Pneumatic Tyre Roller Maintenance Manual

TABLE OF CONTENTS
PNEUMATIC TYRE ROLLER MAINTENANCE MANUAL
Chapter 1 General……………………………………………………………………………………………1-1
1.1 About this Manual………………………………………………………………………………………………1-1
1.2 Overall Structure………………………………………………………………………………………………1-2
Chapter 2 Mechanical Part…………………………………………………………………………………2-1

2.1 Maintaining the Rear Wheel Assembly………………………………………………………………………2-1
2.1.1 Filling Oil into Driving Axle…………………………………………………………………………………2-1
2.1.2 Removing and Maintaining the Rear Wheel Assembly…………………………………………………2-1
2.2 Maintaining the Tyre…………………………………………………………………………………………2-7
2.2.1 Removing the Tyre…………………………………………………………………………………………2-7
2.2.2 Fitting the Tyre………………………………………………………………………………………………2-27
2.2.3 Inflating the Tyre……………………………………………………………………………………………2-9
2.3 Maintaining the Diesel Engine………………………………………………………………………………2-11
2.4 Cleaning the Diesel Tank……………………………………………………………………………………2-14
Chapter 3 Hydraulic Part……………………………………………………………………………………3-1

3.1 Traveling Pump: 90 Series Plunger Pump………………………………………………………………3-1
3.2 51D Series Traveling Motor……………………………………………………………………………………3-2
3.3 Replacing the Oil Cylinder……………………………………………………………………………………3-3
3.4 Troubleshooting the Typical Hydraulic Elements……………………………………………………………3-7
3.4.1 Axial Plunger Pump……………………………………………………………………………………3-7
3.4.2 Axial Plunger Motor…………………………………………………………………………………………3-11
3.4.3 Change Valve………………………………………………………………………………………………3-13
3.4.4 Overflow Valve………………………………………………………………………………………………3-16
3.4.5 Steering Cylinder……………………………………………………………………………………………3-20
3.4.6 Sealing Elements……………………………………………………………………………………………3-25
3.4.7 Oil Filter………………………………………………………………………………………………………3-27
3.4.8 Hydraulic Steering Gear……………………………………………………………………………………3-28
3.4.9 Other Faults…………………………………………………………………………………………………3-30
Chapter 4 Electrical Part……………………………………………………………………………………4-1

4.1 Basic Vehicle Electrical System………………………………………………………………………………4-1
4.2 Electrical System on Working Device ………………………………………………………………………4-3
4.3 Air Conditioning System………………………………………………………………………………………4-5
4.3.1 No Refrigeration ……………………………………………………………………………………………4-5
4.3.2 Insufficient Refrigeration……………………………………………………………………………………4-7
4.3.3 Abnormal Noise in Refrigeration System…………………………………………………………………4-9
4.3.4 Faults of Heating Device……………………………………………………………………………………4-9
4.3.5 Other Faults…………………………………………………………………………………………………4-10
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II
CHAPTER 1 GENERAL
Chapter 1 General
1.1 About this Manual
This Manual must be put in the file of cab or the file

depository in the back of driver seat.
This Manual covers the information on routine

maintenance and troubleshooting.
Some photos or details in figure or optional parts in

this Manual may differ from your machine.
Some modifications as a result of constant

improvement may not be covered in this Manual.
Please read this Manual carefully and keep it with
the machine.
All instructions described in this Manual are about

the basic maintenance technique.
The operator's technique and skills will be

enhanced as he knows the machine's properties
and performance better.
If you have any queries about the machine or this

Manual, please contact SANY service engineer for
the latest data.
Presently, we have two series of pneumatic tyre

rollers manufactured and sold in batch: YL series
and SPR series.
1-1
CHAPTER 1 GENERAL
1.2 Overall Structure
1-Frame 2-Air conditioning system 3-Electrical system 4-Covering parts assembly

5-Control system 6-Cab assembly 7-Spraying system
8-Central tyre inflation system 9-Rear wheel assembly 10-Hydraulic system
11-Power system 12-Front wheel assembly 13-Oil injection system (for SPR series)
1-2
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1-4
CHAPTER 2 MECHANICAL PART
Chapter 2 Mechanical Part
2.1 Maintaining the Rear Wheel Assembly
Note:
The rear wheel assembly is already

assembled and calibrated before delivery.
Normally, you don't need to adjust it. Never
disassemble the rear wheel assembly by
yourself within the warranty period.
2.1.1 Filling Oil into Driving Axle
Undo the bolt at the oil level port on axle housing

till you can see oil flowing out from the oil level port
(as shown in the figure). (Note: Normally, the
heavy-duty vehicle is filled with 8kg of GL-5
85W/90 gear oil as per GB12895-92.)
Oil level port

(oil fill port) Oil drain port
2.1.2 Removing and Maintaining the Rear Wheel

Assembly 32B chain
1) Preparation: Jack up the rear part of the

complete vehicle with a jack to make the four
rear wheels off ground.
Adjusting bolt
2) Remove the spraying pipe and oil injection
tube on the rear wheel brush carrier (as
shown in the right figure). Remove the inflator
connector from the rear wheel shaft.
3) Rotate the two adjusting bolts to loosen the

two 32B chains. Take off the split pin at the
joint of the chains to remove the chains.
2-1
4) Undo the M6 bolt and washer on the cover to

remove the cover (as shown in the right M6 bolt and washer Cover
figure). Remove the steel tube assemblies 2,
3, 4 and 5
Steel tube
assemblies
2, 3, 4 and 5
5) Undo the bolts (2 kinds) connecting the rear

wheel support and frame (as shown in the
right figure). M20 bolt and washer Rear wheel
support
Frame
M24 bolt and washer
2-2
6) Separate such parts as the rear wheel support

from the frame and set them upside down on
the maintenance platform (as shown in the
right figure).
7) Undo the fixing nut and washer unit on the

tyre and then carry out maintenance for the
Fixing nut and washer Tyre assembly
tyre (as shown in the right figure). .
2-3
8) If you wish further maintenance, you must

undo the screw and locking nut to remove the Screw Locking nut Brake drum
brake drum (as shown in the right figure).
9) Remove the flat key. Undo the fixing bolt unit

on the brake to remove the brake, the steel
Flat key Brake
tube assembly 1 and its joint (as shown in the
right figure). Separate the steel tube and its
joint if necessary.
Screw and
washer
Steel tube
assembly
1 and its joint
2-4
10) Undo the fixing screw and washer on the oil Adjusting Screw and
pad Oil seal washer
seal cover (as shown in the right figure). Pull
out the oil seal cover and oil seal by the wire
drawing hole on the cover. Take off the
adjusting pads. (The quantities of adjusting
pads at both ends may be different.)
11) Undo the bolt on the sprocket wheel cover

and remove the sprocket wheel cover (as Sprocket
shown in the right figure). Bolt and washer wheel cover
2-5
12) Successively remove the parts as shown in

the right figure from outside to inside. The
bearing must be removed by the wire drawing
holes on the bearing seat and end cover. End Bearing Small
Oil seal bearing
cover seat
Big Adjusting
bearing pad
13) Remove such parts as clipping key to

separate the sprocket wheel seat and rear
wheel shaft (as shown in the right figure). Take Retainer Clipping Sprocket Sprocket
ring key cap wheel seat wheel
off the rear wheel shaft from one side.
Remove the sprocket wheel and its seat from
the support. Undo the bolt, and then the whole
rear wheel assembly is completely
disassembled. After that, you can replace or
maintain the parts as needed.
Bolt and Rear wheel
washer shaft
Clipping
key
2-6
2.2 Maintaining the Tyre
2.2.1 Removing the Tyre
1) Discharge the air in the tyre. Screw off the

valve core by using the valve cap. (The end
with clamping groove of valve cap can be
used as spanner. Insert this end into the valve
body to screw off the valve core.) Screw down
the fixing nut of valve cock. Step on or use a
hammer to tap the side face of tyre, so as to
make the tyre flange get out of the rim flange
and slide into the groove in the middle of rim.
Push the valve cock into the rim.
2) Insert a tyre lever between the tyre flange and

rim around the valve cock to pry up the tyre
flange. Meanwhile, press the tyre wall on the
opposite of the lever to move the tyre to the
groove in the middle of rim (i.e., the position
with the max. rim diameter) and then release
the part pried out.
3) Insert the second tyre lever around the first

one to pry out the tyre flange along the rim.
For the part not pried out yet, press it to the
groove with the min. rim diameter. When one
side of tyre has been pried out, you can easily
take out the tube and the other side of the
tyre.
2.2.2 Fitting the Tyre
1) Check the rim for distortion and crack, the

inner tyre for air leakage and the tyre bead for
breakage before fitting the tyre.
2-7
2) To fit the tyre: first, fasten the lining band of

