The following manual is for reference purpose only and we make no claim of representation for the product or manufacturers.
This operator's manual covers general information that applies to most 1 ton China made mini excavators.
HYDRAULIC MINI EXCAVATOR
OPERATION & MAINTENANCE MANUAL
Preface
Chapter I Usage Features and Performance Parameters of Excavators
Section I Usage and features
Section II Main performance parameters
Chapter II Basic Structures and Work principle of Excavators
Section I Overview
Section II Work principle
Section III Basic structure of mechanical system
Section IV Basic structure of hydraulic system
Chapter III Service Technologies of Excavators
Section I Basic construction knowledge
Section II Preparation for work
Section III Operational essentials
Section IV Operational precautions
Chapter VI Maintenance of Excavators
Section I Daily inspection
Section II Periods of overhaul, medium and minor repair
Chapter VII Troubleshooting of Excavator
Section I General
Section II Troubleshooting of mechanical system
Section III Troubleshooting of hydraulic system
Section IV Troubleshooting of electrical control system
Section V Troubleshooting of engine
Section VI Other
Attachment: BOM List of Parts
As product improvements, technical data and parameters change
1
Chapter I Usage Features and Performance Parameters of
Excavators
Section I Usage and features
Excavators are provided with excavating, crushing, ditch cleaning, drilling and bulldozing, with their
attachments quick hitched and thus its utilization up greatly. In addition, they are easy to operate and transport
and flexible to work at narrow site.
Excavators, hydraulic type with single bucket
This type of excavators are mainly applied to: farming, landscaping, ditching and fertilization in garden, vegetable
greenhouse, agricultural transformation, indoor demolition, small earthwork, civil engineering, road recovery,
basement and indoor construction, concrete breaking, burying of cable, laying of water supply line, garden
cultivation, desilting and others.
The excavator are equipped with Changchai diesel engines.
Excavators are able to equipped with multiple work equipments, such as quick hitch, log grab, ripper, leveling
bucket, auger and narrow bucket, as well as optional roof, radiator and others, so as to meet your needing.
2
Quick hitch
Narrow bucket
Log grab
Mechanical thumb
Auger
Ripper
Rake
3
Section II Main performance parameters
4
Overall dimensions
A Wheel track
Unit: mm
895
B Overall length of track
C Ground clearance of platform
D Ground clearance of platform tail
E Chassis width
1203
357
800
930
F Crawler width
180
H Crawler height
313
I Transportation length
J Overall height
2775
2219
Work range
Unit: mm
2850
1650
2600
1800
1380
1300
110
A Max. digging radius on ground
B Max. digging depth
C Max. digging height
D Max. unloading height
E Max. vertical digging depth
F Min. swing radius
G Max. lifting height of dozer blade
H Max. digging depth of dozer blade
110
Performance parameters
Weight of complete machine kg
Standard bucket capacity m³
Rated power kw
900
0.025
8.2Kw/3600r/min
5
Chapter II Basic Structures and Work Principle of Excavators
Section I Overview on excavators
Excavator is composed of power train, work equipment, swing mechanism, control mechanism, drive system,
traveling mechanism and auxiliary equipment, as shown in fig. 1-1. Mounted on the rotary table are the regular
full-swing type hydraulic excavators, main components of drive system, swing mechanism and auxiliary devices,
which are referred to as upper rotary. Therefore, a excavator is divided into work equipment, upper rotary and
traveling mechanism.
6
Section II Work principle of excavators
Diesel engine changes the chemical energy of diesel into mechanical energy that is then altered with hydraulic
gear pump to hydraulic energy that is distributed to each actuating element (such as hydraulic cylinder, swing
motor and traveling motor). After that, each actuating element transform the hydraulic energy back to mechanical
energy, driving the work equipment and running the complete machine.
Central
slewing joint
Movement and power transmission route of excavator shown below:
1
2
3
4
5
.
.
.
.
.
Traveling power route: diesel engine —— coupler —— hydraulic pump (mechanical energy changed to
hydraulic energy) —— distributor valve —— central swing joint —— traveling motor (hydraulic energy
changed to mechanical energy)—— sprocket —— rubber crawler—— starting of traveling
Swing power route: diesel engine —— coupler —— hydraulic pump (mechanical energy changed to
hydraulic energy) —— distributor valve—— swing motor (hydraulic energy changed to mechanical energy)
—— slewing bearing —— realizing of wing
Boom power route: diesel engine —— coupler —— hydraulic pump (mechanical energy changed to
hydraulic energy) —— distributor valve —— boom cylinder (hydraulic energy changed to mechanical
energy)——boom movement
Arm power route: diesel engine —— coupler —— hydraulic pump (mechanical energy changed to hydraulic
energy) —— distributor valve —— arm cylinder (hydraulic energy changed to mechanical energy) —— arm
movement
Bucket power route: diesel engine ——coupler —— hydraulic pump (mechanical energy changed to
hydraulic energy) —— distributor valve —— bucket cylinder (hydraulic energy changed to mechanical
energy) —— bucket movement
7
Section III Basic structure of excavators mechanical system
1
Power system
Excavator is equipped with single-cylinder air-cooling diesel engine.
2
Drive system
Excavator's drive system could transfer the output power from diesel engine through the hydraulic system to
work equipment, swing mechanism and traveling mechanism.
3
Swing mechanism
Swing mechanism could turn the work equipment and upper rotary leftwards and rightwards, so as to do the
excavating and the unloading. excavator’
s swing mechanism has to fix the rotary table onto frame and has it swing flexibly, without any inclining risk.
Therefore, excavator is equipped with a slewing support (supports) and a slewing drive (power of turntable
slewing), which are called by a joint name as swing mechanism.
3
.1 Slewing support
Excavator has its rotary table supported with a rolling bearing, realizing the swinging of upper rotary.
.2 Rotary drive
3
Excavator adopts the direct drive type. Namely, the output shaft of low-speed high-torque hydraulic motor is
mounted with a driving pinion which meshes with the slewing gear ring. .
4
Traveling mechanism
Traveling mechanism supports the complete weight of excavator and drives it to run.
Excavator has the crawler traveling mechanism similar to other crawlers, with one hydraulic motor driving one
track. This excavator adopts low-speed high-torque motor. When two hydraulic motors run in the same direction,
this machine goes straightly forward; when one motor is supplied with oil and the other is braked, excavator steers
around the braked track; when two motors runs reversely, excavator rotates insitu.
Each part of traveling mechanism is mounted on integral traveling frame. The pressure oil from hydraulic pump
goes through the multi-way directional valve and the central swing joint into the hydraulic traveling motor that
changes the pressure energy into output torque that then goes to sprocket, driving excavator to run.
Excavator’s sprockets are of integral castings and able to correctly engage with track, featuring balance drive.
Sprockets located at rear part of excavator, shortening the tensioner part and relieving the track abrasion, wear
and power consumption. Each track is equipped with a tensioner, adjusting the track tension and reducing the
track vibration noise, abrasion, wear and power loss.
