressure
p gauge
Measurrement proccess:
1. Plaace the loaader in the service loccation. Layy
thee bucket onn the ground
nd. Pull up the
t parkingg
braake. Shut down the engine. Operate O thee
haandle of the working device han ndle 3 - 5
tim
mes to releaase residual stress in th
he hydraulicc
oill pipe.
2. Reemove the inlet pipe off the pilot filter.
f Installl
thee T-junctio
on on the location of o removal..
Install the test joint aand oil piipe on thee
T-jjunction.
3. Co
onnect one end of thee test hoes to t the jointt
an
nd the other end to the ppressure gau
uge.
Fig. 9-9 T-jjunction annd test joint
4. Staart the engiine. Move tthe pilot haandle to thee
lim
mit position
n. Graduallyy accelerate to observee
thee pressure gauge
g for a sstable presssure value.
5. Thhe control handle
h migght be moveed to otherr
lim
mit positionn to repeatt the measuurement too
guuarantee acccuracy of tesst data.
6. Affter test, rep
peat step 1 of pressuree releasing..
Reemove the T-junction
T an
and install th
he oil pipe.
7 Wipe
W hydraullic oil leakinng in the rem
moval.
Fig. 9-10 440300003688 pressure measuring
m hhose

7
Service Maanual of Wheel
W Loadeer

Fig. 9-11 P
Primary presssure measu
uring positioon of pilot control
c
924 Secondar
S y pressu
ure meassuring off
pilot control
c
Note: This
T operation is appliccable to mo
odel of pilott
control only.
Measurrement of oiil temperatuure: 45 - 55℃.
Pressurre measurinng tool: 66Mpa presssure gaugee
(641000 03106), pressure connnector (4120001854),,
T-junctiion (41900000208) anand piezommetric tubee
(403000 00368).
Pressurre measuring
g standard: 2.5 Mpa.
Pressurre measurin
ng positionn: Pilot pip
pe joint off
multi-w
way valve.
Fig. 9-12 664100031066 pressure gauge
g
Pressurre measuring
g process:
1. Plaace the loaader in the service loccation. Layy
thee bucket onn the ground
nd. Pull up the
t parkingg
braake. Shut down the engine. Operate
O thee
haandle of the working deevice handlle 3-5 timess
to release ressidual stresss in the hy
ydraulic oill
pippe.
2. Reemove the pilot
p oil pippe as shown n in Figuree
9-15. Install the
t T-junctiion on the location off
rem
moval. Instaall the test jjoint and piilot oil pipee
on
n the T-juncttion.
3. Coonnect one end of thee test hoes to the testt
joiint and the other
o end too the pressure gauge.
Fig. 9-13 T
T-junction and
a test jointt
4. Staart the engin
ne. Manipuulate the piloot handle too
mo ove the bucket to the liimit position
n. And thenn
graadually accelerate
a to the maximum..
Ob bserver the oil pressurre gauge to o obtain thee
staable pressuure value, which is the pilott

8
Service Maanual of Wheel
W Loadeer
preessure at the back joint
nt position of
o the testedd
loaader.
Measurrement meth
hods of othher joints are similar too
it.

Fig. 9-14 440300003688 pressure measuring


m hhose
5. Th he control handle
h mighht be moveed to boom
m
lifft position to repeat the measu urement too
guuarantee acccuracy of tesst data.
6. peat step 1 of pressuree releasing..
Affter test, rep
Reemove the T-junction
T aand install and
a removee
thee oil pipe. Wipe
W hydrauulic oil leak ked.

Fig. 9-15 P
Pilot pressurre measurem
ment point oof back join
nt
925 Settlemen
nt detectioon of cyliinder
Measurrement of oiil temperatuure: 50 ± 3℃
℃.
Pressurre measuring
g tool: Timeer and meteer ruler.
Measurrement stand
dard:
Cylindeer of rotatin
ng bucket ≤220mm/h;
Lift cyllinder ≤50m
mm/h.
Measurring positio
on: Boom cylinder or buckett
cylindeer
Measurrement proccess:
1. Looad the buck ket to the raated workin
ng mass andd
revverse it backward.
b Operate the boom m
cy
ylinder to lift the buucket to the t highestt
po
osition. Mo ove the muulti-way vaalve to thee
neeutral positio
on and turn off the enggine.
2. Measure the extension
e leength of boo
om cylinderr
nd bucket cylinder evvery 15 minutes
an m andd
reccord the data in corrresponding table. Thee
tottal test duraation is 3h.

