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 products 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

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 Operators 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
3

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
4

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

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
Model

DEUTZ corporate in Germany

BF4M1013C

Type

2-stage combustion water cooling diesel

Power Rating

63kw

Maximum Torque

275Nm

1.1.2 Hydraulic Torque Converter

Production Factory
Model
Type

DANA corporate in American

C272-300
with hydraulic pump

1.1.3 Kinetic Change Gear Case

Production Factory
Model
Type
Number

DANA corporate in American

R32366
KINETIC CHANGE GEAR
6(forward 3 backward 3)

1.1.4 Axle
Production Factory

Xuzhoumeichi-Beijing Anchises
6

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
2m3

Bucket Volume (Nominal Heaped)

Bucket boom Raise Time

5.6s

Bucket dump Time

6.4s

Maximum Raised Height

4218mm

Maximum dump HEIGHT

1743mm

Dump Distance

900mm
7

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

04.76km/h

2nd Gear Forward/Reverse

09.4km/h

3rd Gear

018.4km/h

Forward/Reverse

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
8

1.2.6 Electric System

System Voltage 24 Volt Starting, 24-Volt Accessories
Electric Theory See Figure 5

1.2.7 Operators 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 2500150mm
Outside 4800250mm

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 operators manual, safety manual and the safety decals on
the vehicle. It is your responsibility to understand and follow the manufacturers
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. Dont 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 hasnt 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: dont 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:

13

trouble

Remedial measure

engine fails to start

runs unevenly or stall
check
CH
A
engine becomes too hot, temperature monitor gives warnadjust
engine give poor performance
Renew
R
engine not working on all cylinders
clean
CL
engine has little/no oil pressure
top up
TU
engine oil consumption exessive
lower level LL
engine smoke
-blue
-white
-black
cause
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

14

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 togear.
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, neednt 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

15

ramp, make triangle mood to tighten the wheel and close the hand brake.
2.10.2 the park steps:
lay down the boom and bucket
move the change gear handle to the neutral position
engine shutup and pull out the ignite key
disconnect the outlet
2.10.3 implement the following work if the scooptram parks for a long time:
move the operating handle to the neutral position
retract all hydraulic oil tank
cover the machine cap with white or lucent cloths and efface (butter) to the
exposure of piston stick and the joint.
unfasten 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:
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.
The annular work areas is large, have bigger making motive force torque.
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

17

3-5 times of the dry type brake.

3.1.1.2.2 the maintenance of the brake is checked
Whether check the brake shell and overlay have crack, nick and whether spline

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

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

they should totally level and have no burr, crack, nick, shave woundedfritting
etc., change it if necessary.
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:

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

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.
18

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.

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.

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:
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.
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.
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.
Take the sun wheel and semi-axis out.
19

 Unscrew the interior wheel lock bolt and take down the lock plate then take
down interior tooth enclose.
Fasten and open the nut, take down the tooth and enclose locating one.
Rock and hang and put down the hub gently
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

20

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

21

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 doesnt 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:

22

When the 50 degree, sport viscidity then 40 lics

Glue temperature index95
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
Cause

Trouble

Remedial method

The fluid is polluted

Wash the valve body, change

The steering core of the valve

There is booty or the valve core

the fluid Wash the valve body,

is blocked

that is damaged in the valve

change the core of the valve

Damage to hitting the spring

Change the spring

Operation of changing direction

The handle is not flexible

is ineffective

There is air in the system

Exhaust systematically

The steering pump breaks

down The systematic relief

Adjust

valve sets the pressure low

again Revitalize

The systematic pressure is too

low

Repair or reinstallation
Repair or reinstallation
the

systematic

pressure

The overload valve sets the

pressure low

The

systematic

fluctuates

pressure

There is air in the system

Hydraulic oil viscidity is abnormal

Adopt the qualified hydraulic oil

The fluid is polluted The

Change the fluid

work of the valve is unstable

change

25

Exhaust

systematically

Repair or

Brake system
Trouble

Cause

Remedial method

The systematic pressure is

adjusted too low The pump

Repair or change Repair or

have

is out of order to apply the brake

change

pressure or the pressure is low

hold the device out of order

7MPa

the

brakes

do

not

Readjust

the

pressure

Fill and press it to

Hold device low to fill pressure

in advance

The foot a brake valve does not

work

The foot brake valve body is

Revitalize Fill and press it to

connected with footboard and

7MPa

the bolt in the place becomes

flexible Hold the device low
to fill pressure in advance
The systematic pressure is