5
Work equipment
The hydraulic excavator could have multiple work equipment, up to dozens of varieties, with backhoe and ripper
most popular.
Excavator has the boom, arm and bucket articulated with each other,
as shown in figure and swing around their articulated points respectively with aid of the hydraulic cylinder,
finishing the excavating,lifting and unloading.
5
.1 Boom
As the main component of backhoe work equipment, the integrated skewed boom is adopted on excavator.
Being of the most popular type at present, skewed boom could allow excavator to dip deeper and to lower the
unloading depth, satisfying the backhoe requirements.
8
5
.2 Bucket
5.2.1 Basic requirements
1
)
The longitudinal profile of bucket meets the law of motion of various materials inside of bucket,
facilitating the material flow and minimizing the loading resistance and thus fulfilling thebucket.
2
)
Bucket teeth are mounted to increase the linear specific pressure of bucket onto material, with unit
cutting resistance relatively low and easing to cut in and break soil. In addition, the teeth are
resistant to wear and easy to replace.
3
)
The load is easy to get off, shortening the unloading time and increasing the effective capacity of
bucket.
5
.2.2 Structure
Bucket shape and size for backhoe are highly related to work objects. In order to meet various excavation,
one excavator could be equipped with multiple types of buckets, with backhoe most popular. Bucket
teeth could be mounted with rubber pins and bolts
Connection between bucket and hydraulic cylinder is of linkage mechanism, with bucket directly
articulated with hydraulic cylinder, which drops the rotation angle of bucket but enables the work torque
to change greatly. .
9
Hydraulic system structure of excavators I. Rotary motor
1
0
II. Main pump
Lug-shaped baffle
Lug-shaped gasket
Side plate
Pump body
Rectangular seal
ring
Front cover
Oil seal NY19×32×7
Retainer 32
Driving gear shaft
Washer 10
Screw M10×65-
D
10.9
Nylon
Rubber L-4
Rubber L-4
Bearing
Combine parts
Combine parts
1
1
Traveling motor
Disc Valve Motors---6000 series -005 and -006
1
2
Section IV Schematics of main valve
Reserved
Steering
Arm
Traveling
Front shovel
Traveling
Boom
Bucket
1
3
Section V. Electrical system diagram
1
4
Chapter III Service Technologies of Excavators
Being of high temperature and pressure, the excavator could have the hydraulic oil temperature as high as 85℃,
the engine silencer temperature as high as 700℃ and pressure as high as 16-18MPa. Therefore,
the operators should be specially trained to obtain the proper certificates and to be familiar with the contents in
this manual before the operations. In addition, maintenance and repair of excavator should be strictly in line with
regulations to avoid any accident.
Section I Basic construction knowledge
There are four basic movements: bucket rotation, arm stretching / backing, boom lifting / lowering and turntable
swinging.
In general, pulling/pushing of hydraulic cylinder and rotation of hydraulic motor is controlled with three-way
axial slide valve through the oil-flow direction and the work speed is controlled by operator or auxiliary devices
according to the quantitative system and the valve openness.
1
.1 Basic requirements on control system
Basic requirements on control system include:
1
)
Control system should be centralized in the driving area of upper rotary and satisfy the man-machine
requirements. For example, controllers and driver seat should be designed according to 160-180 cm for
males and 150-170 cm for females.
2
3
4
5
)
)
)
)
Startup and stop should be steady, with its speed and strength in control. At the same time, the combine
actions should be also in control.
Easy, handy and visual operations In general, the operational force on handle does not exceed 40～60 N
and handle travel does not exceed 17cm.
Control mechanism should minimize the deformation of its lever, as well as the inside clearance and the
idle travel.
Ensure the operational performance does not change in -40～50℃.
Section II Preparation for work
1
.
Inspection before startup
In order to prolong its service span, check the following before startup:
①. Check if there is dirt around or below machine, bolts loosened, any oil leaked and if any part damaged or
worn.
②. Check if all switches, lamps and fuse box could work normally.
③. Check if the work equipment and hydraulic parts could work normally.
④. Check if all engine oil levels and fuel level are proper.
The above should be checked normal; otherwise engine cannot be started up until they are checked normal after
troubleshooting.
2
.
Maintenance before startup
Before startup each shift, it is needed to grease the work equipment and the slewing bearing.
Preheating of machine on cold days
3
.
If it is cold, engine is difficult to start up, fuel may be frozen and hydraulic oil may increase its viscosity.
Therefore, selection of fuel should be dependent on environment temperature.
1
5
When hydraulic oil is less than 25℃, it is needed to preheat the machine before any work; otherwise
machine may not respond or react very quickly, leading to severe accident.
Therefore it is needed to preheat machine if it is cold:
①. Adjust the manual accelerator to have engine run at medium speed, and then slowly move bucket forth and
back for 5min.
Caution: do not operate other actuators than the bucket.
②. Adjust the manual accelerator to have engine run at high speed, and then move the boom, the arm and the
bucket for 5-10min.
Caution: operations are merely limited on boom, arm and bucket, instead of any slewing or traveling.
③. Each complete action of excavator should be carried out for a few times, completing the preheating and ready
to work.
Section III Operational essentials
1
.
Traveling
Use the traveling handles.
1) Straight
Forwards or backward move the handle, running the machine forwards or backwards.
2) Steering
(
(
A. Left turn in situ: backward shift the left handle and meanwhile forward push the right handle.
b. Right turn in situ: backward shift right handle and meanwhile forward push the left handle.
c. Left turn with left track as axis: forward move the right handle
d. Right turn with right track as axis: forward move the left handle
2
.
Excavation
2
.1 The excavator slewing and the work equipment are respectively controlled with two handles, with positions
shown below:
Forward
Forward
Forward
Right travel
Dozer shovel
Left travel
Back
Back
Back
1
6
2
1
.2 Basic excavation
.
Before excavation, the arm cylinder should have angle with the arm as 90°, bucket with ground to be
excavated as 30°. Only in such case, can each cylinder have the max. excavating force. It is suitable for
relatively hard soil, so as to decrease the excavating resistance.
2
2
.
To excavate any soft soil, bucket should be angled with the soil to be 60°, increasing the work efficiency.
.3 Lower excavation
Keep the angle between bucket base and the bevel at 30°, and retract the arm to start work.
.4 Upper excavation
Keep the bucket blade vertical to the ground, and retract the arm to start work.
.5 Ditching is carried out in 7 steps, as shown in figure.
2
2
1
7
Section IV Operational Precautions
Prohibitions and precautions for hydraulic excavators
1
2
3
.
.
.
Avoid the landsliding and the stone falling.
Avoid any striking of work equipment.
Avoid the bucket from colliding with other vehicle body, the loaded bucket crossing over other vehicle cab or
persons.
4
5
6
7
8
.
.
.
.
.
Avoid the excavator from sinking into soft ground or wetland.
In traveling, avoid any large obstacles such as large stone.