9
Service Maanual of Wheel
W Loadeer

926 Pressuree adjusttment of safetyy


valve
If any y pressurre abnorm mity afterr pressuree
measurement of the t hydraullic system, adjust thee
pressurre of the saffety valve. T
The set presssure of thee
main saafety valve on the muulti-way vallve decidess
the wo orking pressure of tthe system m. The sett
pressurre of the safety
s valvee on the pilot
p pumpp
decidess the primaary pressurre of the pilot
p pump..
Now it is to introd
duce how to adjust the sets value off
safety pressure
p with the mai ain safety valve
v as ann
examplle.

Fig. 9-16 P
Position of main
m safety valve
Adjustm
ment processs:
1. Reemove the lead
l sealingg and protection coverr
at the end su
urface of thhe pressuree regulatingg
scrrew .
2. Lo
oosen lockn
nut with a w
wrench.
3. Rootate the pressure reggulating scrrew with a
socket head wrench. Th The pressuree increasess
whhen the sccrew is rottated clock kwise. Thee
preessure decrreases whenn the screw
w is rotatedd
an
nticlockwisee. Adjust too the proper pressuree
an
nd fasten locknut. R Reference value:
v Thee
adj
djustment am mount for rotating the adjustingg
scrrew by a cirrcle is 4Mpaa.
4. Peenetrate a fine steel wirre into the hole on thee
preessure regu
ulating screww 3 and theen penetratee
intto the proteection coveer. Seal it with
w a leadd
seaaling.
1 2 3
Fig. 9-17 M
Main safety valve
1 Locknut 2 Pressurre regulating screw
3 Protectioon cover
Adjustmment of the safety valvve on the pilot pump iss
similar to the ab bove descrription. Butt referencee
values of adjustment are difffferent to so
ome extent..
The addjustment am mount for rotating the adjustingg
screw by
b a circle iss 1Mpa.
Note: The
T adjustm ment vales aare for refeerence only..
The speecific adjusttment shoulld be subjecct to the sett
pressurre value.
Fig. 9-18 P
Position of safety
s valvee of pilot puump
10
Service Maanual of Wheel
W Loadeer

93 Precautio
P ons for repairiing thee
hydra
aulic systtem
1. Avvoid addingg hydraulic oil or repllacing filterr
or preparing the
t machinne in rains or
o places off
strrong wind or
o much dusst.
2 Thhe hydraulicc device shhould be disassembledd
an
nd maintaineed in a speccial dust-freee workshopp.
In addition, its
i performaance should d be testedd
wiith special test devices..
3. Paay attention to openingss of the seall.
4. It is suggesteed to replacce the oil when
w the oill
tem
mperature is hot. U Used oil should bee
disscharged thoroughly inn oil replaceement.
5. In disassem mbly, asseembly of hydraulicc
eq
quipment orr oil replaceement, rinsee pollutant,,
fattlute and used oil in tthe hydraullic oil withh
flu
ushing oill. Rinse twice in normall
cirrcumstancess: Rinse the first time withh
flu
ushing oil; rinse thee second time withh
specified hydraulic oil.
6 In the processs of dismanntling and maintenance
m e
off hydraulic system, it is requiredd to fastenn
according to the
t torque rrequired in the
t manual..
Exxcessive or insufficiennt torque might
m causee
leaakage of hydraulic oil.
7 Prressure of the systemm should be
b releasedd
according to steps beloow before maintaining
m g
thee hydraulic system:
(1) Start the engine.
e Drivve the vehiccle to a flatt
an
nd wide grround. Movve the boom to thee
hig
ghest position. Retroveert the bucket.
(2) Push the con ntrol handlle of the pilotp valvee
baackward slowly. Ante tevert the bucket too
disscharge oil in the buckeet cylinder.
(3) Affter the buccket is movved in place, push thee
haandle forwaard slowly to lower the boom m
graadually to discharge
d oiil in the boo
om cylinderr.
Plaace the bu ucket on thhe ground. Move thee
co
ontrol handle all arounnd 5-6 timess to releasee
thee oil pressurre in the sysstem.