tube to the rim; apply some soap stone to the
inner wall of tyre and the surface of the tube;
fit one side of tyre into the rim; place the tube
valve cock in the valve cock hole rightly; push
the tube through the gap between the rim and
tyre flange; take the valve cock out from the
circular hole on the rim and fit the valve cap.
After that, fit the other side of tyre. When
prying the last section of tyre flange, use a
tyre lever to pry it up and hold it. Slowly insert
the other tyre lever between the rim and tyre
flange to pry the tyre flange into the rim. Step
on or use a hammer to tap it if necessary.
3) When inserting the lever into the tyre, do not

insert it too deeply, as otherwise the tube may
be damaged or the bead in the tyre flange
may be broken.
4) After fitting the tyre onto the rim, check and

adjust the valve cock to align it with the center
of hub. You can rotate the tyre to adjust the
position of valve core when it is half inflated.
5) The tyre flange and rim should be evenly in

contact with each other, rather than tilting over
to one side. To adjust it, you can let the tyre
impact the ground or use a hammer to tap it
when it is half inflated.
6) You must inflate the tyre slowly. The tube is

soft and foldable. If you inflate the tyre
suddenly and heavily after fitting the tube into
the tyre, the folded part of tube may be
pressed before fully extension, leading to the
damage of tube. Thus, you must inflate the
tyre in two steps: first, inflate it with a little air,
hold on for a while, and then deflate it so that
the tube may be fully extended; after that,
inflate the tyre to the specified inflation
pressure.
2-8
7) For the sake of safety, you must insert a thick

steel rod into the circular hole on the wheel
pan flatly to block the locking ring and retainer
ring. Besides, you must make the retainer ring
facing toward the ground or other buildings to
avoid injury due to the suddenly ejected Pressure Pressure
gauge gauge
locking ring and retainer ring.
2.2.3 Inflating the Tyre
The tyres of pneumatic tyre roller are inflated by

the central tyre inflation system. You can read the
tyre pressure directly from the pressure gauges in
the cab. The air passage between the front and
rear tyres are connected through, so the tyre
pressures of front and rear tyres are the same.
Besides, their tyre pressures can be adjusted
automatically to adapt to the road conditions. Each
tyre is set with a switch valve. If you don't need
tyre pressure adjustment or you want to lay the
tyre aside for a long time, you can close each
switch valve.
After overhaul of pneumatic system, you can carry

out adjustment according to the following steps:
1) Adjust the pressure of unloading valve: the

adjusting pressure for unloading valve is
0.8MPa (error range: 0.7 ± 0.02MPa) and that
for air reservoir is 0.92MPa (already set
before delivery). The specific adjusting
method is as follows:
a) Fit the adjusting screws on the air switch
valve. During fitting, you must apply even
force. Never apply excessive force.
b) Open the control valve cover of air pump,
loosen the locking nut of adjusting screw, and
then turn the adjusting screw anti-clockwise to
the “Max. pressure” position.
c) Meanwhile, turn the adjusting screw of
unloading valve anti-clockwise to the “Min.
pressure” position.
d) Set the handle of manual valve to the
“Inflation” position.
2-9
e) Start the engine up. Engage the rated gear

and carry out inflation. Observe the pressure
gauge and unloading valve. Slowly turn the
adjusting screw of unloading valve clockwise
till the indication on pressure gauge becomes
0.8MPa and doesn't increase any more.
Tighten the locking nut of unloading valve
when the valve is under unloading state.
2) Turn the adjusting screw of air pump control

valve clockwise to the “Min. pressure”
position. Set the handle of manual valve to the
“Deflation” position. Observe the pressure
gauge. When the pressure falls to 0.4MPa,
set the handle to the “Inflation” position and
slowly turn the said adjusting screw anti-
clockwise. When the indication on pressure
gauge doesn't increase any more and the
unloading valve is not under unloading state,
the adjustment is finished.
3) Fit and tighten the control valve cover of air

pump and withdraw the 9 adjusting screws of
air switch valve to the proper position.
4) Set the handle of manual valve to the neutral

position and shut down the engine.
5) Check the air tightness:

a) Check if the adjusting screws of air switch
valve are withdrawn properly.
b) Set the handle of manual valve to the
“Inflation” position. Start the engine up and
engage the rated gear. Observe the pressure
gauge to check if the system pressure is set
at 0.7MPa (error range: 0.7 ± 0.02MPa).
c) Check the air tightness of system: check as
per the method in step 2); if it meets the
requirement, shut down the engine and
observe the pressure (at this time, the handle
of manual valve must be set at the “Inflation”
position). As long as the pressure drop within
1h is no more than 0.1MPa (pressure drop
within 6min ≤ 0.01MPa), the air tightness of
system is acceptable.
2-10
d) Check the air tightness of tyre: shut down the

engine; set the handle of manual valve at
“Deflation” position to bleed the system (the
system pressure is 0 when the system is
bled); observe the deformation of tyre for at
least 4h. The tyre deformation must be evenly
distributed and without any obvious
abnormality. If the tyre deformation is
obviously greater, the tyre is leaky. In this
case, you must find out the causes and rectify
the fault. During troubleshooting, do brace up
the frame, as otherwise the frame may tilt
over and result in accident.
2.3 Maintaining the Diesel Engine
Table 2-1 describes the common faults in diesel

engine, and also ways in which you can rectify them.
Table 2-1 Troubleshooting the Diesel Engine
Fault Cause Remedy

Fuel used up Fill up fuel and bleed system.
Fuel filter blocked Replace filter.
Engine can not be
started Leakage of fuel pipe Check and tighten all connections.
Discharge or poor connection of storage Clamp polar clamp and check cables.
battery
Slow starter rotation speed due to too low Check storage battery and clean, re-
voltage, loose or oxidized polar clamps of connect and grease polar clamps.
storage battery
Engine oil with excessive viscosity, Use appropriate engine oil.
especially in winter
Unsmooth fuel supply; block in fuel system Replace fuel filter, check all oil pipes
and use the winter-grade diesel when
caused by the paraffin in winter it turns cold.
Difficult startup or
unstable working Incorrect valve clearance Adjust valve clearance.
power of engine
Nozzle with defects Check by the expert.
Turbocharger with defects Check by the expert.
Dirty dry-type air filter Clean or replace dry-type air filter.
Defective vacuum switch Check vacuum switch.

Too tight throttle cable Adjust or replace throttle cable.
2-11
Fault Cause Remedy
Too much engine oil Drain redundant engine oil.
Dirty dry-type air filter Clean or replace dry-type air filter.

Too much smoke
discharged
Insufficient compression due to burnt or Check by the expert.
broken piston
Incorrect valve clearance Adjust valve clearance.
Cylinder or cooling fin of radiator at the top Clean cooling fin of the radiator, esp.
of cylinder blocked by dirt the vertical fin at the top of cylinder.

Engine too hot or
shut down suddenly Incorrect adjustment of injection pump Check by the expert.
Limited cooling air flow Clean cooling air conveying pipe.
Loose or broken fan belt Adjust or replace fan belt.

Fill up engine oil, immediately shut
Too low oil pressure Too
oil
much oil consumption or less engine down the machine and find out the
causes, and check oil filter or cooler
for leakage.
Charging alarm Too low engine speed Check, adjust or replace the belt.
indicator lamp of
storage battery lit on Fault in generator or adjuster, and no
during operation charge of storage battery Check by the expert.
Too much engine oil Discharge redundant engine oil.
Dirty dry-tyre air filter Clean or replace dry-type air filter.
Insufficient power of Turbocharger with defects Check by the expert.

engine
Leakage of pressure tube Check and tighten screws and nuts on
pressure tube.
Incorrect valve clearance Adjust valve clearance.
Loose and eroded wiring of storage battery Clean and tighten the wiring.
Crankshaft rotates
slowly and can not Insufficient voltage of storage battery Charge storage battery.
be started
Incorrect lubricating oil model Change it with the lubricating oil of
specified grade.
2-12
Fault Cause Remedy
No fuel supply of oil injector Check oil injector and high-pressure

lines.
Failure of fuel cut-off electromagnetic valve Check the resistance of

electromagnetic valve.
No fuel supply of oil injection pump Check the low-pressure oil circuit and
oil tank for fuel.
Crankshaft rotates
normally but can not Abnormal operation of pre-heating system Check pre-heating system.
be started
Defective pre-heat plug Replace pre-heat plug.
Leakage of oil injection tube Re-tighten adaptor or replace fuel

tube.
Improper oil injection timing Adjust oil injection timing.
Damaged oil injector or its seat Repair or replace oil injector or its
seat.
Improper adjustment of throttle cable Adjust throttle cable.
Too low idling speed Re-adjust idling speed.
Fuel leakage Check, tighten or repair the leaked

part.
Unstable idling Improper oil injection timing Adjust oil injection timing.
Damage or abnormal operation of oil Check, adjust or replace oil injection

injector or oil supply valve pump or oil supply valve.
Insufficient oil supply of oil injection pump Check and adjust it.
Note: The above information is only for rectifying

the common faults of the engine. As for details,
please refer to the relevant section in the
Operation Manual of DEUTZ or Cummins engine.
2-13
2.4 Cleaning the Diesel Tank
Firstly, blow the outside of tank with compressed