It is prohibited to work with water depth exceeding the allowable limit.
While unloaded or loaded, the large stones should be handled carefully not to fall down.
On cold days, park the machine on solid ground to avoid the track being frozen. Remove any scrap away
from track and its frame. If track is iced onto ground, use boom to lift track and carefully move the machine,
so as not to damage the sprocket and the track.
9
1
.
Before movement of machine, make sure the traveling direction is consistent with its handle. When traveling
motor is at rear part, forward push the traveling handle, to drive machine forwards.
0. For long - distance traveling, please rest for 5min every running for 20min, so as not to damage the traveling
motor.
1
1
1
1
1. Never try to cross over a slope of more than 15 degree, so as to avoid the machine from overturning.
2. Avoid any accidents occurring during machine reversing or slewing.
3. In work, do not completely dig the soil out of bottom of machine.
4. Avoid any collapse: never run on high dam or slope, which otherwise may have the machine collapsed or
sliding away, leading to severe accident.
1
1
5. Be careful of underground facilities: unexpected cutoff the underground cables or gas pipe may lead to
explosion, fire or even personal casualty.
6. Be careful of overhead facilities such as bridge: if work equipment or other parts collides with over-bridge or
others, it may result in personal injury; care must be taken to prevent the boom or the arm from colliding
with any elevated item.
1
7. Keep safe distance from overhead power line: in work around power line, do not have any part of machine or
any load move to 3m timed by 2 of away from the power insulation. Verify and abide by the local related
laws and rules. Wetland may have the range of electric shock enlarged. Therefore, the irrelative should be
kept away from work area.
1
8
Chapter VI Maintenance of Excavators
Section I Daily inspection and maintenance
Interval (h)
50
S/N
Item
Quantity
Remark
1
0
Check the engine oil level in sump
Check the hydraulic oil level in hydraulic oil tank
Check the fuel level in tank
1
1
1
★
★
★
★
Check the oil-water separator to completely drain
any water or sediment out.
1
Check if the fuel pipe is leaked or cracked.
Check if the fuel pipe is cracked or bent.
Check the work equipment pivots
----
----
----
----
4
★
★
★
★
Check if the hydraulic hose and the pipeline leak
Check if the bucket teeth is worn or loosened.
Check the seatbelt
★
●
1
★
Check the bolts and nuts for tightening torque
Check the bolts and nuts for tightening torque
----
----
Aperiodically
Note: ★: Maintenance interval under normal conditions
: Maintenance needed at the first inspection
: Initial 100h
●
◆
1
9
Section II Periods of overhaul, medium and minor repair
Interval (h)
Quantity
S/N
Item
Remark
1
00 250 500 1000 1500 2000 2500 4000
Greasing of slewing
bearing
1
★
Greasing of slewing
bearing gears
2
3
4
★
Change the engine oil
●
▲
★
Change the hydraulic
oil.
△
★
△
Change the hydraulic
oil suction filter
elements
5
★
Check if the fuel pipe
is cracked or bent.
6
7
8
9
★
Change the oil-water
separator
★
Check the fuel hose
for leakage / crack
★
★
Check the fuel hose
for crack / leakage
1
0
1
Change the bucket
1
Connection of bucket
Remove the traveling
handle
1
1
1
2
3
4
Replace the seatbelt
Check the defection of
track
★
Maintenance of
tensioner
1
5
★
★
Note: ★: Maintenance interval under normal conditions
▲
△
☆
: Maintenance interval of engine oil
: Change interval of hydraulic oil is dependent on the work oil type.
: Under the dusty environment, shorten the maintenance interval.
2
0
Technical maintenance
A Grease
Interval (h)
250
Parts
Quantity
10
1
0
50
100
500
1000
2000
Pivot at base of boom
Pivot at base of boom
cylinder
1
. Lubrication
★
★
of work
equipment
pins
Pivots of bucket and
connecting rod
Others:
6
2
2
3
. Lubrication of slewing bearing
★
. Lubrication of external meshing
gear of slewing bearing
1
★
Note: it is recommended to use the lithium grease.
Maintenance interval under normal conditions
★
1
.
Maintenance and lubrication of work equipment pivots
●
Pivot between bucket and connecting rod
●
Pivot at base of boom
●
Pivot at base of boom cylinder
2
1
●
Others
Pivot between boom and arm; pivot of arm cylinder plunger; pivot at
base of bucket cylinder.
2
1
2
3
4
5
6
.
.
.
.
.
.
.
Slewing bearing - every 250h
Park machine on the flat ground.
Lower the bucket onto ground.
Idle engine at low speed for 5min.
Turn the ignition switch to OFF and then take off the key.
With the upper-structure standing still, add the grease into the two grease nipples.
Start up engine to lift the bucket free from the ground, and then swing the upper-structure by 45 degree (1/8
cycle).
7
.
Lower the bucket onto ground.
3
. External meshing gear 45 of slewing bearing----- every 500h
Lower the bucket onto the ground
Turn off the engine.
1
2
3
4
5
.
.
.
.
.
Park machine on the flat ground.
Lower the bucket onto ground.
Idle engine at low speed for 5min.
Turn the ignition switch to OFF and then take off the key.
The grease has to be stored on the top of external meshing gear of slewing bearing, free of any pollution.
Add approximate 0.5kg of grease if needed.
Any polluted grease should be replaced with new one.
2
2
B. Engine oil
Interval (h)
Parts
Quantity
1
0
50
100
●
250
▲
500
★
1000
2000
Engine oil
1
1
Engine oil filter
●
▲
★
According to the temperature range during the interval, select the viscosity of oil listed in the table below:
Recommended engine oil brand: 15W—40 engine oil
2
3
Inspection of engine oil level ―――-each day
Change of engine oil ―――every 500 h
Change the engine oil filter ―――every 500 h
1
2
3
4
5
6
7
8
9
1
1
1
.
.
.
.
.
.
.
.
.
Start up engine to preheat up engine oil properly.
Park the vehicle on the flat ground.
Lower the bucket onto the ground.
Idle engine at low speed for 5min.
Turn the ignition switch to OFF and then take off the key.
Take off the drain plug to have oil pass through clean cloth into the 2L container.
After that, check if there is metal scrap or others left on cloth.
Put the drain plug back on and tighten it
Loosen the drain plug to have oil flow through the filter cylinder into a container.
0. Take off the screws fixing the engine oil filter elements with a screwdriver to take the filter element out.
1. Reinstall the new filter and tighten the screws fixing the new element with a screwdriver.
2. Remove the oil filter cap to add the recommended oil into engine. After 15 min, check if the oil level is
between the circle markers.
1
1
1
1
3. Put the oil filler cap back on.
4. Shut down engine Unplug the ignition key.
5. Check if the drain plug is leaking.
6. Check the oil level on dipstick.
Caution: keep your body and face away from the breather. When gear oil is still hot, please wait until
it cools down and then slowly release the breather pressure!