Fig. 9-19 P
Pressure reliief of the sy
ystem

11
Service Maanual of Wheel
W Loadeer

94 Introdu uction to hy
ydraulicc
ponents
comp
941 Hydraulic
H c oil tank
k
It is used
u to sup
pply oil to the wholee hydraulicc
system.. An oil retu
urn filter tannk is set in the oil tankk
to remove impuriities in thee hydraulic system too
guaranttee cleanlineess of hydraaulic oil.

Fig. 9-20 H
Hydraulic oiil tank

942 Working
W pump
p
L936/L L938 workiing pump iis duplex pump. p Thee
first on
ne supplies oil to workking hydrau ulic system,,
and thee second onee supplies ooil to pilot sy
ystem.
Table 9-1
9 L936 wo orking pump
mp parameterrs
Name Parameeter
Coonnection mode
m Rectangulaar spline
Rottation direction Laevorottatory
Nomiinal displacement 100/110
Range
R of speeed 600-2500 0r/min
Figure 9-23 L936 worrking pump Woorking presssure 20Mp pa
Safetty valve preessure 3.5 Mpa
M
Table 9-2
9 L938 wo orking pump
mp parameterrs
Name Parameeter
Coonnection mode
m Rectangulaar spline
Rottation direction Laevorottatory
Nomiinal displacement 100/110
Range
R of speeed 600-2500 0r/min
Woorking presssure 20Mp pa
Figure 9-244 L938 worrking pump
Workin ng pump annd steering pump of L936
L loaderr
in Chin na belong to the sam me pump. Please seee
steering
g system forr details.

12
Service Maanual of Wheel
W Loadeer

943 Multiway
M vallve
Multiwway valve ofo the loadeer can be divided
d intoo
mechan nical contrrol multiw way valve and pilott
control multiway valve accoording to co ontrol type..
Mechan nical conttrol multiw way valvee controlss
movem ment of valvve rod throuugh flexiblee shaft, thuss
realizin
ng make-brreak of oill liquid; piilot controll
multiwway valve realizes
r moovement off valve rodd
throughh piloting oil
o liquid. In China, mechanicall
control multiway valve moddel is DFS--25-16, andd
pilot co
ontrol multiw
way valve mmodel is D3 32-16.
In the non-Chinese
n e region, muultiway valvve model iss
D32A-16.

Figure 9--25 DFS-25-16 multiwaay valve Figure 9-26 DFS-2


25-16 multiw
way valve principle
p

Figure 9-27 D32-116 multiway


y valve Figurre 9-28 D32
2-16 multiw
way valve prrinciple

13
Service Maanual of Wheel
W Loadeer

Figurre 9-29 D322A-16 multiiway valve Figure 9-3


30 D32A-166 multiway valve

Precauttions for insstallation annd using off multi-wayy


valve
Take annd place geently in hanndling and installationn
to avoid
d collision.
To prevvent foreiggn matters, plastic pluug of eachh
hydraullic oil port shall not bbe removed
d before thee
machin
ne is assemb bled.
The insstallation plate
p and brracket shou
uld be flat..
Installaation bolts should be fastened unniformly too
preventt the valve body
b from ddeformation
n
The woorking oil should be cllean. The cleanness off
oil and
d system sh hould not be lower than gradee
19/16 of
o ISO4406 or grade 111 of NAS1638.
Multi-v
valve and piilot valve sh
should be co
onnected too
workingg oil port co
orrectly.

14
Service Maanual of Wheel
W Loadeer
Fault an
nd troublesh
hooting of m
multi-way valve:
v
Table 9-2 F
Fault and trooubleshootiing of multii-way valvee
Refereence map off fault
S/N Fault Causse Soluttion location

Clamping of valve
C
UUnpick and wash or
e
element of high
h
Auutomatic rreplace high
h pressure
p
pressure oveerload
duump and ooverload vallve
v
valve
1 fallling of
rotating
buucket E
Excessive in
nterior RRefer to the cylinder
lleakage of rotating
r mmanufactureer for
b
bucket cylin
nder ddetails.