air for several times to remove the dust and foreign
materials. Open the oil drain plug (Fig. 2-1) at the
bottom of tank to drain the dirty oil.
After that, open the cover (Fig. 2-2) on the top of

tank. Blow out the remaining oil in the tank with
Oil drain plug
compressed air. Try to completely blow out the
remaining oil and grain materials, especially for the
blind corner in the tank.
Secondly, fill an appropriate amount of clean diesel

oil (or kerosene) into the fuel tank. Use a new
brush to clean the tank up and down. When the oil
gets dirty, change it with new oil and continue
cleaning till no dirt and sediment are found on the
wall and bottom of tank. Fig. 2-1
Finally, paste the wall and bottom of tank with a

piece of dough. The foreign materials attached on
the inner wall of tank are hard to blow off and clean
up. It is better to use dough for cleaning. Do not
use cotton rag, cotton silk, etc., as otherwise the
line may be blocked. The dough with moderate
hardness should be made with 1~2kg of edible
flour and separated into small pieces for standby.
Carefully clean up the wall and bottom of tank as
well as the blind corner. Carry out the cleaning for
several times till you find no foreign materials in the
new dough any more. After that, flush the tank with
new diesel oil. Blow off the wall of tank and clean it
with kerosene. Fit the oil drain plug and then fill
new oil. Fig. 2-2
CAUTION
During oil filling, you must clean up the oil fill tube
and oil tank port and keep them away from dust.
Do not shake the oil barrel and do not insert the oil
suction tube to the bottom.
Fit the tank cover immediately after oil filling.
2-14
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2-16
CHAPTER 3 HYDRAULIC PART
Chapter 3 Hydraulic Part
3.1 Traveling Pump: 90 Series Plunger

Pump
A cam-type axial piston pump is adopted for the

roller as the hydraulic traveling pump (Fig.3-1).
Two high-pressure overflow valves are set at the
high-pressure oil side on the pump to protect the
pump and motor against overload. The pressure
for working oil port of variable pump is set as
380bar, with the maximum allowable instantaneous
pressure of 420bar. The pump is controlled through
hydraulic-controlled and mechanical servo. The
hydraulic oil flows through the pressure oil circuit of
oil fill pump and is filtered by an externally
connected filter. The pump is provided with a
pressure cutoff valve which may be activated by
the pressure adjustment. As soon as the setpoint
value is reached, the control valve will adjust the
output of oil pump to 0. In the case of acceleration
or deceleration, this cutoff valve may disable the
opening of high-pressure overflow valve to prevent
the system against heating.
Since the above functional valves are integrated

Fig. 3-1
on the pump body, do not disassemble or adjust
them under normal circumstances. If replacement
is required as a result of pressure faults approved
by SANY engineers, you must arrange the
technicians with adjustable wrenches or suitable
hexagon socket spanners for removal. Besides,
keep the exposed oil port on the pump body clean,
as otherwise the contamination will cause
secondary faults. To adjust the pressure of
functional valves, you can ask technicians to
loosen the nuts with an adjustable wrench and
adjust the bolts with a suitable hexagon socket
spanner (half a circle each time). Do lock the nuts
after adjustment, as otherwise accident may
happen.
Fig. 3-2
3-1
Tools required: hexagon socket spanners,

socket spanners and adjustable wrenches in
all sizes.
3.2 51D Series Traveling Motor
Inserted bent-axis motors are adopted for the roller

as the hydraulic traveling motors (Fig.3-3). The
output of motor is controlled by a proportional
electromagnet. One of these motors is provided
with a speed sensor to detect the traveling speed
and prevent the wheel from skidding. The
mounting flange of motor is set in the middle of
shell, which saves the space of structure.
Fig. 3-3
Fig. 3-4
3-2
3.3 Replacing the Oil Cylinder
Environmental Requirements for Removing and

Fitting Oil Cylinder:
☆ Keep the environment for removing and fitting

clean. Never remove or fit oil cylinder
outdoors, as otherwise the dirt and foreign
materials would cause secondary
contamination.
☆ Use pressure oil of 0.8~1.2MPa to take the
piston rods out during removal. All the oils
must be kerosene or hydraulic oil of the same
grade.
☆ Before fitting, clean all elements by kerosene
or hydraulic oil of the same grade, dry them
by high-pressure air and then apply some
clean hydraulic oil of the same grade.
☆ When fitting the cylinder, if you want to
operate the piston rods, use the high-pressure
air as the power source.
Tools required: adjustable wrench, socket spanner,
retainer pliers, ball hammer and magnet.
The steering of the machine is realized under the

effect of articulation frame, which is driven by the
steering cylinder activated by the steering gear.
One articulation steering cylinder is between the
fork foot and frame.
The steering cylinder mainly comprises cylinder

cover, cylinder body, piston rod, piston, oil cup and
various seals. The seal of piston rod comprises the
OD type seal ring combined with BS type seal ring,
the FR type guide ring for piston rod, the dustproof
ring and the O-ring. The seal of piston body
comprises the OK type seal ring, the FR type guide
ring for piston and the O-ring. Fig. 3-5
3-3
Removing the Oil Cylinder
1. Use a pair of retainer pliers to remove the

retainer ring and the retainer sleeve which is
mounted on the piston rod (Fig. 3-6).
Fig. 3-6
2. Tap the guide sleeve with a ball hammer to

make it move inwards till you can see the
front clipping key. (Fig. 3-7).
Fig. 3-7
3. Take off the front clipping key with magnetic

tools. (Fig. 3-8).
Fig. 3-8
3-4
4. Set the oil cylinder on the fixing rack and

secure it. (Fig. 3-9).
Fig. 3-9
5. Fill pressure oil of 0.8MPa~1.2MPa (i.e.,

hydraulic oil or kerosene of the same grade)
from the oil port at the other end of the piston
rod. (Fig. 3-10)
Fig. 3-10
6. Take out the piston rod and piston under the

effect of pressure oil. (Fig. 3-11)
Fig. 3-11
3-5
7. Check the seals of piston rod for damage. If

any, replace it with a new one of the same
size.
8. Use a pair of retainer pliers to remove the

retainer ring mounted at one end of piston.
9. Take off the clipping key cap.
10. Forcibly tap the rear clipping key outwards

and take it down to remove the piston. (Fig. 3-
12)
Fig. 3-12
11. Check the seal ring of piston and the
compression allowance. If you find any
damaged seal ring, replace it with a new one
of the same size.
Fitting the Oil Cylinder

1. Check all disassembled elements.
2. Use kerosene or hydraulic oil of the same

grade to wash elements. Otherwise, dust and
foreign materials would cause secondary
contamination.
3. Use the high-pressure air to blow all

disassembled elements for several times till
they become dry.
4. Fit the piston on the piston rod, and fit the

rear clipping key and clipping key cap.
5. Use a pair of retainer pliers to fit a retainer

ring at one end of the piston.
6. Set the cylinder body vertically and fit the

piston rod (together with the piston) into the
cylinder body under the effect of external
force. (Note: Apply even force to the piston
when tapping it with a hammer.)
3-6
7. Set the oil cylinder on the fixing rack and

secure it.
8. Use magnetic tools to set the tri-semi clamp

ring into the mounting groove. Tap the guide
sleeve by a hammer.
9. Charge some high-pressure air from the oil

ports at both ends of oil cylinder.
10. Turn on the switch to make the piston rod

move outwards under the effect of high-
pressure air, so as to make the tri-semi clamp
ring locked firmly.
11. Fit the retainer sleeve by the same means.

Apply even force to the retainer sleeve when
tapping it with a hammer.
12. Use a pair of retainer pliers to fit the retainer

ring.
13. Strictly carry out dwell test to the oil cylinder

till it meets the requirements.
3.4 Troubleshooting the Typical Hydraulic

Elements
3.4.1 Axial Plunger Pump
Common faults of axial plunger pump comprise:

insufficient oil drain, sluggish action of actuator,
insufficient pressure or strong pressure pulse of
output oil, excessively loud noise, leak, heating of
hydraulic pump, fault of variable mechanism and
no rotation of pump shaft. Table 3-1 describes the
causes for such faults and the ways in which you
may rectify them.
3-7
Table 3-1 Troubleshooting the Axial Plunger Pump
Fault Cause Remedy
Blocked oil suction pipe and oil filter or Unblock oil pipe and clean oil filter.
great resistance
Low oil level in oil tank Check oil level and fill oil.
Air in pump body (not filled up with oil) Bleed pump (filling oil into pump)
Wear between plunger and cylinder Replace plunger, grind the contact face
hole, or between oil distributor and between oil distributor and cylinder body, and
Insufficient oil cylinder body ensure good contact.
drain or
sluggish No seal between cylinder body and oil
action of distributor, because plunger returns
actuator incompletely or can not return due to Check and replace center spring.
broken center spring
Failure of variable mechanism fails to Check variable mechanism: check whether

meet the working requirements variable piston or variable mechanism is agile,
and correct their adjustment error.
Internal leak or difficult oil suction due Select suitable oils according to the actual
to improper oil temperature or air condition of temperature rise and fix the joint
suction of hydraulic pump where the air leak may occur.
Blocked oil suction port or narrow oil Unblock oil suction port and widen the cross
passage section for oil passage.
High oil temperature, low oil viscosity Control oil temperature, and change oil with
and more internal leak new one of greater viscosity.
Large internal leak due to wear Trim the contact face between cylinder body
between cylinder body and oil and oil distributor, and replace the plunger. In
Insufficient distributor, or between plunger and case of heavy wear, sent them to the factory
pressure or cylinder hole for repair.
strong
pressure
pulse Small flow as a result of small Widen deflection angle of variable mechanism.
deflection angle of variable mechanism
Increasing internal leak due to fatigued Replace center spring.