C. Hydraulic system
Interval (h)
Parts
Quantity
1
0
50
100
250
500
1000 1500 2500 4000
Check the hydraulic oil level
1
1
★
Clean the drain pipe of
hydraulic oil reservoir
★
Change the hydraulic oil.
16.5L
1
★
Change the hydraulic oil
suction filter elements
★
Check the
hose and
pipeline
--
★
--
★
Change the hose
39
★
Note: ★ normal maintenance interval
2
4
Inspection and maintenance of hydraulic system
Caution: in work, the hydraulic system may become very hot. Please cool the machine down before
inspection or maintenance!
1
2
3
.
.
.
Before maintenance of hydraulic system, make sure the machine stands on flat and solid ground.
Lower the bucket onto ground and shut down engine.
Do not start any maintenance until the systems, hydraulic oil and lubricant completely cool down, as the
hydraulic system may be still hot and pressurized as soon as work is over.
a. Drain the air out of hydraulic oil reservoir to release inside pressure.
b. Cool the machine down.
Caution: inspection and maintenance of hot and pressure parts may cause them or hydraulic oil to
spray out, leading to personal injury!
c. While removing the bolts or nuts, do not have your body facing them, as the hydraulic parts, even if
they cools down, still have pressure. .
d. Never try to check the traveling or slewing motor circuits on slope, as they may have pressure due to
their dead weight. .
4
.
While connecting the hydraulic hoses and pipeline, keep the seal surface free of any dirt and damage. Keep
the above mentioned in mind:
a. Clean the hose, the pipeline and inside of hydraulic oil tank with detergent, and then thoroughly dry
them.
b. Use the O-ring free of any damage or defect.
c. While connecting the pressure hose, do not twist it; otherwise its service span will be shortened. .
d. Carefully tighten the low-pressure hose clamp.
5
6
.
.
The hydraulic oil to be added should have the same grade. Namely, do not mix the oil with different grades.
The hydraulic oil has been added before delivery, and therefore, please use the recommended oil. All oil in
system should be changed at once.
With no hydraulic oil, never start up engine.
2
5
I. Inspection of hydraulic oil level --- each day
Important: With no hydraulic oil, never start up engine!
1
2
3
5
6
8
.
.
.
.
.
.
Park machine on the flat ground.
Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine.
Lower the bucket onto the ground.
Idle engine at low speed for 5min.
Shut down engine Unplug the ignition key.
Check if the oil level in hydraulic oil tank between the markers on dipstick, and add it if needed. . .
Caution: Hydraulic oil tank has pressure, and therefore slowly open its cap to release pressure before adding of
oil. .
9
1
.
Open the hydraulic oil tank to add oil and then
check the oil level again. .
0. Put the cap back on hydraulic oil tank
2
6
III. Change the hydraulic oil ---2000 h
Replace the hydraulic oil suction filter element-----every 1000 h
Caution: do not do so until the hydraulic oil cools down as it may be very hot.
1
2
3
4
5
6
7
8
9
1
1
.
.
.
.
.
.
.
.
.
Park machine on the flat ground.
Completely retract the arm cylinder and extend out the bucket cylinder, so as to locate the machine.
Lower the bucket onto the ground.
Idle engine at low speed for 5min.
Shut down engine Unplug the ignition key.
Dismantle the covers
Clean the top of hydraulic oil reservoir to avoid any dirt into its system.
Slowly open the hydraulic oil cap to release the pressure.
Loosen and take down the oil-pickup filter element cap.
0. Loosen and take down the drain plug at bottom of hydraulic oil tank to drain the oil out of tank.
1. Take out the oil-pickup filter and the levers.
Caution: the hydraulic oil tank has pressure. Slowly open the hydraulic oil cap to release the pressure
before taking off the cap!
1
1
1
1
1
1
2. Clean the filter and inside of hydraulic tank.
3. Use oil -pickup pump to suck the oil residue out of bottom of hydraulic oil tank.
4. Put on the filter and the levers to make sure the filter is correctly fixed onto the outlet.
5. Clean and re-install the drain plug onto the bottom of tank.
6. Add the oil until between markers on oil dipstick.
7. Put on the oil-pickup filter element cap to make sure the filter and the levers are at correct position and then
tighten the bolts to 49N.m.
Important: with no oil in hydraulic pump, starting up of engine may damage to hydraulic pump!
1
1
8. Tighten the oil tank cap.
9. With engine idling at low speed, slowly and steadily control
the lever for 15min to drain the air out of hydraulic system.
2
0. Completely retract the arm cylinder and extend out the
bucket cylinder, so as to locate the machine.
2
2
1. Lower the bucket onto the ground.
2. Turn off the engine. Unplug the ignition key.
2
7
2
3. Check the hydraulic oil level in hydraulic oil tank and add it if needed. .
V. Inspection of hose and pipeline
--- Each day
---every 250 h
Caution: any sprayed fluid could penetrate your skin, leading to personal casualty!
Therefore, use a paperboard to check for leakage.
In addition, care must be taken to keep your hands and body away from pressure oil.
In case of accident, please immediately go to doctor with trauma experience. Any fluid into skin has to
be removed in a few hours, which otherwise may lead to gangrene.
Caution: leaked hydraulic oil and lubricant may lead to fire or personal casualty!
1
2
3
.
.
.
Park machine on the flat ground. Lower the bucket onto the ground. Shift the pilot switch to Lock Turn off
the engine. Unplug the ignition key.
Check if there is lost part, loosened pipe clamps, twisted hose, pipeline or hose rubbing with each other. In
case of any abnormal, please replace or tighten it according to table 1-3.
Tighten, repair or replace any loosened, damaged or lost pipe clamps, hoses, pipes, oil cooler and flange bolts.
Do not bend or impact any pressure pipeline.
Never install any bent or damaged hose orpipeline.
Caution: related positions of check points and the abnormalities
2
8
Please use the genuine excavator parts
Interval (h)
Check points
Abnormal
Measures
Replace it
Replace it
Hose surface
Hose end
Leakage 1
Leakage 2
Leakage 3
Every day
Tighten or replace the
hose or O-ring
Connector body
Crack 4
Crack 5
Replace it
Replace it
Replace it
Replace it
Replace it
Hose surface
Hose end
Reinforcing material
protruded 6
Hose surface
Hose surface
Hose
Every 250h
Local part protruded 7
Bend 8
Change it (proper bending
radius)
Hose
Bend 9
Hose end and joint body
Deformation or corrosion
Replace it
1
0
2
9
Fuel system
capacity of fuel tank: 7L
Interval (h)
250
Parts
Quantity
1
0
50
100
500
1000
2000
Drain dirt out of collector of fuel
tank
1
★
Check the oil-water separator
Change the oil-water separator
1
1
★
★
Leakage
--
--
★
★
★
★
Check the
fuel hose.
Crack / twist / others
★
Maintenance interval under normal conditions
Recommended fuel:
Merely use the quality diesel (selection of fuel grade should be dependent on environmental temperature).