Clamping of valve
C
Rootating UUnpick and wash or
e
element of low
l
buucket rreplace low pressure
p
pressure oveerload
inccapable ooverload vallve
v
valve
2 orr fails to
suupport
thee
veehicle Excessive in
E nterior RRefer to the cylinder
l
leakage of rotating
r mmanufactureer for
b
bucket cylin
nder ddetails.

Clamping of the
C
UUnpick and wash or
s
safety valvee
rreplace relieef valve
e
element

Inncapable
orr slow Excessive lo
E ow
3 AAdjust posittion of
thee boom s
safety valvee
rrelief valve
liffting p
pressure

Lose efficieency of
L
M
Maintain oill pump
p
pump

Excessive in
E nterior RRefer to the cylinder
l
leakage of boom
b mmanufactureer for
Exxcessive b
bucket cylin
nder ddetails.
4 settlement
off boom Excessive leeakage
E
RReplace the entire
i neutral po
in osition
vvalve
o the valvee body
of

15
Service Maanual of Wheel
W Loadeer

RReplace
O
O-rings dam
maged
ccorrespondin
ng O-rings

Exxternal
5 oill
leaakage Relevant fassteners
R TTighten corrresponding
a loose
are ffasteners

16
Service Maanual of Wheel
W Loadeer

944 Pilot
P control valvee
Pilot control
c hyddraulic syste tem is equipped withh
pilot control
c valv
ve. The ppilot contro ol valve iss
installeed on the rig
ght side of ddriver’s seatt in the cab..
Throug gh controlliing the pillot control lever, thee
personn nel can conttrol action oof slide valvve of boom m
or slidee valve of rotating buucket in thee multiwayy
valve, thus realiziing control of working g device off
the vehhicle.

Figure 9-31 Pilot conttrol valve Figure 9-32 Oil po


orts at the bbottom of pilot
p controll
valve

boom rotating bucket

Figure 9-33 Schematicc diagram of


o pilot conttrol valve

17
Service Maanual of Wheel
W Loadeer
Trroubleshootiing of pilot control valv
ve
Table 9-4 T
Troubleshoooting of pilo
ot control vaalve
S/N Fault Cause Reemoval metthod
Check thee cleannesss of the oil,,
Jam
mmed vaalve elem
ment or
clean the valve coree and valvee
moovement fauult
hole.
Deeformation of pressu
ure relief
1 Pilot valve faault Replace th
the spring
sprring
Inssufficient control flow or Check wwhether the oil supplyy
preessure system wo
works normaally.
Un
niversal joinnt inflexiblee Add greasse for jointss
Poor contact oof circuit Check and
nd maintain the circuit
Low power suupply voltag
ge Replace th
the battery
Remove dirt on th he junctionn
M
Magnet poosition Du surface oof pure iron
n plate andd
2 ust cover daamaged. Du ust entering
unnreliable electromaagnet. App ly a smalll
eleectromagnett resullts in
amount of anti-ru ust oil orr
inssufficient suuction.
hydraulicc oil and replace
r thee
dust coveer.
Eleectromagnett damaged Replace th
the electrom
magnet
Flloating fuunction Claamping of th
the valve eleement Clean parrts
3
fauult Sprring deform
med Replace th
the spring
0-rring damageed Replace th
the sealing element
e
4 Leeakage Replace componentts of thee
Oill leakage off dynamic seal
dynamic ssealing cover

18
Service Maanual of Wheel
W Loadeer

945 Pressure
P selector
s vvalve
The preessure selecctor valve iis installed in the pilott
oil-wayy. It is mainlly composeed of valve body,
b valvee
element, spring, etc.
e The prressure seleector valvee
role is to provide control oil of certain pressure too
the pilo
ot valve and d guaranteee to place th
he boom onn
the grouund even if the diesel eengine has flameout.
f
The mo odel of the pressure seelector valvee is SF8-D..
Its nom
minal pressu ure is 20Mpaa. The exit pressure off
the relieef port is 4±
±0.2MPa.