center spring
Incoordination of variable mechanism For occasional pulsations, change oil; for

(e.g., large pulse due to incoordination frequent pulsations, remove and repair the
between servo piston and variable mating elements, as whose damage or
piston.) incoordination is likely to cause such pulse.
3-8
Fault Cause Remedy
Air in pump Bleed pump and check the part into which the
air may enter.
Bearing improperly assembled, or Check bearing for damage, and replace it in

abraded or damaged at one side time.
Difficult oil suction due to blocked oil Clean oil filter.

filter
Dirty oil Check oil at random and change it with clean

oil.
Large oil suction resistance due to high Change it with oil of lower viscosity.
Excessively oil viscosity
loud noise
Low oil level or air suction in hydraulic Fill oil to the specified height and check the
pump sealing.
Pump not fitted concentrically with Readjust them to the allowable range.
motor, which increases the axial load
Lines vibrate Take insulation and vibration absorption

measures.
Connector between plunger and ball

head of sliding boot seriously loosen or Check, repair or replace components.
flakes off
Wear between cylinder body and oil Trim contact face.

distributor
No seal between cylinder body and oil

distributor due to damaged center Replace center spring.
spring
Internal leak
Large axial clearance Adjust axial clearance to specified value.
Wear between plunger and cylinder Replace plunger and regrind the contact face.
hole
Internal leak due to low oil viscosity Change it with oil of proper viscosity.
Damaged seal on drive shaft Replace seal ring.
External leak
Nuts and bolts on joint surfaces and
pipe connectors not tightened, and seal Tighten them and check and replace the seal.
damaged
3-9
Fault Cause Remedy
Serious internal leak Check and grind relevant sealing surfaces.
Serious air suction in hydraulic pump Check and seal relevant sealing parts.
Heating of Wear in matching contact faces (e.g.

hydraulic between cylinder body and oil Trim or replace the worn parts, such as oil
pump distributor, or between sliding boot and distributor and sliding boot.
swashplate)
High oil viscosity is too high, small Change oil, increase capacity of oil tank or set
capacity of oil tank, or high rotation a cooling device, or lower rotation speed.
speed of hydraulic pump
Blockage in control oil circuit Filter oil, and flush oil circuit (if necessary).
Wear between variable piston and Trim, grind, or replace them.

variable shell
Fault of
variable
mechanism Servo piston, variable piston and spring For the mechanical seizure, grind moving
element shaft get stuck parts; change dirty oil.
Spring on one-way valve in the control Replace spring.

oil circuit damaged
Seizure of plunger and cylinder hole as Change dirty oil; in the event of too low oil
a result of dirty oil, the change in oil temperature, change oil with new one of lower
temperature, or the adhesion due to viscosity; or use a scrapper to scrape away the
high temperature metal crumbs.
No rotation
(i.e. seizure)
of pump Sliding boot flakes off due to stuck or Replace or refit sliding boot.
flaked off plunger or loaded startup
Broken plunger ball due to stuck Replace plunger ball.

plunger or loaded startup
3-10
3.4.2 Axial Plunger Motor
Common faults of axial plunger motor comprise

low output rotation speed, small output torque,
internal and external leaks and abnormal sounds.
Table 3-2 describes the causes for such faults and
the ways in which you may rectify them.
Table 3-2 Troubleshooting the Axial Plunger Motor
Fault Cause Remedy
Insufficient oil supply of hydraulic Try to improve oil supply condition.

pump
Low rotation speed of motor Find out the causes and carry out adjustment.
Blocked filtration screen of oil Clean or replace filter element.

filter
Insufficient oil in oil tank or Fill oil, and increase pipe diameter to ensure smooth oil
difficult oil suction due to small suction.
pipe diameter
Internal air leak due to poor seal Tighten relevant joints, and increase pipe diameter to
ensure smooth oil suction.
High oil viscosity Change oil with new one of lower viscosity.
Low Large axial and radial

rotation clearances, great leak volume, Repair hydraulic pump.
speed and and low volumetric efficiency
small
torque Insufficient input pressure of Try to increase the pressure.
hydraulic pump
Low efficiency of hydraulic pump Check and rectify the fault of hydraulic pump.
Insufficient adjusting pressure or Check and rectify the fault of overflow valve, and
failure in overflow valve increase the pressure.
Slender line and great resistance Increase diameter of line and adjust the layout.
High oil temperature, low oil Check causes for oil temperature rise, cool down oil and
viscosity, and more internal leak change oil with new one of higher viscosity.
Serious leaks on joint surfaces of Tighten connecting bolts on each joint surface and check
hydraulic motor. the sealing condition.
Serious leak due to heavily worn Check damaged parts, and grind or replace these
internal hydraulic elements elements.
3-11
Fault Cause Remedy

Large axial clearance due to Grind end faces of oil distributor and
wear in end faces of oil cylinder body.
distributor and cylinder body
Internal leak Fatigued spring Replace spring.
Heavy wear between plunger Grind cylinder hole and refit plunger.
Leak and cylinder hole
Poor seal at shaft end or Replace seal ring.
damaged seal ring
External leak Bolts on joint surfaces and pipe Tighten the bolts of relevant connecting
c o n n e c t o r s l o o s e n o r n o t positions and pipe connectors.
tightened
Bearing improperly fitted or worn out Refit or replace bearing.
Air in pump due to poor seal Check seal of air inlets and tighten
connecting parts.
Dirty oil or air bubble in oil Replace it with clean oil.
Coupling not concentric. Calibrate its concentricity.

Abnormal
noise
High oil viscosity Replace oil by new one of lower
viscosity.
Heavy wear at radial side of hydraulic motor Grind cylinder hole and refit plunger.
Take measures (e.g. adding an

External vibration insulating cover) to insulate the external
vibration source.
3-12
3.4.3 Change Valve
Common faults of change valve comprise: no

switch; the lower action speed of actuator than
specified at the time of controlling the actuator to
switch; oil leak at the push rod of dry
electromagnet; the sluggish attracting and
releasing of wet electromagnet; oil leak at the joint
surface of plate change valve; the overheating or
burnout of electromagnet; torpid switch; and the
impact and noise during switch. Table 3-3
describes the causes for such faults and the ways
in which you may rectify them.
Table 3-3 Troubleshooting the Change valve
Fault Cause Remedy
Valve element “stuck” due to the special oil port for Check and connect the port with
electromagnetic change valve not connected with oil oil return tank, and lower the
return tank or the counter pressure of oil drain line counter pressure of line.
No switch
Abnormal switch due to the vertically fitted
electromagnetic change valve affected by the Fit electromagnetic change valve
gravitation of elements (e.g. armature of valve horizontally.
element)
Lower action Insufficient stroke of valve element, lower opening

speed of of valve and small flow, which are resulted by the Replace push rod or
actuator than shortened switch push rod (as a result of abrasion electromagnet.
specified due to long-term knocking), or the worn contact
point of armature
Oil leak at the Oil leak due to heavy wear at seal ring of push rod Replace seal ring.
push rod of
dry
electromagnet
change valve
Oil leaking to push rod due to large counter If the counter pressure is too
pressure at oil drain (oil return) chambers at both high, respectively connect these
ends of electromagnetic valve chambers to the oil return tank.
Sluggish There are two sealing screws at the rear end of

attracting and electromagnet, and the air enters into the rear
releasing of chamber during the initial installation of these Screw off these sealing screws,
wet screws. When oil flows into the armature fill sufficient oil, and then screw
electromagnet chambers, if the air in rear chamber can not be down the screws for sealing.
change valve released, it will be compressed to engender damp
which leads to sluggish action.
3-13
Fault Cause Remedy
Valve element stuck in hole and not

acting or acting torpidly due to small Check clearance and repair or
clearance between slide valve replace valve element.
(valve element) and valve body
Axial hydraulic seizure due to valve Check, grind or refit valve element.
element (or valve body) bruised, or Change oil with new one, if
stuck by dirt or particles necessary.
Seizure of slide
valve
Axial hydraulic seizure due to
geometric over-deviation in opening Check and correct geometric over-
and closing of valve element or non- deviation and non-concentricity.
concentricity of valve element and
valve hole
Valve element stuck due to distorted Refit, tighten and overhaul valve
valve body or valve element body and valve element.
Insufficient power for electromagnet Check supply voltage and make it

to propel the valve element due to as per requirements (i.e. within
low supply voltage +10% ~ -15% of the specified
voltage).
No
switch Fault of AC electromagnet burnt out as a
electromagnet result of core not attracted to the Rectify the stuck slide valve and
end due to blocked slide valve. replace electromagnet.
Difficult to propel the valve element Find out the causes for and
as a result of insufficient attraction replace electromagnet.
due to magnetic leak
Low pressure of hydraulic control oil Increase control pressure, check

to propel valve element whether the spring is over rigid,
and replace spring (if necessary).
Throttle valve on the hydraulic Check, adjust and clean throttle