Fill up the fuel
1
2
4
5
.
.
.
.
Park machine on the flat ground.
Lower the bucket onto ground.
Idle engine at low speed for 5min.
Shut down engine Unplug the ignition key.
Caution: fuel should be disposed carefully. Before filling of fuel, shut down engine. No smoking
before filling fuel or with fuel system working.
6
.
Pay attention to the fuel scale. Add the fuel if needed.
Important: keep any dirt, dust, water or other foreign material from getting into fuel system!
7
8
.
.
While filling of fuel tank, make sure the fuel is not sprayed on machine and added properly.
Put the cap back on fuel filler to avoid any lost or damage.
Inspection of oil-water separator ---every 200h
Oil-water separator ① is used to separate the water or sediment from fuel. Oil-water separator ① has a float able
to rise up when water becomes full. When there is water or sediment in the collector of oil-water separator, please
drain oil-water separator ①.
Important: shorten the inspection interval of oil-water separator ① if there is excessive water in the fuel!
Drain steps:
Caution: the drain plug is designed to be counter - thread type and should be turned with hands, instead of vise
and wrench for protection of threads.
3
0
1
.
Manually loosen the drain plug at bottom of oil-
water separator.
2
.
After the draining, manually tighten the drain to
ensure no leakage of oil or air.
Caution: after the draining, make sure air is drained out
of fuel system to make sure the engine could start up
normally.
Electrical system - battery
I. Check the battery electrolyte level and the terminals.
Caution: gas inside of battery may explode it. Therefore, keep any spark and flame away from battery.
Use a flashlight to check the electrolyte level. In addition, the sulphuric acid in battery electrolyte is as toxic as to
burn your skin or your cloth holes or to blind your eyes. . .
Therefore, take the following methods to avoid any rick:
1
2
3
4
.
.
.
.
Refilling of battery should be done at well-ventilated site.
Put on goggles and plastic gloves.
Care must be taken not to spray out the electrolyte.
Use the proper measures to assist battery startup.
If touched with acid:
1
2
3
.
.
.
Rinse the skin
Use the soda or the lime to neutralize the acid.
Rinse eyes for 10 - l5 min and then go to doctor.
Caution:
a. Always firstly disconnect the battery clips (-) away from the ground and then lastly connect it.
b. Always keep the terminals at top to battery and the breather clean, to avoid the battery from discharging.
Check if the battery terminal is loosened or rusted. Coat the terminals with vaseline to avoid anycorrosion.
3
1
Replace the battery
There is a 12V battery with one negative pole (-) grounded.
If battery cannot be charged or store any electricity, replace the battery with same model.
Replace the fuse.
If the electrical device does not work, please firstly check the fuse.
Important: please install the fuse with correct amperage, so as to prevent against burning of electrical system due
to overloading!
Others
Interval (h)
Parts
Quantity
1
0
50
100
250 500
1000
2000
4000
Check if the bucket teeth is worn or
loosened.
★
Change the bucket
—
—
If needed
Replace the bucket and connect the
new one to machine.
If needed, replace the bucket and connect the new one to
machine.
Adjust the connecting rod of bucket
Take down the traveling lever
Check and replace the fuse
Check the track defection
1
2
1
If needed
If needed
★
Every 3 years
2
2
★
Maintenance of tensioner
★
Check the fuel injection timing
—
If needed
Measure the compression pressure of
engine
—
—
—
Check the starter and the A/C
generator
Check the bolts and nuts for
tightening torque
★
Note:
★
Maintenance interval under normal conditions
Maintenance needed at the first inspection
Contact dealers or Rhinoceros.
Check the bucket teeth --- each day
Check if the bucket teeth is worn or loosened.
1
.
Worn beyond the service limit, the bucket teeth may be replaced.
Bucket tooth dimensions mm
New
Service limit
130
1
90
3
2
Caution: care must be taken to avoid the metal scrap from flying out, leading to personal injury. Wear
the goggles or the safe glasses or safe devices suitable for operations!
Change the bucket
Caution: while hitting out or into the connecting pin, care must be taken to prevent against any
personal injury due to out-flied metal scrap. Wear the goggles or the safe glasses or safe devices suitable for
operations!
1
.
Park the machine on flat ground and lower the flat surface of bucket onto ground to make sure the bucket
does not move after the removal of pin.
2
3
.
.
Slide the O-ring out, as shown in the figure.
Remove the bucket pins A and B to separate the bucket and the arm. Clean the pin and its pin hole and then
properly grease them.
4
5
6
7
.
.
.
.
Adjust the arm and the new bucket correctly, and make sure the bucket does not roll away..
Install the bucket pins A andB.
Put the locker and ring onto pins A andB.
Adjust the connection clearance of bucket at pin A. Refer to the way to adjust the bucket connection
clearance.
8
9
.
.
Grease the pins A andB.
Start up engine and run it at low speed. Slowly rotate the bucket to two directions to check if there is any
interference to movement of bucket. Do not use any machine with interference, which should be solved
immediately. .
3
3
Check the bolts and nuts for tightening torque
…every 250 h (initially at 50 h)
…
Check the tightness at initial 50h and then every 250 h. Tighten it to the set torque if needed. Replace it with bolts
and nuts with same or higher grade.
Important: please use the torque wrench to check the torques of bolts and nuts!
Metric bolts and nuts
Thread dimensions
Standard torque (N.m)
Thread dimensions
Standard torque (N.m)
160±30
M6
M8
12±3
28±7
M14
M16
M20
M30
240±40
M10
M12
55±10
100±20
460±60
1600±200
2
. Torque of main components: (N.m)
Thread dimensions
Recommended torque
M16 bolts fixing the traveling motor
M16 bolts fixing the sprocket
252±39.2
252±39.2
570±60
M20 bolts fixing the slewing bearing
M20 bolts fixing the swing mechanism
570±60
Important:
1
2
.
.
Before installed, the bolts and nuts should be cleaned.
Grease the bolts and the nuts (such as the white zinc b able to be dissolved to lubricant), so as to stabilize
their abrasion coefficient.
3
.
The counterweight bolts should be kept tightened up.
Caution: all the tightening torques should be expressed with kgf.m.
For example: use a wrench with 1m long to tighten the bolts and nuts, and apply 12kgf of force to the end of
wrench, generating the following torque:
1
m×12kgf=12kgf.m
To generate the same torque with 0.25m wrench: 0.25m×y=12kgf.m
Needed force: y=12kgf.m／0.25m=48kgf
3
4
Maintenance under the special cases
Operational conditions
Precautions for maintenance
Before operation, check all the drain plugs are tightened up.
Moor land, rainy or snowy
On beach
After operation, clean machine and check bolts and nuts for break, damage,
looseness or loss. Lubricate all parts to be lubricated on time.
Before operation, check all the drain plugs are tightened up.
After work, thoroughly clean the clean to remove the salt. Frequently maintain
the electrical system from being corroded.