Fig. 9-26 A
Appearance of pressuree selector vaalve

Fig. 9-27 S
Section of pressure
p seleector valve Fig. 9-28
9 Schem
matic diagraam of pressu
ure selectorr
valve

19
Service Maanual of Wheel
W Loadeer

95 Fault diaagnosis and


d
bleshootiing of hyydraulic system
troub
961 Bucket
B fallling
Fault phenomeno on: the bbucket au utomaticallyy
anteverrts (falling) when the control han ndle of thee
pilot vaalve is in thee neutral poosition.
Fault analysis:
a whhen the buucket is in the closedd
state an
nd the contrrol handle oof the pilot valve is inn
the neu n, dead loadd of the bucket causess
utral position
the buccket cylindeer suffer prressure fromm the largee
cavity. At this point, thhe bucket antevertss
automaatically as loong as the ppressure oil in the bigg
cavity pressure has h leakagge against the returnn
openingg.
Fault caauses:
1. Pippeline fault: There iss apparent leakage inn
pip
pe fittings, joints
j of cyylinder largee cavity andd
muulti-valve and junnction su urface off
insstallation.
2 Oiil cylinder fault:
f Besidees inner leaakage of thee
rottating buckket cylinderr, the smalll cavity off
thee rotating bucket cylinder also a leakss
co
ompared witth the returnn opening.
3. Multi-way vaalve or pilot valve fault:
 The reverrsing slid valve of th he rotatingg
Filter valvve bucket fails to return
rn the neutrral positionn
so that thhe small ccavity of th he rotatingg
bucket cyylinder is coonnected too Port P off
multi-wayy valve, largge cavity an
nd returningg
opening.
Rotating
R
bu
ucket valve  The overrload presssure of thee overloadd
valve for the large cavity of the
t rotatingg
bucket cylinder on thhe multi-wayy valve.
Rotating buck
ket  The oil supplementaary valve of o the largee
slide valve of cavity of the rotatingg bucket cyllinder leakss
multi--way valve
oil.
 Valve element or valve ho ole of thee
reversing valve is exxcessively worn
w so thatt
the fit cleaarance of vaalve elemen
nt and valvee
hole is mu uch higher than the deesign value..
As a result, pressure oil in the large
l cavityy
of the rotaating buckett cylinder leeaks.
Fig. 9-29 S
Schematic diagram
d of rotating
r buccket joint
Fault deetection and
d troubleshoooting

20
Service Maanual of Wheel
W Loadeer
1. Chheck the pipeline
p foor leakage: Start thee
maachine and raise the booom to a cerrtain heightt
to return the bucket
b to thhe maximum m. Observee
whhether theree is appareent leakagee on pipes,,
joiints from th
he large cavvity of rotating buckett
cy
ylinder to the multi--way valvee and thee
jun
nction surfaace of installlation, etc.
2. Ju
udge whetheer the pilot valve has fault: If noo
ex
xternal leakaage, raise thhe boom to the highestt
po
osition by operating
o thhe pilot valve handle..
Affter the bucket is raissed to the maximum,,
cloose the eng gine and reemove pilo ot pipes onn
bo
oth ends of the slide vvalve of thee multi-wayy
vaalve rotating
g bucket joinnt The buckket does nott
falll, it might be the pillot valve which
w causee