Fault on control change valve closed or blocked orifice.
oil circuit of
hydraulic Oil ports at both ends of hydraulic Check and connect oil ports with
change valve slide valve not connected with oil oil return tank, and clean and
return tank, or oil drain pipe blocked unblock oil return pipe.
Slide valve can not switch or reset

due to broken, omitted, or too soft Check, replace or fit spring
spring
3-14
Fault Cause Remedy
Loose mounting screw Tighten mounting screw.
Oil leak at the Poor processing precision of surface of bottom Trim the surface of bottom mounting
joint surfaces mounting plate plate to get a good precision.
of plate
change valve
Seal ring for bottom face aged or of poor Replace seal ring.
sealing effect
Screw made of material not as per Replace and tighten screw in

requirements, thus screw distorted after being accordance with requirements.
stretched
Overheating of coil due to supply voltage Check supply voltage, and make it as
higher than the specified value per requirements (i.e. within +10% ~ -
15% of the specified voltage).
Defective insulation of electromagnetic coil Use wet DC electromagnetic coil.
Overheating of coil due to frequent switch Check and refit coil.
Poor contact due to defective welding of wires Remove and refit wires.
Overheating
or burnout of
electromagnet Electromagnetic element not concentric with Replace electromagnet.
the axis line of slide valve.
Overheating and burnout of coil due to large

current as a result of failure to attract the
electromagnet core, which is caused by the Repair push rod.
length of push rod not in proportion to the
stroke of electromagnet
Burnout of coil due to oil entering dry Check and rectify the fault of oil leak
electromagnet at push rod, or replace seal ring.
Slide valve stuck by dirt in oil Clean slide valve and change oil.
Large or small force of spring Replace spring with a proper one.
Dirt at the contact part of electromagnetic Remove dirt.

element.
Torpid switch
Large or small clearance between slide valve Face up or replace slide valve.
and valve body
Incomplete or torpid steering due to short

movement of valve element as a result of Check and repair push rod, or replace
insufficient length or incorrect stroke of worn it (if necessary).
push rod of electromagnet
3-15
Fault Cause Remedy

Diminish the orifice of one-way throttle
Rapid movement of slide valve of hydraulic valve on hydraulic change valve, and
change valve slow down the movement of slide
valve.
Large fitting clearance between hole and

element of one-way throttle valve (on the Check and adjust the clearance to a
hydraulic change valve), omitted installation of proper value and fit a spring.
spring for one-way valve and ineffective
resistance
Impact and
noise during
switch Uneven contact face or poor contact of Remove foreign materials, and repair
electromagnet core electromagnetic element.
Vibration of piping and other elements due to Control pressure difference of two
hydraulic impact (The two circuits with great circuits; under worse conditions, use
pressure difference instantaneously wet AC change valve, or the change
connected) valve with buffer.
Slide valve acting fitfully or high local Grind or replace slide valve.
pressures
Bolt fixing electromagnet loosen Tighten bolt, and fit a locking washer.
Impact and
noise during
switch Long or short push rod of electromagnetic
change valve Repair or replace push rod
strong or weak attraction of electromagnet overhaul or replace electromagnet.
3.4.4 Overflow Valve
Common faults of overflow valve comprise:

vibration and noise; failure in raising adjusting
pressure, or no pressure, and useless adjustment;
failure in lowering adjusting pressure and useless
adjustment; fluctuant pressure and leak. Table 3-4
3-16
Table 3-4 Troubleshooting the Overflow Valve
Fault Cause Remedy
Noise of liquid Check and rectify it.
Noise of cavitation, swirling and It is a design problem. Replace overflow

Vibration and intercepted liquid after the overflow
noise (squeal) releases liquid valve.
Impactive noise of pressure wave Prolong releasing time and gradually open
when the overflow valve is unloading or close change valve which controls
unloading.
Repair leading valve and main slide valve

Uneven pressure distribution for to enhance their geometric precision, and
leading valve and main slide valve increase diameter of oil return pipe, and
use softer spring for main slide valve and
oil of proper viscosity.
Air in oil return line Check, seal and bleed the line.
Great counter pressure in oil return Increase diameter of oil return pipe and
line separately set the oil return pipe.
Air in inner pressure control area of Check, seal and bleed the area.
overflow valve
Vibration and Flow exceeds the allowable value Use overflow valve suitable for the flow.
noise (squeal)
Mechanical noise Check and rectify it.
Tight or loose fitting of slide valve Repair slide valve and valve hole.
and valve hole
Too soft or distorted pressure Replace pressure adjusting spring.

adjusting spring
Loose pressure adjusting screw Tighten pressure adjusting screw.
Worn cone valve Grind and face up cone valve.
Resonance with other elements of Diagnose and rectify the vibration and
system noise of system.
3-17
Fault Cause Remedy
Control oil lacks of pressure due to

plug at unloading port of leading Fit and seal plug.
overflow valve not fitted
Control oil flows back to oil tank due Check remote control circuit, and close oil
to oil circuit connecting with remote circuit for control oil flowing back to oil
control port of overflow valve getting return tank.
opened
Failure in raising
system pressure,
or no pressure No pressure in overflow valve
(reading of unloading system due to blocked Clean damping hole and change oil.
pressure gauge damping hole of leading overflow
almost equals to valve
0), and useless
adjustment
Cone valve, steel ball or pressure Fit it.
adjusting valve is omitted to be fitted.
Overflow valve stuck at full opening Clean overflow valve.

position by dirt.
No pressure in hydraulic pump Diagnose and rectify the fault of hydraulic

pump.
Serious oil leak due to damaged Check, repair or replace them.

elements and line of system
Leading valve lacks of control

pressure oil due to blocked control Check and unblock control oil circuit.
oil circuit from main valve to leading
valve
Inner oil drain port of leading valve Clean inner oil drain port of leading valve.
Failure in lowering for returning oil blocked by dirt
excessively great
system pressure
Slide valve can not be opened due Insert a stainless steel slice or a slender
to even oil pressures at both sides of soft wire into damping hole to plug up a
main valve element as a result of part of this hole.
heavy wear in damping hole
Slide valve stuck at closing position Clean slide valve and valve hole, and
due to dirty oil change oil.
3-18
Fault Cause Remedy
Oil leak or defective seal at remote Check oil leak and oil trickle at remote
control port of leading overflow valve control port of leading overflow valve,
and seal leaking parts.
Oil leak or defective seal at control valve Find out the causes of oil leak or internal
and line of remote control oil circuit for leak of remote control oil circuit, and seal
leading valve leaking parts.
Oil at oil return port when the pressure

Failure in had not reached the setpoint value, as a Overhaul, ream, repair or replace, and
raising system result of serious internal leak at slide grind slide valve.
pressure and valve or internal leak and oil overflowing
useless at overflow valve
adjustment
Slide valve stuck due to dirty oil Clean slide valve and valve hole, and
change oil.
Internal leak due to improper fitting Face up cone valve and valve seat,
between cone valve/ball valve and valve replace steel ball or cone valve, or lightly
seat tap cone valve to make it pressed against
valve seat.
Pressure rises slowly or no longer rises

due to small flow of leading valve as a Clean damping hole, and change oil.
result of partially blocked damping hole
Too soft or distorted pressure-adjusting Replace it with a new one of proper

spring for control valve element can not pressure grade according to the pressure
maintain a stable working pressure control range.
Fluctuant
pressure
(fluctuant or Face up cone valve and valve seat,
jumpy reading Fluctuant internal leak due to improper replace steel ball or cone valve, and
on pressure fitting between cone valve/steel ball and clean valve. Alternatively, lay cone valve
gauge) valve seat as a result of seizure by dirt or or steel ball on valve seat, tap it with a
wear wood plate to make it pressed against
valve seat.
Damping hole on main valve sometimes Check damping hole on main valve, and
blocked by dirty oil change oil (if necessary).
3-19
Fault Cause Remedy

Slide valve acts stiff due to slide valve Overhaul or replace slide valve, and
pulled, distorted, or seized by dirt, or repair valve hole or slide valve to make
having ellipses, or valve hole bruised or its ellipses less than 5μm.
having ellipses.
Change valve connected with remote Diagnose and rectify the fault of change
control of overflow valve out of control, or valve, and seal the remote control port51of
constant more or less leak at remote overflow valve, the change valve and the
control port and change valve line.
Fluctuant pressure and large noise Check and rectify such phenomena.
Improper fitting between cone valve/steel Clean them, grind cone valve, face up
ball and valve seat due to wear or seizure valve seat, or replace steel ball.
by dirt
Large fitting clearance between slide Replace slide valve element.