Park and brake does not work

adjusted

too

low

The

Revitalize the pressure

Repair or change

electromagnetic valve is out of

order

The pressure of the device is

unstable that can hold

hold the device serve as the

Fill and press it to 7MPa

pressure in advance low

Repair or change

hold the device leak the vapor

Job system

Trouble
The cylinder does not act

Cause

Remedial method

the fuel tank liquid is low

Mend the oil Revitalize the

The systematic pressure is low

pressure Reduce load

Exceed load work

The cylinder is out of order

Movements of the cylinder are

The systematic pressure is

Revitalize the pressure The

slow

too low Mixed with the air in

system exhausts

Repair

the

cylinder

the system

Repair the cylinder

Change and strain the core

The hydraulic oil is warm and

Revitalize the pressure The

Fill the hydraulic oil Carry on

too high

system exhausts

the hydraulic pressure system and

exhaust

The hydraulic pressure system

shakes the noise

The oil level is too low

Check the oil level, fill the

Mixed with the air in the system

hydraulic oil

suction oil pipe to stop up

hydraulic pressure system and

Hydraulic oil emulsification goes

exhaust Check and suck the

bad main overflow valve is

oil and strain the core, change in

tremble.

case of necessity Change the

Carry on the

hydraulic oil Check the overflow

26

valve, change in case of necessity

The

hydraulic

pressure

pipeline is let out

rise jar is unable to lift

the

pressure is too low in the main

overflow valve The reversing
valve blocking

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
z
z

Light from beginning to end;

Cab light

3.3.4Signal system
Include signal lamp and chime

3.3.5Instrument system
z

Engine oil manometer (number 1788)

Engine oil thermometer (number 3425)

The rotational speed hour instrument

27

Check the pipeline to let out

Adjust

the

overflow valve

Overhaul the reversing valve

Voltmeter 30~+30

3.3.6Electric circuit
z

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

The battery is connected -12V 24V

Lasting time

inside out
The battery contacting in +24V

series
Switch key disconnection

2040V

Several ms

The regulator Work

50100V

Several 100us

All load disconnection

50150V

0.10.5s

Battery disconnection

50100V

0.10.5s

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

z

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

The headlight and taillight

go out

All indicator lamps are not

bright

Some indicator lamps are

not bright

Cause

Remedial mention

The bulb is out of order

Change the bulb Change

The circuit takes off broken

the bulb or tighten the connect

circuit loose

Change the wire, check whether

circuit breaker trip

The

short out or not Change the

switch damaging

switch

Battery switch disconnection

Open the switch Charge

Power shortage of the

battery
The specific sensor is out of

order The specific indicator

Change the indicator lamp

Change

the

sensor

lamp damaging

Power shortage of the

battery
Incorrect indication

QF3, QF4

The

specific

indicator lamp damaging

Charge

indicator lamp

Change

the

Change the

sensor

The specific sensor is out of

order

Alternating current generator section

Trouble

Cause

Remedial mention

It is high to charge the voltage

Change the voltage regulator

The battery is charged

Binding post earth of electric

Correct installation alternating

excessively

brush regulate the resistance

current generator

too big

and maintain

It is excessive to charge

Check the alternating current

The shell of the battery is let out

generator Change the battery

Connect and damage with the

Wash , maintain or change

The battery is too big in

power consumption

The battery can't keep

charging the state

wire The alternating current

generator

damaging

battery damaging

30

The

Check

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
Check the hydraulic pressure and oil level of the fuel tank.
Check all points lubricated situations.
Check case , lid , covering , plug , pipeline etc..
32

 Check the tightening torque of the rim bolt.

Check the atmospheric pressure of the tire.
Check the function of the electric system.
Check the operate component and control the function of the instrument.
Check the function of the brake system.
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:
Measurement

Engine
Safeguard the work

The hours of Operate

Observation
Consult each other

10

The eye depend on that

50

150 300 600 1200

checks seepage
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
footboard

and

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

Opinion

Safeguard the job bridge,

the transmission

Measurement

The hours of Operate

Opinion

Observation Consult

10

each other

50

150 300 600 1200

The eye looks at and

checks

the

seepage

situation
Axle: Changing with oil of
differential mechanism

The changing of planet

gear oil

See relevant chapters fill

the volume and technical

data with
See relevant chapters fill
with

the

volume

and

technical data

Wash the air cleaner

Check the interval that Check

the

installing

the final drive inputs the flange in the drive shaft

bearing of the gear wheel with hands
Transmission:

Needle

bearing interval of the Check on eye

Hookes joint

According to server time to maintain regularly figure 3:

Measurement

Maintenance
Tire and wheel
Check
model
pressure

The hours of Operate

Opinion

Observation Consult

10

each other

and See technique date

about inflating pressure

50

150

Check the destruction

situations of the tire and
the pattern profundity of

Check by eye

the tire
If need to tighten
Check the tightening
tightening torque see in
torque in the rim
technique data

According to server time to maintain regularly figure 4:

34

300

600

1200

Measurement

Maintenance
Electric system

The hours of Operate

Opinion

Observation Consult

10

each other

Indictor
instrument
functionsignal lamp
control component and
illuminating system

50

150

300

600

1200

Battery: check oil level. Put special battery fluid

About
breaking-down
the cable

the
of Check by eye

According to server time to maintain regularly figure 5:

Maintenance
Working system

Measurement

The hours of Operate

opinion

Observation Consult

10

each other

50

150 300 600 1200

Check the interval of

Check by eye
the bucket pin shaft

Check the interval of

Check by eye
the boom pin shaft

Check the rotating joint

Check by eye
pin shaft

Check the stabilized

device/connecting stick
Check by eye
of pin shaft interval (if
have)

Unload device

Check the bearing

interval
of
scooptram bucket
Check the interval
which rotates the pin
joint bearing
Check
rotator
knuckle joint place If need to tighten
fasten set bolt of tightening torque see
in technique data
device

According to server time to maintain regularly figure 6:

35

The hours of Operate

Safeguard work

Measurement

Steering and unload

Observation Consult
each other

Rise hydraulic pressure

Check the oil level of the

fuel tank

opinion
10

50

150

300

600

1200

Count from liquid location

eye to check Flexible

cylinder

Check the seepage of If seepage, find out the

the junction, pipeline and reason;

necessary,

would change the part

hose

See
Check

If

the

the

steering picture

pressure

systematic
about

test

pressure

and

measurement
Changing the oil of fuel
tank

See relevant chapters

Signal lamp is on or "

Change

the

returning

training core of oil filter

(strain tube)

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

Measurement

torque converter and

Observation Consult

gearbox Hydraulic part

each other

Opinion
10

50

150 300 600 1200

Make engine in operate

temperature
Check oil level

to

turn

round, test with oil chi or

gearbox oil spiral plug

check to look at.
Check

the

seepage If seepage, find out the

situations of the tube, reason;

hose junction

necessary,

would change the part

Blow

Wash the oil cooler

If

the

compressing

tube

by

the

air,

make it cross the tube

Change the hydraulic oil
filter
Change oil

See relevant chapters

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

Manual on the flange of

the drive shaft

input
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:

Measurement

Maintenance

The hours of Operate

Observation Consult

Brake system

10

each other

50

150 300 600 1200

Check the function of the

stopping brake and the

working brake
Check

seepage If seepage, find out the

the

situations of the tube, reason;

Check the pressure of

brake

necessary,

would change the part

hose junction

the

If

or

check

respectively.

Daily

test

pressure

instrument (sensor). See

the

systematic

picture

about the test pressure

The slope of car fully

Text

the

brake

with

recorder

loaded with the vehicle

stay:

working

minimum

35%,

brake
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

Opinion

situation of working brake of

brake

slice

smaller than 3mm

isnt
on

the brake disc and drum

brake
Change the filter input oil

According

to

the

maintenance

Check pressure of all See the system picture

brake system

about test pressure

According to server time to maintain regularly figure 9:

Maintenance
Lubricating point

The hours of operating

Measure observe
See each other

10

50

Drive shaft
convertergearbox

Butter pump nozzle

Drive shaft
gearboxfront axle

Butter pump nozzlethree

Drive shaft
gearboxrear axle

Butter pump nozzle

Swing rotation axis

Butter pump nozzle

Central

knuckle

joint

pivot

Butter pump nozzletow

The steering cylinder

Butter pump nozzletow

Rising cylinder

Butter pump nozzletow

The tumble cylinder

Butter pump nozzletow

Butter pump nozzle

Butter pump nozzle

Butter pump nozzle

Stabilization plant pole

(prop up the foot)
Big boom- connecting
rod
The big boom rotates
bearing

Big boom bucket

Butter pump nozzletow
bearing

Working
shaft

operating

150

Butter pump nozzletow

Steering operate shaft Butter pump nozzle

38

300

600 1200

Note

Gearbox
shaft

operating

Position that all joints

move about

Butter pump nozzlefive

HDengine oil

39

Figure 1

40

Figure 2

41

R1
T1
T1
R
T2

T2
R2
N

Figure3

42

Figure 4

43

Figure 5

44