Air filter: clean the filter element periodically or at shorter interval
Radiator: clean the oil cooler screen to avoid any blockage.
Dusty environment
Stony roads
Fuel system: clean the filter and its element periodically or at shorter interval.
Electrical devices: periodically clean it, specially the AC generator and starter’s
rectifier.
Track: careful operations Frequently check if bolts and nuts are broken, damaged
or lost. Loosen the track a little than the usual.
Work equipment: parts may be damaged on stony roads, and therefore please use
the reinforced bucket or heavy-duty bucket. .
Fuel: use the high fuel suitable for low temperature
Lubricant: hydraulic oil and engine oil with dry quality and low viscosity.
Battery: keep the battery fully charged and maintain it at shorter interval. The
electrolyte may be frozen if it is not fully charged.
Freezing cold
Track: keep the track clean. Park the machine on solid ground to avoid the track
frozen.
Roof at driver seat: add the protective for cab roof if needed to prevent the
machine from being damaged with falling stone.
Falling stone
Storage of machine
1
2
3
4
5
6
7
.
.
.
.
.
.
.
Repair any worn or damaged parts, and put the new one if needed. .
Clean the primary air filter elements.
If possible, retract all the hydraulic cylinders. If not, grease all the plungers exposed out of cylinder.
Lubricate all the grease points.
Put the track on the solid and long pad.
Cleaning of machine especially in winter, clean each part of excavator, especially thetrack.
Fully charged, the battery should be stored at dry and safe site. If battery cannot be taken down, separate the
battery negative pole from (-) pole.
8
9
1
.
.
Painting if needed to avoid rusting.
Store the machine at dry and safe site. If outdoors, it should be covered with water-proof cloth.
0. If machine is to be stored for long time, run it at least once each month.
3
5
Chapter XII Troubleshooting
Section I General
To ensure excellent performance of excavator, all components and parts are of high quality. Machine’s
performance and service life are determined not only by manufacturing quality and assembling quality,
but also maintenance quality.
The marketing representative and service engineer shall remind the user that preventive maintenance is the easiest
and most economical one among various ways of maintenance.
There are daily inspection and long-, medium- and short-term maintenance according to maintenance frequency.
Section II Troubleshooting of mechanism system
Symptom
Possible causes
How to solve
1
2
.
.
The loose fasteners make noise.
1. Inspect and tighten
Noisy structural components
Aggravated
abrasion
between 2. Adjust the clearance to less
bucket and end face of bucket rod
than 1mm
1
.
Deformed spring and weakened
elasticity of bucket tooth pin
Bucket teeth have dropped
during operation
Change the bucket tooth pin
2. Unmatched bucket tooth pin and
seat
1
.
Loose crawler
1. Tighten the crawler
The crawler has tangled up
2. The driving wheel moves fast in
front on rugged road.
2. The guide wheel shall move
slowly in front on rugged road
Section III Troubleshooting of hydraulic system
Symptom
Possible causes
How to solve
Low oil level of hydraulic oil tank that the
main pump sucks no oil
Add enough hydraulic oil
Change the filter and clean the
system
Oil filter is blocked
Engine coupling is damaged (such as plastic
plate, elastic plate)
Change
The main pump is damaged
Change or repair the main pump
Adjust to regular pressure. If it fails
to increase the pressure of servo
overflow valve, disassemble to wash;
if the spring is fatigue, add a washer
or change the spring.
The whole excavator
does not move
The servo system pressure is low or zero
Adjust to regular pressure. If it fails
to increase the pressure, disassemble
and wash. If the spring is fatigued,
ass a washer or change the spring.
The safety valve is set at low pressure or
stuck.
Oil suction pipe of main pump explodes or
comes off
Change with a new one
3
6
Symptom
Possible causes
How to solve
The main pump supplying fuel to unilateral
crawler is damaged.
Change
The main valve rod is stuck and the spring is
broken
Repair or change
Change
The unilateral crawler
fails to move
Traveling motor is damaged
The upper and lower chambers of swivel
joint are connected
Change the oil seal or clean the
assembly
Fuel pipe of traveling system explodes.
Less oil in hydraulic oil tank
Low engine rpm
Change
Add enough hydraulic oil
Adjust engine rpm
Low system safety valve pressure
Serious leak inside the main pump
Adjust to specified pressure
Change or repair the pump
The traveling motor, rotation motor and
cylinder are worn of different degree, which
causes internal leak.
Change or repair the worn parts
The aged sealing components, worn
hydraulic elements, degraded oil of old
excavator cause the operation speed becomes
powerless along with the increase of
temperature.
The whole excavator
moves slowly or
powerless
Change hydraulic oil, change sealing
components of the whole machine,
adjust the fit clearance and pressure
of hydraulic components.
The blocked engine filter causes serious
decrease of loaded rpm and even flames out.
Change the element
The blocked hydraulic filter accelerates
abrasion of pump, motor and valve and leads
to internal leak.
Clean and change the element
according to the maintenance
schedule.
Serious between main valve rod and valve
hole causes serious internal leak
Repair the valve rod
Change the oil seal and change the
groove if it is damaged
Central rotation connector is damaged.
The high pressure chamber and low pressure
chamber of traveling operation valve is
connected.
Change
The right and left
traveling systems do not
move (no other
Serious leak inside the traveling operation
valve
Change
abnormalities)
Low overloaded pressure of traveling valve
of main valve or the valve rod is stuck.
Adjust and grind
The left and right traveling reducers fail
The left and right traveling motors fail
The oil pipe explodes
Repair
Repair
Change
Wrong adjustment of variable point of main
valve or serious internal leak of a pump
Adjust or repair
Change
Deviation during
traveling (no other
abnormalities)
Internal or external spring of one traveling
valve core of main valve is damaged or
tightened
The traveling motor leaks inside due to
abrasion.
Repair or change
3
7
Symptom
Possible causes
How to solve
The sealing component of central rotation
connector is aged and damaged.
Change the sealing component
The left and right crawlers are of different
tightening.
Adjust
Boom (bucket rod and
bucket) move to one
direction only.
Main valve core is stuck or valve rod spring
breaks.
Repair or change
Boom valve rod is stuck or of low
overloaded pressure
Repair
Fuel supply pipe leaks, detached, O ring
damaged or pipe fitting is loose
Boom (bucket rod and
bucket) does not move.
Change the damaged component
Sandstone in main valve or the low pressure
chamber is connected to the high pressure
chamber
Change
Adjust
Boom (bucket rod and
bucket) drops too quick
or the cylinder drops at a
certain height even it is
not operated due to dead
weight
Low overloaded valve pressure
Serious internal leak of cylinder
Loose oil pipe fitting, damaged O ring
Change the sealing component, repair
the inner wall or groove of cylinder
or change the cylinder.
Change
Change
Serious internal leak of multiway valve or
sandstone inside it
Boom (bucket rod and
bucket) works
Low overloaded pressure
Adjust
Serious internal leak of oil cylinder
Change the oil seal
powerlessly
The main valve is disabled due to internal
leak.