thaat the slidee valve off the multi--way valvee
rottating buck ket fails tto return thet neutrall
po
osition and d thus cau auses buck ket falling..
Diismount, ch heck and cleean or replaace the pilott
vaalve. Or oth herwise, coontinue thee followingg
steeps for judg
gment.
3 Ju
udge whetheer the oil cyylinder leak ks: Operatee
thee handle of the pilot vaalve to loweer the boomm
to the lowest position annd retrovertt the buckett
to the maximum. Cloose the engine e andd
dissconnect the hose for tthe small caavity of thee
rottating buck ket and llead it baack to thee
hy
ydraulic oil tank. Then,, start the machine
m andd
op
perate the handle off the pilott valve too
rettrovert the bucket. Obbserve whetther the oill
po
ort of the laarge cavity of the rotating buckett
cy
ylinder leakss hydraulic oil constan ntly. If yes,,
thee rotating bucket ccylinder has h seriouss
leaakage. It is required too dismount,, check andd
reppair or replace the cyylinder. If oil
o cylinderr
haas no leakaage, continnue the nex xt step forr
juddgment.
4. Ju
udge wheth her the oveerload valv ve and oill
su
upplementary valve is damaged: Connect a
40
0mpa pressure gaugge to thee pressuree
meeasuring po ort of the large cav vity of thee
rottating buckket cylindeer. Start thee machine..
Opperate the handle
h of thhe pilot valve to makee
thee bucket in
n the most fforward position. Stepp
on
n the acceleerator and operate thee handle off
thee pilot. Obsserve whethher the reading of thee
preessure gaug
ge reaches thhe design value
v duringg
thee lifting process
p off the boom m. If not,,
dissmount, cheeck and cleean the overload valvee
or oil supplemmentary vallve of the large
l cavityy
21
Service Maanual of Wheel
W Loadeer
off the rotating
g bucket cyllinder.
5. Chheck whetther the slide valv ve of thee
mu ulti-way vaalve is dam maged: If the abovee
sittuations are excluded, stop the machine
m andd
lowwer the booom and the bucket to the t bottom..
Reemove the rotating buucket slid valve
v of thee
mu ulti-way vaalve and cheeck the vallve rod andd
vaalve holes caarefully for fitness. Vallve elementt
or valve ho ole of thee reversing g valve iss
ex
xcessively worn
w so thaat the fit clearance off
vaalve elemen nt and valvee hole is much
m higherr
thaan the desig
gn value. A As a result, pressure
p oill
in the large cavity off the rotating buckett
cy
ylinder leakss.
962 Boom settlem
ment
Fault phenomenon n: when thee control haandle of thee
pilot valve is in the neutraal position, the boom m
lowers automaticaally and exxceeds the settlementt
Conneccted by pressuure selector valve
v standarrd of the cylinder.
Fault annalysis: wh
hen the boom m is lifted and kept att
any heeight, dead load off the boo om makess
correspponding oil pressure bee reserved ini the largee
cavity of
o the boomm cylinder. A
At this poinnt, the boom
m
lowers automaticaally as long as the pressure oil inn
Boom the big cavity presssure has leeakage commpared withh
cylinder urn opening.
the retu