Leak valve and valve body
External leak Check seals.
Loose pipe connector or defective seal Screw down pipe connector, or replace
seal ring.
Defective or ineffective sealing on Trim joint surfaces, or replace sealing

relevant joint surfaces elements.
3.4.5 Steering Cylinder
There are various faults of steering cylinder.

However, the frequent faults, in practice, mainly
cover insufficient propulsion, failed action,
creeping, leak, hydraulic impact and vibration.
There may be a single fault appearing, and
sometimes may be several faults occurring
together. Table 3-5 describes the common faults
for steering cylinder and the ways in which you
may rectify them.
3-20
Table 3-5 Troubleshooting the Steering Cylinder
Fault Cause Remedy
Set an exhaust device; alternatively, start

Air in hydraulic cylinder and line leads to hydraulic device and make it run at its
the following result: normal or slightly low maximum stroke for several times to
reading on pressure gauge, and two ends compulsorily discharge the air. In addition,
of hydraulic cylinder creeping seal the system and line to prevent oil leak
and air intrusion.
Negative pressure at certain part of

hydraulic cylinder leads to the following Locate and seal the part with negative
result: slightly low reading on pressure pressure to prevent air intrusion; and
gauge, no or few air bubbles in oil tank, discharge the air.
and the creeping gradually aggravating
Air suction of hydraulic pump leads to the

following result: quite low reading on Bleed the hydraulic pump and oil suction
pressure gauge, powerless hydraulic pipe if the fault is caused by air suction of
cylinder, air bubbles in oil tank, and hydraulic pump and oil suction pipe.
useless exhaust
Excessively tightened seal ring leads to

the following result: normal or slightly low Adjust seal ring to be neither very loose nor
Creeping reading on pressure gauge, and the very tight, and ensure that the piston rod can
surface of piston rod whitening with be pulled by hand and without oil leak.
creaks
Non-concentricity of piston rod leads to

Fit two piston rods together, and calibrate
the following result: slightly high reading
them on a V-shaped iron plate to keep the
on pressure gauge, and the creeping at
non-concentricity within 0.04mm; or else,
two ends of hydraulic cylinder gradually
replace pistons.
aggravating
Bent piston rod leads to the following Put a single piston rod, or a piston along
result: slightly high reading on pressure with a piston, on the V-shaped iron plate,
gauge, regular creeping positions, and straighten it or them by a press machine or a
partially whitened piston rod partially micrometer.
Adjust the tightness of guide rail or pressing

Excessively clamped guide rail or sliding
block (bar) of sliding block to ensure the
block or uneven hydraulic cylinder leads
precision of acting elements and reduce the
to the following result: slightly high
sliding resistance. If it doesn't work, check
reading on pressure gauge, regular
the parallelism between hydraulic cylinder
creeping positions, jutter at moving parts,
and guide rail, trim and calibrate their
and whitened surface of guiding device
contact faces.
3-21
Fault Cause Remedy

Confliction between hydraulic cylinder
and moving parts due to excessively Adjust the tightness of nuts to keep piston
tightened nuts at both ends of two piston rod not tight or loose.
rods
Poor lubrication leads to the following Check and readjust the pressure and flow of
result: the normal reading on pressure lubricating oil. Otherwise, check whether the
gauge, slight shake or vibration at moving oil hole is blocked and the oil viscosity is too
parts (e.g. the work bench), or whitened high or lubricating performance is ineffective;
surface of guide rail and timely change oil (if necessary).
Score at inner wall of hydraulic cylinder or

surface of piston, or heavy wear or
corrosion at certain parts leads to the Bore cylinder, and refit new piston.
following result: fluctuant reading on
pressure gauge, and regular creeping
Serious internal leak of hydraulic cylinder

leads to the following result: very low Replace (aged and damaged) seal ring on
reading on pressure gauge, and slow or piston.
difficult pressure rising
Adjust steering time, slow down movement

Fast moving speed and hydraulic cylinder
of hydraulic cylinder; alternatively, add a
without a buffering device
buffering device.
Serious leak due to large clearance Replace buffering plunger or set a sleeve in
Impact between plunger and hole in buffering the hole to adjust the clearance to the
device, and ineffective throttle valve specified value; check throttle valve.
Ineffective buttering of one-way valve

Repair and grind one-way valve and valve
buttering at the end as a result of serious
seat, or replace them.
leak
Defective seal ring on piston rod due to

Check piston rod for damage. If any, repair
damaged surface of piston rod or
it. Replace damaged or aged seal ring.
damaged or aged seal ring
Oil lead due to poor sealing of pipe Check seal ring and contact face for scratch.
connector If any, replace or repair them.
External Defective seal at cylinder cover due to Check the processing precision of contact
leak poor processing precision of contact face face and the aging condition of seal ring,
or aged seal ring and timely replace or repair them.
Oil leak due to seal ring damaged by

local high temperature, which is caused Add exhaust device and timely discharge the
by air insulation compression as a result air.
of poor exhaust
3-22
Fault Cause Remedy
Check the processing precision of contact

Oil leak at buffering device due to poor
face and the aging condition of seal ring,
processing precision or aged seal ring
and timely replace or repair them.
If the piston is heavily worn, bore the

Internal leak and interchange between
cylinder, lathe the piston to be thin with
high/low-pressure chamber due to
several grooves, and then fit a seal ring to
excessively large fit clearance between
the piston for sealing, or fit a new piston
worn cylinder hole and piston
instead.
Internal leak and interchange between

high/low-pressure chamber due to worn Replace damaged or aged seal ring in time.
or aged seal ring on piston
Internal leak
Internal leak due to inclined or
Check concentricity of cylinder body, piston,
deflectively worn piston as a result of
and hole of piston rod for cover, and make
non-concentricity or eccentric load on
them align with each other.
cylinder body and piston
Internal leak due to local drum shape

caused by poor processing linearity of Bore hydraulic cylinder, and replace piston.
diameter of cylinder hole or local abrasion
Serious leak due to large fit clearance Replace seal ring in time if the aged seal
between piston and hydraulic cylinder ring brings on serious internal leak and the
(caused by wear), or defective sealing hydraulic cylinder moves downward. In case
(caused by damaged or aged piston seal of large clearance, lathe the piston with
rings due to fitting and abrasion) several grooves, and then fit a seal ring or
replace piston.
Internal leak in high/low-pressure

chamber at local sections due to
defective seal caused by error in local Bore hydraulic cylinder, repair the diameter
geometric shape as a result of uneven of cylinder hole, and replace piston.
wear at local sections of hydraulic
Insufficient cylinder
propulsion,
falling
speed and
unstable Confliction due to increasing friction or
Adjust the tightness of seal ring for piston
running resistance caused by excessively
rod (to the extent that no oil leak occurs),
pressed seal ring of piston rod at cylinder
and straighten piston rod.
end or bent piston rod
Lower operating speed and unstable

operation due to large sliding resistance Change oil.
caused by dirt in oil entering sliding parts
Lower operating speed of hydraulic

Find out the causes for oil temperature rise,
cylinder due to high oil temperature,
and take radiating and cooling measures.
lower oil viscosity and increasing leak
3-23
Fault Cause Remedy

In case of insufficient capacity, replace
Low working pressure or capacity of
accumulator; in case of insufficient pressure,
accumulator, which is used for enhancing
apply enough air pressure to the
the operating speed of hydraulic cylinder
accumulator.
Adjust the pressure of overflow valve as per

Insufficient propulsion due to low system
the requirements of propulsion; check
pressure cause by lower pressure of
pressure of overflow valve; check overflow
overflow valve or the leak in pressure
valve for internal leak, if any, repair or
control area of overflow valve
replace overflow valve.
Unstable operation due to air in hydraulic Rectify this fault by the method for faults on
cylinder air suction and creeping.
Lower operating speed and unstable

Check the hydraulic pump or flow adjusting
operation due to insufficient oil supply of
valve, diagnose and rectify the fault.
hydraulic pump
Friction sound of sliding metallic surface

Stop the machine for checking, avoid the
due to poor lubrication caused by
sintering of sliding surface and improve the
damaged oil film of sliding surface or high
lubrication.
pressure
Improve the lubrication, and in case of

Abnormal sound around seal ring due to serious scratch of seal ring, polish the lip
damaged oil film of sliding surface or edge with sand paper or sand cloth, or
Abnormal serious scratch of seal ring adjust the compaction degree to eliminate
sound and the abnormal sound.
noise
Shake and huge noise resulted from the

insulated and compressed air under the Move the piston slowly to the top for several
piston when the piston is moving to the times in order to discharge the air in cylinder,
end of hydraulic cylinder especially for which can eliminate this serious noise and
vertical hydraulic cylinder or the piston is prevent burnout of seal ring.
moving to the end point.
3-24
3.4.6 Sealing Elements
Table 3-6 describes the common faults for sealing

elements and the ways in which you may rectify
them.
Table 3-6 Troubleshooting the Sealing Elements
Fault Cause Remedy
Lower the pressure; set supporting rings or

High pressure
retainer rings.
Large clearance Overhaul or replace sealing elements.