Repair or change
Multiway valve core is stuck or serious
internal leak
Grind or change
Change
Multiway valve rod spring breaks
Boom (bucket rod and
bucket) moves even it is
not operated
Leak of working cylinder, or the working
device drops due to dead weight
Change the oil seal
Low pressure of overload overflow valve or
the spring breaks
Adjust to specified pressure. Change
the spring if it is broken.
Wrong grade of hydraulic oil for excavator
Change the hydraulic oil
Wash
Hydraulic oil cooler surface is polluted by oil
and dirt, which blocks the air hole.
Hot hydraulic oil
Low oil level of hydraulic oil tank
Add enough hydraulic oil
The hydraulic components such as motor,
main valve and oil cylinder or sealing
components are seriously worn and cause
internal leak, which increases the oil
temperature. Traveling rotation and working
device are delayed and powerless. The hot
temperature degrades the hydraulic oil. The
safety valve is of poor air tightness, which
leads to overflow.
Change the elements in time
No action of rotation (no Hydraulic oil pipe breaks
Change
3
8
Symptom
Possible causes
Rotary valve rod on main valve is stuck.
Rotary motor is damaged
How to solve
Repair
other abnormalities)
Repair or change
Change
The rotation support is damaged.
The right and left rotation of multiway valve
is of different overloaded pressure
Adjust
Indifferent left and right
rotation speed (no other
abnormalities)
Rotation valve rod of multiway valve is
slightly stuck.
Change pipe fitting and sealing
components
Serious external leak of hydraulic oil pipe
Low overloaded pressure for rotation of
multiway valve
Adjust
Delayed or powered
rotation (no other
abnormalities)
Serious internal leak of rotary motor
Repair or change
The high and low pressure chambers of
multiway valve are connected, sand hole on
valve body due to casting, which causes one-
way action or linked actions
Change
The rotation mechanism
moves even it is operated
Main valve rod spring breaks
Change
Low oil level of hydraulic oil tank
The oil contains too much moisture and air
Safety valve of multiway valve makes noise
Damaged coupling
Add oil
Change
Adjust
Change
The excavator makes
abnormal noise and
Vibration caused by loose pipe clamp
Adjust
shakes during operation. Blocked filter
Air exists in oil suction hose
Change
Release the air
Adjust
Uneven engine rpm
The bearing of working device is not
lubricated or scraped
Apply lubrication oil or change the
shaft or sleeve
Damaged sealing components
Change the sealing components
Coat, paint, repair or change
A groove is found on the piston rod due to
Powerless oil cylinder or abrasion or detachment of chromium coating
oil leak
of piston rod, which causes oil leak.
The air in the cylinder causes shaking noise
during operation
Release the air
3
9
Section IV Troubleshooting of electrical control system
Fault codes of electrical control system of excavator
The engine fails to start
The engine flames out during operation
The engine fails to flame out
Automatic slow-down does not work
Slewing and traveling of all working devices.
Principle diagram
1
.
The engine fails to start
Fault description
●
The engine fails to start
Low engine rpm
Pump fault
Adjust to regular rpm
Change
The fuel pump system does not
supply fuel or supply less fuel
Less fuel in the tank
Add fuel
Fuel tube breaks, tube connector is loose
and O ring is damaged
Change
Possible causes
Standard value in regular condition and reference value of fault diagnosis
Battery voltage
Above 12V
Color of charge state densimeter
1
2
Low battery
Green (if it is white, change the battery)
In case the fuse is burnt, the GND fail may happen.
Fuse F1 and F11 fail
If he monitoring indicator on the monitor panel is not illuminated, inspect the
circuit between battery and specified fuse.
★
Turn the start switch of engine to OFF as preparation and keep it at OFF
during diagnosis.
Engine ignition
switch fault
Ignition switch
Position
OFF
Resistance
1MΩ
3
Between 30 and 17
Start
Below 1Ω
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis.
Pin
85-86
Resistance
200-400Ω
Above
4
5
Starter relay K3 fault
8
7-30
1
MΩ
Below 1Ω
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis.
8
7a-30
★
Security lock switch
fault (open circuit
inside)
Lock rod
Resistance
4
0
Possible causes
Standard value in regular condition and reference value of fault diagnosis
Unlocked
Locked
1MΩ
Between 105 and
GND
Below 1Ω
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis. If all PS, GND, signals and engine start input are correct while engine
start output is abnormal, the engine starter relay fails.
Start motor fault
(open circuit or short
circuit inside)
Engine or start motor
Engine start switch
Voltage
6
PS; terminal B and
GND
2
2
0~30V
0~30V
Start
Input of engine start,
terminal C and GND
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis.
7
8
Alternator fault
Voltage
Below 1V
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis.
Disconnected wire
harness (disconnect
from connector or
poor contact)
Resistance
Below 1
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
diagnosis.
Poor GND of wire
harness (contact with
earth circuit)
9
Resistance
Above 1M
★
Turn the start switch of engine to OFF as preparation and keep it at OFF during
Short circuit of wire
harness (contact with
diagnosis.
1
0
2
4V circuit)
. Engine flames out during operation
Symptom Engine flames out during operation
Voltage
Below 1V
2
●
Standard value in regular condition and reference value of fault
diagnosis
Causes
Disconnected wire
★Turn the start switch of engine to OFF as preparation and keep it at
harness (disconnect from
connector or poor
contact)
OFF during diagnosis.
1
2
Between CN-12T ② and CN-132F ⑥
Resistance
Below 1
★Turn the start switch of engine to OFF as preparation and keep it at
Poor GND of wire
harness (contact with
earth circuit)
OFF during diagnosis.
Between CN-12T ② and CN-132F ⑥
Resistance
Above 1M
4
1
Section V Troubleshooting of diesel engine
1
.
Symptoms of failed startup of engine:
When starting the engine, the starter drives the engine but the engine fails to be started.
Possible causes:
(
(
(
(
(
1) Low battery;
2) Battery terminal is rusted or loose;
3) Battery earth wire is rusted or loose or poor GND of engine;
4) Starter relay armature fails to disengage.
5) Ignition switch fault or starter fault;
How to solve:
(
1) Low battery is caused by electrical appliances that are not powered off in previous day. Next time, do not
forget to power off all electrical appliances at the end of the day. If you have well charged the battery during
driving the day before, the battery shall be on a full charge at the end of the day. For failed start-up caused by
low battery, change the battery pack or connect to another battery pack in parallel to start theengine.
(
(
(
(
(
2) Clean the battery terminal, tighten the PS wire clip to contact the PS wire with battery terminal reliably.
3) Clean the battery earth wire terminal to ensure reliable GND; ensure reliable GND of engine;
4) Repair or change starter relay;
5) Inspect and repair ignition switch and inspect and repair the starter;
6) Long period operation of battery may increase the internal resistance; therefore, it is necessary to repair the
battery and correctly charge the battery and change with new battery pack if necessary; the battery shall be
fully charged to ensure successful start-up of engine.