Fig. 9-30 S
Schematic diagram
d of boom
b joint
Fault caause:
1. Pippeline fault: There iss apparent leakage inn
pip
pe fittings, joints
j of cyylinder largee cavity andd
muulti-valve and junnction su urface off
insstallation.
2. Oiil cylinder fault:
f Besidees inner leaakage of thee
bo
oom cylindeer, the smaall cavity off the boom m
alsso leaks com
mpared withh the return opening.
3. Multi-way vaalve or pilot valve fault:
 The boom m reversinng valve rod r of thee
multi-wayy valve faills to return the neutrall
position so
s that thee small cav vity of thee
boom cylinder is connnected to pump port,,
large cavity and returrning openin
ng.
 Valve element or valve ho ole of thee
reversing valve is exxcessively worn
w so thatt

22
Service Maanual of Wheel
W Loadeer
the fit cleaarance of vaalve elemen
nt and valvee
hole is mu uch higher than the deesign value..
As a result, pressure oil in the large
l cavityy
of the booom cylinderr leaks.
Fault deetection and
d troubleshoooting
1. Chheck the pipeline
p foor leakage: Start thee
maachine and raise the boom to the t highestt
po
osition to reeturn the buucket to the maximum..
Obbserve whether there iis apparent leakage onn
pip
pes, joints from the llarge cavity y of boom
m
cy
ylinder to the multi--way valvee and thee
jun
nction surfaace of installlation, etc.
2. Ju
udge whetheer the pilot valve has fault: If noo
ex
xternal leakaage, raise thhe boom to the highestt
po
osition by operating
o thhe pilot valve handle..
Affter the bucket is raissed to the maximum,,
cloose the engine and dissconnect pillot pipes onn
oth ends of the slide vvalve of thee multi-wayy
bo
vaalve boom slide
s valve. If the boom m does nott
setttle, it migh
ht be the pillot valve whhich causess
thaat the slidee valve off the multi--way valvee
bo
oom slide valvev fails to return the neutrall
po
osition and thus causses boom settlement..
Diismount, ch heck and cleean or replaace the pilott
vaalve. Or oth herwise, coontinue thee followingg
steeps for judggment.
3 Ju
udge whetheer the oil cyylinder leakss: Raise thee
booom to the maximum. Close the engine andd
oppen the hosee of the smamall cavity of
o the boom m
cy
ylinder to leead it backk to the hy ydraulic oill
tannk. Start thee machine aand operatee the handlee
off the pilot vaalve. Observve whether the oil portt
off the small cavity
c of thhe boom cyllinder leakss
hyydraulic oill constantlyy. If yes, the boom m
cy
ylinder has inner leaka kage. It is required
r too
dissmount, ch heck and rrepair or replace
r thee
cy
ylinder. If oiil cylinder hhas no innerr leakage, itt
is required forr analyze fuurther.
4. udge fault off multi-wayy: Lower thee boom andd
Ju
bu
ucket to the bottom. Reemove boom m valve rodd
off the multi-way valve. Check thee valve rodd
nd the valve hole carefuully for fitneess.
an
963 Slow lift of
o the booom
Fault phenomenon
p n: operate ththe handle of
o the pilott
valve ata the rated speed of tthe diesel engine.
e Thee
time reequired to lift the boom m from thee bottom too
the hig ghest positiion is longger than th
he standardd
lifting time.
t
23
Service Maanual of Wheel
W Loadeer
Fault analysis:
a according to the characcteristics off
the hyddraulic power componeent, the cau use for slow
w
lifting of
o the boomm is: the floow delivereed from thee
pump to o the hydrau
ulic oil cylinnder is insu
ufficient.
Faault cause:
 Joints, pipes and vaalves from the pumpp
opening to t the largee cavity off the boom
m
cylinder and
a other juunction surrfaces havee
severe leaakage.
 The hydraaulic oil coontains a larrge amountt
of air bub
bbles or apppears black, gets severee
deterioratiion and losses the corrrespondingg
viscosity.
 The suctiion filter iis blocked or interiorr
rubber off the fuel ssucking pippe falls outt
and thus causes the fuel sucking pipe bee
blocked. As
A a result, severe insu
ufficient oill
suction caauses insuff
fficient outp
put flow off
the workinng pump.
 The workk pump hass severe inn ner leakagee
which cau
uses insufficcient outputt flow.
 The boom cylindeer has sev
vere innerr
leakage.
 Main saafety valvve pressuree of thee
multi-way
y valve is tooo low.
 There is severe
s inner
er leakage between
b thee
oil inlet passage
p andd return passsage of thee
multi-way y valve bodyy.
 Reversingg valve or hhole of thee multi-wayy
boom is excessivelyy worn so that the fitt
clearance of valve ellement and valve holee
is much higher
h than tthe design value. As a
result, pressure oil leaks from m the largee
cavity of the
t boom cyylinder.
 The openiing degree of the multti-valve rodd
is insufficcient.
Fault deetection and
d troubleshoooting
1. Ch heck for outter leakage: Start the machine
m andd
lifft the boom
m. Observe whether jo oints, pipess
annd valves fro
om the pum mp opening to the largee
caavity of the boom cylinnder and oth her junctionn
su
urfaces have severe leakkage.
2. heck the oiil: In case of no outer leakage,,
Ch
co
onduct bassic inspecctions: wh hether thee
hy
ydraulic oil level in thee oil tank iss above thee