Pulled
clearance
Improper size of groove, etc. Overhaul or replace sealing elements.
Sealing element fit improperly Refit, overhaul, or replace sealing elements.
Sealing elements are not

Replace seal ring or change hydraulic oil.
compatible with hydraulic oil
Expansion Sealing elements dissolved by Strictly keep sealing elements away from
(frothing) solvents solvents (e.g. kerosene and petroleum).
Aged hydraulic oil Change hydraulic oil.
Check oil temperature; in case of serious friction

or overheating (poor lubrication or excessively
High temperature
tight mating), timely overhaul or replace seal
elements.
Aging and Naturally aged and deteriorated

cracking sealing elements as a result of
Overhaul or replace sealing elements.
being stored or used for a long
term
Sealing elements hardened Find out the cause, and improve the lubrication
under low temperature on sealing elements.
Sealing elements distorted due to

Distortion Use retainer rings to obviate distortion.
lateral (or longitudinal) load.
3-25
Fault Cause Remedy
Fitting surfaces of sealing Check the impurities in oil, the process quality of
elements damaged due to fitting surfaces and the quality of seal rings, and
movement and friction timely overhaul or replace sealing elements.
Wear and
damage on
surface Sealing elements damaged due
Overhaul or replace sealing elements.
to cutting during installation
Sealing elements worn due to Find out the cause, and improve the lubrication
poor lubrication on sealing elements.
High pressure, heavy load, and

Additionally set supporting rings or retainer rings.
poor working conditions
Damage,
Poor quality of sealing elements Check the quality of sealing elements.
adhesion and
deformation
Poor lubrication Improve the lubrication.
Improper installation Refit, overhaul, or replace sealing elements.
Sealing elements not compatible

Replace seal ring or change hydraulic oil.
with hydraulic oil.
Shrinkage
Age hardening or drying
Replace sealing elements.
shrinkage due to closed storage.
3-26
3.4.7 Oil Filter
Table 3-7 describes the common faults for oil filter

and the ways in which you may rectify them.
Table 3-7 Troubleshooting the Oil Filter
Fault Cause Remedy
If the oil filter is not strong and seriously

blocked, the oil-passed clearance
Deformation of oil
decreases greatly, and the resistance
filter element
increases to a great extent, the filter Use a stronger skeleton instead, and
(usually on
element, under the effect of large filter or change oil.
sintering oil filter
pressure difference, will be deformed, and
or screen oil filter)
even crushed (the skeleton of oil filter,
sometimes, will be damaged, too.).
Replace filter element, and check the

new filter element, to which the
requirements are listed as follows:
Under the vibration at an acceleration

of 10g, the filter element shall not
shed granules;
Sintering oil filter The quality of sintering oil filter not in
shedding granules accordance with requirements.
Under the effect of a pressure at
21MPa, the filter element shall not
shed granules within 1 hour;
During the impact load test by a

manual pump, the filter element,
under the accelerated pressure of
10MPa, shall not be damaged.
Such a phenomenon usually appears on

the grid oil filter which is fitted at the inlet
of high-pressure pump. The reason of this
is as follows: the melting point of
Solders breaking Replace the plumbum- stannum
plumbum-stannum electrode is 183℃,
away from metallic electrode by the argentum-cadmium
and the temperature at the inlet of oil filter
grid and skeleton electrode, which has a higher melting
has reached 117℃, the strength of
of grid oil filter point.
electrode consequently decreases to a
great extent and finally the electrode
breaks away under the impact of high-
pressure oil.
3-27
3.4.8 Hydraulic Steering Gear
Common faults of hydraulic steering gear

comprise: oil leak, difficult steering, failed steering,
failure of steering wheel in automatic aligning, and
failure in switching to manual steering. Table 3-8
Table 3-8 Troubleshooting the Hydraulic Steering Gear and Valve Block
Fault Cause Remedy
Oil leak at joint surfaces

Damaged seal
between stator of valve body Replace seal ring.
ring
and rear cover
Oil leak at joint surfaces

Dirt at joint
between valve block and Remove the dirt.
surfaces
Oil leak steering gear
Oil leak at adjusting bolt for Fixing bolt not

Replace bolt.
safety valve rigid enough
Oil leak at bolt of steering Uneven Grind or replace

gear washer washer.
Easy steering when turning Check whether the

Insufficient oil
the wheel slowly; hard pump is normal. If
supply of
steering when turning the not, replace or
pump
wheel quickly repair pump.
If steel ball is lost,

Defective one- fit a new Φ8 one; if
Hard steering when turning way valve with the valve is seized
the wheel slowly or quickly; steel ball by dirt, clean it; if
feeble turning inside the the crown bar is
steering gear deformed, calibrate
or replace it.
Difficult steering
Set pressure
of overflow
Adjust set pressure
Easy steering under no load valve lower
of overflow valve,
or light load, but hard than working
or clean overflow
steering under heavier load pressure, or
valve.
stuck overflow
valve
Discharge the air,

Bubble in oil and abnormal Air in steering and check oil
sounds; steering cylinder system, low oil suction pipe for
acting fitfully when the level, and high leak, or add oil (i.e.
steering wheel is turned oil viscosity recommended
hydraulic oil).
3-28
Fault Cause Remedy
Steering wheel can not

return back to center
automatically, and pressure Broken spring Replace spring.
drop increases at the center
position
Pin, or
Pressure fluctuation opening of
Replace pin and
obviously increase and universal
shaft (do not use
steering wheel can not driving shaft,
other substitutes).
turned broken or
distorted
Failure in steering
Rotor fitted at
incorrect Make tooth A on
Steering wheel automatically
position in driving shaft due
turns or wobbles leftwards
relation to aligned with a gear
and rightwards
universal root of rotor.
driving shaft
Defective two-
The roller travels
way buffering
deflectively; steering Replace spring or
valve or
cylinder does not act or acts clean two-way
spring, or steel
sluggishly when the steering buffering valve.
ball stuck by
wheel is turned
dirt
Rectify the fault

Broken spring according to its
causes.
Steering shaft
axially butts
Steering wheel can not turn back to center automatically: when valve element
the pressure drop increases at the center position or steering
wheel stops turning, steering gear does not unload (i.e. the roller Large coaxiality
travels deflectively.). error between
axial lines of
steer shaft and
valve
Large rotation
resistance of
steering shaft
Failure in switching to manual steering: during power steering, Large axial or

the driver can not feel he has turned the steering wheel to the radial
Replace rotor and
limit when the piston of steering cylinder is already at the limit; clearance
stator.
during manual steering, the steering cylinder doesn't switch between rotor
when turning the steering wheel and stator
3-29
3.4.9 Other Faults
Besides the foresaid faults, there are other

common faults such as insufficient braking force in
braking system and overheating of brake. Table 3-
9 describes the causes for such faults and the
ways in which you may rectify them.
Table 3-9 Troubleshooting Other Common Faults
Fault Cause Remedy
Brake disc Check the thickness of brake disc; adjust the clearance of
misadjusted brake disc if the brake disc has not been excessively worn.
Insufficient
braking force
Heavy wear at Check the thickness of brake disc, and replace the brake disc
brake disc as described in Section 3 (if necessary).
Improper oil level Check oil level, and fill or drain oil till the oil level is correct.
Overheating of Small clearance of

brake Adjust the clearance of brake disc as described in Section 3.
brake disc
Improper
Drain off lubricating oil, and fill the proper one instead.
lubricating oil
3-30
K
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3-32
CHAPTER 4 ELECTRICAL PART
Chapter 4 Electrical Part
The operating principle and structure of roller's

electrical system are specified in User's Guide.
This chapter explains the common faults in roller's
electrical system and the ways in which you may
rectify them. The electrical schematic diagram can
be found in Section 2.5 of the User's Guide.
4.1 Basic Vehicle Electrical System
Table 4-1 describes the common faults in basic

vehicle electrical system and the ways in which
you may rectify them.
Table 4-1 Troubleshooting the Basic Vehicle Electrical System
Fault Cause Remedy
Break-off of fuse FU7 Replace fuse FU7
No power supply of When the machine is blocked, dismantle it for

complete machine Damage of ignition switch S1 coating lubricant, replace ignition switch S1
when the contact is damaged
Damage of direct current

Replace direct current contactor K0.
contactor K0
Check whether the indicator light HL1 and

Failure of charging lines resistance R3 are normal and in good
connection; replace it if necessary.
Insufficient power in Charge it when the indicator of storage battery

Damage of storage battery
storage battery is black; replace it if it is white.
If the voltage on the B+ end is less than 26V

after starting the engine, it indicates the
Fault of engine
generator is damaged. It is required to send it
for maintenance by professional personnel.
4-1
Fault Cause Remedy
No resetting on neutral of travel

Turn travel handle and vibration option switch
handle and vibration option
S16 to the neutral position.
switch S16
Replace starter relay K1 if the circuit is