2
.
Check if it is low fuel level that makes hard to start the diesel engine
Symptom:
When starting the engine, the starter runs at acceptable rpm; however, it fails to start the engine.
Possible causes:
(
(
(
(
(
1) Fuel tank is empty;
2) Fuel supply system channel fault;
3) Air, water or foreign matter exist in fuel system, which block the system;
4) Fuel pump fault;
5) Engine fault;
How to solve:
(
(
1) Fill the fuel tank with standard fuel, start the engine and run the engine to deliver the fuel to carburetor;
2) Inspect pipeline of fuel supply system, fuel filter and fuel pump; change blocked and damaged assembly if
necessary to ensure unobstructed fuel supply.
(
(
3) Release air in fuel system. If the engine can not be started due to air blockage, decrease the temperature
properly.
4) Inspect the fuel pump. Only when the fuel pump works well can the fuel supply be unobstructed. Fuel supply
seldom fails and air blockage and water blockage seldom happen when the fuel supply of fuel pump islarge.
4
2
(
5) Inspect and repair the engine. Only when the engine works well can the start-up fail never or seldom happen.
3
.
Check if it is hard to start the engine
Symptom:
(
(
(
1) Starter runs at correct rpm and drives the engine; however, it is hard to start the engine.
2) It is hard to start the engine when it is cold.
3) It is hard to start the engine when it is hot.
Possible causes:
(
(
(
(
(
(
(
(
(
(
1) Fuel filter is blocked;
2) Fuel pump fault;
3) Wrong injection timing;
4) Low temperature of oil and intake air;
5) Intake air filter is blocked.
6) Leak of fuel tube;
7) Starter fault;
8) Improper start operation;
9) Wrong fuel grade;
10) Engine fault;
How to solve:
(
(
(
(
(
(
(
(
1) Inspect and change the fuel filter;
2) Inspect and change the air filter element;
3) Inspect and adjust the fuel pump;
4) Inspect the fuel tube and oil channel to ensure unblocked oil supply;
5) Inspect the starter and start control device for reliable operation.
6) Start the engine in correct ways.
7) Add fuel of correct grade and discharge the water in fuel in the low part of fuel tank if necessary;
8) Repair the engine.
4
.
Check if the starter fails to start the engine
Symptoms:
(
(
(
(
1) Turn the ignition switch to ON, the starter does not work.
2) The driving gears of starter do not engage.
3) The driving gears of starter fail to disengage.
4) Low engine rpm and uneven engine rpm;
Possible causes:
(
(
(
1) The battery is not fully charged.
2) Terminals of battery are loose.
3) Battery earth wire is loose.
4
3
(
(
(
(
(
(
(
4) Start circuit is disabled.
5) Electromagnetic relay armature is adherent;
6) Starter fault
7) Driving gear of starter is stuck by engine flywheel gear ring;
8) Driving gear of starter adheres to the bearing.
9) The starter fails to drive the engine;
10) Engine fault;
How to solve:
(
(
(
(
(
1) Check if the battery is fully charged; if not, charge it; change the battery if necessary.
2) Connect the battery terminal and connector;
3) Repair the battery earth wire.
4) Inspect the start circuit and ensure the terminal of starter shall be live.
5) Inspect starter electromagnetic relay to eliminate fault of electromagnetic relay; it shall obvious to hear the
sound making by the relay when it sucks and separates.
(
(
(
(
(
6) Inspect and repair the starter.
7) Start again to engage the starter driving gear and engine flywheel gear.
8) Inspect the bearing on the end of starting shaft of starter;
9) Small torque of starter, change the starter if necessary.
10) Repair the engine to ensure sound operation of engine.
4
4
Attachment: BOM of vehicle parts
Exploded drawing of 1 . 0 T excavator assembly
S/N
1
Name
Quantity
Remark
Upper frame assembly
1
1
1
1
1
1
2
2
Lower frame assembly
3
Front work equipment assembly
Slewing bearing assembly
4
5
Connecting shaft between boom and upper frame
Connecting shaft between boom and upper frame
Pivot sleeve
6
7
4
5
1
Lower frame
Part Name
S/N
1
Part No.
1.1
Quantity
Remark
Welded dozer shovel
Welded lower frame
Slewing joint
1
1
2
1.2
3
1.3
1
4
1.4
Rubber crawler
2
5
1.5
Lock nut
2
6
1.6
Sprocket nuts
16
2
7
1.7
Drive wheel
8
1.8
Connecting disc
2
9
1.9
Sprocket bolts
16
8
10
11
12
13
14
15
16
17
18
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
Bolts fixing the track roller
Traveling motor
2
Track roller
4
Idler assembly
2
Pivot nuts
4
Connecting shaft of dozer shovel
Connecting shaft of cylinder
Cylinder of dozer shovel
Bolts fixing idler assembly
2
2
1
8
4
6
2
Upper frame assembly
S/N
1
Part No.
2.1
Part Name
Welded upper frame
Covers of rear housing
Covers of left housing
Covers of right housing
Welded inside support frame
Rear counterweight plate
Arm rest
Quantity
Remark
1
2
2.2
1
3
2.3
1
1
4
2.4
5
2.5
1
6
2.6
1 set
1
7
2.7
8
2.8
Seat and supports
1
4
7
2
Upper frame assembly
S/N
9
Part No.
2.9
Part Name
Left- upper cover
Right - upper cover
L- shaped covers
Console
Quantity
Remark
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22
2.23
2.24
2.25
2.26
2.27
2.28
2.29
2.30
2.31
2.32
2.33
2.34
2.35
2.36
2.37
Pedal
Hydraulic oil tank
Hydraulic oil tank
Hydraulic oil tank support
Diesel tank
Multiway valve
Battery platen
Master cylinder
Coupler
Pump disc
Engine
Rear bracket base of engine
Front bracket base of engine
Intake cover
Battery
Rotary motor
Slewing bearing
Dust cover
Main power switch
Manual accelerator
Key starter
Traveling handle
Work handle
Front shovel handle
Slewing joint pallet
4
8
3
. Front work equipment
S/N
1
Part No.
3.1
Part Name
Boom
Quantity
Remark
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3.2
Arm
3
3.3
Bucket
4
3.4
Connecting rod
5
3.5
Push rod
6
3.6
Boom cylinder
7
3.7
Arm cylinder
8
3.8
Bucket cylinder
9
3.9
Medium shaft of boom
Rear shaft of arm cylinder
Front shaft of arm cylinder
Front shaft of boom
Rear shaft of bucket cylinder
Medium shaft of arm
Front shaft of bucket cylinder
Front shaft of arm
10
11
12
13
14
15
16
3.10
3.11
3.12
3.13
3.14
3.15
3.16
Connecting shaft between bucket and
connecting rod
1
1
7
8
3.17
3.18
1
7
Shaft locker sleeve
4
9
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