24
Service Maanual of Wheel
W Loadeer
low
west levell; whetherr the hyddraulic oill
co
ontains larg
ge amount of bubblees or turnss
blaack.
3. Chheck sound d: It is rrequired to o start thee
maachine to ju udge whethher the hydrraulic oil iss
abbnormal. Op perate the ppilot valve to
t add loadd
to the hydraaulic system m. Meanw while, it iss
reqquired to pay
p attentiion to judgge whetherr
theere is any sq
queal in thee working pump. If yess,
it means thatt the oil suuction of th he workingg
puump is woeefully inadeequate. Cheeck the oill
su
uction filter and hose.
4. Chheck the wo orking pump mp for inner leakage: Iff
thee working pump
p has nno squeal, operate thee
pillot valve to
o make the pump load ded for 1-22
miinutes. Closse the enginne. Touch thet shell off
thee working pump
p with hand careffully. It thee
shell is very hot. It couuld be judg ged that thee
wo orking pump has severre inner leak kage, whichh
caauses insuffiicient outpuut flow.
5. Teest pressuree: Connectt a 40MP Pa pressuree
gaauge to the pressure m measuring opening off
thee multi-wayy valve Poort P. Start the enginee
an
nd operate thet handle of the pilo ot valve too
preess the hydraulic
h system. Meanwhile,
M ,
ob
bserve the pressure
p gauuge. Its readding shouldd
reaach the design
d preessure. Co onduct thee
folllowing insspections iff it fails to
o reach thee
deesign pressu
ure.
6. Teest the oil cy
ylinder for iinner leakag
ge: Start thee
maachine. Opeerate the haandle of the pilot valvee
to lower the boom to thhe lowest position andd
rettrovert the bucket
b to thhe maximum m. Close thee
en
ngine and disconnect
d tthe hose fo
or the largee
caavity of the boom
b cylinnder and leaad it back too
thee hydraulic oil tank. TThen, start thhe machinee
an
nd operate the t handle of the pilo ot valve too
lowwer the boo om. Observve whether the oil portt
off the large cavity
c of thee boom cyllinder leakss
hyydraulic oill constantlyy. If yes, the boom m
cy
ylinder has serious leakkage. It is required too
dissmount, ch heck and rrepair or replace
r thee
cy
ylinder.
7. Ch heck the main
m safetyy valve: disassemble,,
ch
heck and cllean the ma main safety valve. Thee
maain safety valve shouldd be replaced in case off
irrreparable isssues such ass deformatiion of valvee
eleement, hole, etc.
8. Ch
heck the multi-way
m vvalve: If the
t system
m
25
Service Maanual of Wheel
W Loadeer
preessure still fails to reac
ach the desig
gn pressuree
aftter the abo ove attemptts. It is suuggested too
dissassemble and
a check tthe boom valvev rod off
thee multi-way y valve. C Check the valve
v body,,
vaalve rod, valve hole as well as vallve rod andd
vaalve hole forr fitness carrefully.
9. If the pressure of the hyddraulic systtem reachess
thee design vaalue and thee slow lifting issue off
thee boom stilll exists, it is required to conductt
thee inspection
ns and troubbleshooting below:
Operatee the pilot valve
v to low
wer the boo om and thee
bucket to the lowest position. Open the end cover off
the slid
de valve end d without sppring of thee multi-wayy
valve boom.
b Move the vaalve rod ax xially. Payy
attentio
on to observ
ve whether tthe movemeent distancee
of the valve
v rod iss proper andd whether th he return iss
free.
Exchan nge the pilo
ot pipes coontrolling the
t rotatingg
bucket valve rod and
a the booom valve ro od. Start thee
machin ne and opeerate the ppilot valvee. Observee
whether the boom lift is norm
mal. If yes, disassemble
d e,
check and
a clean thhe boom vaalve block of the pilott
valve.
964 In
nability of
o boom llift
Fault phenomenon
p n: operate th
the handle ofo the pilott
valve to lift the boom
b with full load ata the ratedd
speed of
o the dieseel engine, bbut it fails to lift thee
boom.
Fault annalysis: the most direcct cause for inability off
the booom lift is thhe excessivve low presssure in thee
large caavity of the boom cylinnder.
Fault caause:
The ov
verload presssure of thee main safety valve off
the mullti-way valv
ve is too low
w.
The woorking pump p has severre inner leak
kage whichh
disabless the system
m to form pressure or reach thee
design pressure.
p
The boo
om cylinderr has severee inner leakaage.
There is
i severe inner leakagee between the
t oil inlett
passagee and return
n passage oof the multii-way valvee
body. It
I disables the systemm to form pressure
p orr
reach th
he design prressure.
Fault deetection and
d troubleshoooting
As for troubleshoo
t oting of inabbility of boo
om lift, it iss
required
d to focus the
t above fo four points and
a refer too

26
Service Maanual of Wheel
W Loadeer
the fau
ult detectio
on of troubbleshooting
g of "slow
w
boom liift".
965 Blow
B buck
ket moveement
Analyze and solve referring too slow boom
m lift.
966 In
nability bucket
b m
movementt
Analyze and solve referring to inabilitty of boom
m
lift.

27

Das könnte Ihnen auch gefallen