Damage of starter relay K1
normal.
No ignition of the
engine Confirm if there is short circuit on lines firstly; if
Breakdown of fuse FU8 not, start it after replacing with the fuse of a
same type.
It is usually caused by the block of clutch

Defective starter moter mechanism and bad performance of control
contact; the professional repair is needed.
Check the lines, in particular the W end

Poor contact of lines
connecting terminal of generator.
No display of engine Damage of engine or without input on W end;

rotary speed signal Failure of engine
the professional repair is needed.
Abnormity of working power on Check whether the lines are short or not, until
PLC input terminal the working voltages of PLC lines are normal.
No speed display in case of

Check it as the fourth step
auto gear
Check the related lines, in particular the plug

Bad contact of lines
Engine rotary speed connecting with the linear step motor
out of control
Dismantle and clean spline push rod
Block of linear step motor
mechanism or replace bearing.
Check whether the resistance of tow group

Failure of linear step motor
coils is about 2Ω; replace it if it is damaged.
The pointer always stay at the

Check and rectify short occurs on lines.
maximum value
Abnormality of The pointer always stay at the Check and rectify short circuit occurs on lines;
indication on fuel minimum value replace damaged sensor.
meter
No action of pointer when the
power is on, or no resetting of Replace damaged fuel meter.
pointer when the power is off
4-2
4.2 Electrical System on Working Device
Table 4-2 describes the common faults in electrical

system on working device and the ways in which
you may rectify them.
Table 4.2 Troubleshooting the Electrical System on Working Device
Fault Cause Remedy

Whether the braking switch S19 Reset braking switch S19 and emergency switch
and emergency switch S12 can S12.
be reset or not
Failure of pressure relay S21 Replace it if the machine can run when the plug on
Failure of running, pressure relay is drawn out.
or pause occurs Failure of lines Check and rectify the short lines or bad contact of
during running electromagnetic valve plug.
Damage of brake and brake Replace electromagnetic valve or clean valve
release electromagnetic valves, element.
or the block of valve element
Whether the emergency switch Reset emergency switch S12.

S12 is reset or not
No vibration in case of manual Replace damaged vibration control selection switch
gear S16 or button switch S17; check and rectify the bad
No vibration of contact of lines, if any.
roller
No vibration in case of auto gear Check it as the fifth step or accelerate it when speed
is not displayed or is less than 25m/min; if such fault
occurs due to the mis-operation of button switch
S17, it is normal.
Whether the emergency switch Reset emergency switch S12.
S12 is reset or not
Defective spraying switch S14 Replace switch S14; check relevant circuit for bad
and its circuit contact and rectify it.
Defective DC voltage regulator If the regulator is under overload protection mode
No spraying of A3 due to increased load current on water pump caused
roller by the blocked line, clean and unblock the line; if the
regulator is damaged, replace it.
Damaged or stuck water cut-off In case of damaged coil, replace the valve; in case
valve Y12 of stuck valve, adjust balance screw.
Damaged water pump Replace water pump.

Stuck float of water level switch Disassemble water level switch to remove the dirt
Alarm error for and foreign materials on its surface.
water level switch
of spraying tank Damaged water level switch If the float moves up and down and the switch is
constantly on, the switch is damaged. Replace it.
4-3
Fault Cause Remedy

Failure of lines Check whether the lines are damaged or bad
contact of connector, in particular the harness of
sensor, and rectify it, if necessary.
No display of
speed signal Large gap between sensor and Readjust the gap within 0.4mm~0.6mm.
flywheel gear of motor
Damaged sensor Replace sensor.
Automatic crabbing during It is a hydraulic fault. Check and rectify it.
traveling
Loose proximity switch S6 Tighten proximity switch.
Abnormal crab- Proximity switch S6 stuck with Remove the foreign materials.
walk indication foreign materials
Damaged proximity switch S6 If the power supply for proximity switch S6 is alright
but the switch doesn't work, the switch is damaged.
Replace it.
The fuses of roller are as shown in Table 4-3.
Table 4-3
Pneumatic Tyre Roller
FU1 Starter motor 30A B241300000026 Fuse 8JS-711-690-00 Orange
FU2 Ignition switch 20A B241300000022 Fuse 8JS-711-688-00 Beige
Front working
FU3 10A B241300000021 Fuse 8JS-711-686-00 Red
lamp
Rear working
FU4 10A B241300000021 Fuse 8JS-711-686-00 Red
lamp
FU5 Brake/horn 5A B241300000020 Fuse 8JS-711-684-00 Light brown
FU6 Headlamp 10A B241300000021 Fuse 8JS-711-686-00 Red
FU7 Turn indicator 10A B241300000021 Fuse 8JS-711-686-00 Red
FU8 Air conditioner 20A B241300000022 Fuse 8JS-711-688-00 Beige
FU9 PLC power 10A B241300000021 Fuse 8JS-711-686-00 Red
FU10 Spraying 10A B241300000021 Fuse 8JS-711-686-00 Red
FU11 Windshield wiper 20A B241300000022 Fuse 8JS-711-688-00 Beige
4-4
4.3 Air Conditioning System
The common faults in air conditioning system

generally comprise electrical faults, mechanical
faults and faults caused by refrigerant and
refrigerant lubricant. Symptoms are always that the
refrigeration is unavailable or insufficient, or the
system is with abnormal noise.
4.3.1 No Refrigeration
Faults: ignite the engine and stabilize its rev. at the

middle speed for about 3min, switch on the blower
fan and air-conditioning system, no cool wind
comes out of the cooling outlet. Table 4-4 describes
the faults and the ways in which you may rectify
them.
4-5
Table 4-4 Troubleshooting the Fault of No Refrigeration
Fault Cause Remedy
Fuse blown off Replace it.
Evaporator's Poor connection of switch Repair or replace it.

blower not
revolving Defective rheostat Repair or replace it.
Defective motor Repair or replace it.
Open-circuit of conductor Repair or replace it.
Bad control of idling Repair or replace it.
Bad temperature control Repair or replace it.
Electromagnetic clutch not Defective pressure switch Repair or replace it.

engaged
Defective
Repair or replace it.
electromagnetic coil
Open-circuit of conductor Repair or replace it.
Loose or Adjust or
damaged belt replace it.
Compressor not revolving
Evaporator's
blower not Defective Remove it for
revolving compressor repair.
Leak of
refrigerant or Fill or
excessive exhaust it.
refrigerant
Electromagnetic clutch
engaged
Expansion valve
Replace it.
blocked
Compressor revolving
Dry-type filter
Replace it.
blocked
Pipe blocked Replace it.
Defective Remove it for

compressor repair.
4-6
4.3.2 Insufficient Refrigeration
Causes: insufficient refrigeration can be caused by

many reasons. Causes for the decline of the
refrigerant flow at the exit of the expansion valve
may lead to insufficient refrigeration; all causes for
excessive high temperature or excessive low
pressure at the high or low-pressure side in the
system may result in insufficient refrigeration. Table
4-5 describes the faults, causes and the ways in
which you may rectify them.
Table 4-5 Troubleshooting the Fault of Insufficient Refrigeration
Fault Cause Remedy
Air filter blocked Clean filter.
Break of thermistor Repair it.
Revolving Low voltage of the

Frost of evaporator Check storage battery.
normally storage battery
Defective thermistor Replace it.

Blower
revolving Displacement of air conductor Check and repair it.
Flake-off or corrosion of storage battery's

Check and repair it.
wiring terminal
Revolving slowly
Check, repair or replace
Defective blower motor
Insuff it.
icient
Wind Revolving at high
speed and no
revolving at Defective rheostat Replace it.
middle and low
speed
Failure of speed-adjustment resistance and Check, repair or replace

Blower blown-off of the fuse it.
not
revolving Defective blower motor Repair or replace it.
No revolving at
high, middle and Defective blower switch Repair or replace it.
low speed
Defective blower relay Check or replace it.
Inappropriate wiring or flake-off of wiring Check and repair it.
4-7
Fault Cause Remedy
Seepage of air from Check the intake.

outside
Normal
pressure Failure of
temperature- Check and replace the
controlled system relevant parts.
High/low pressure Release appropriate

values excessively Excessive refrigerant amount of refrigerant from
high low-pressure valve.
Refrigeration cycling Release refrigerant,

with air perform vacuum-pumping
and then fill refrigerant.
Defective condenser Check and repair it.

High-pressure value
excessively high; Condenser pipe Repair or replace it after
low-pressure value blocked finding out causes.
excessively low
Expansion valve Adjust or replace it.

Compress excessively opened
or working
normally High-pressure value Excessive high
Normal normal; low- temperature at the inlet Check the intake and
Wind Abnormal pressure value of evaporator inspection port.
pressure excessively high
Inappropriately
installation of
expansion valve's Check and repair it.
temperature sensing
pack
Defective compressor Check, repair or replace it.
High-pressure value
slightly low; low- Insufficient refrigerant Check for leak and fill it
pressure value after rehabilitation.
excessively high
Air filter blocked Clean it.
Expansion valve' filter Clean or replace it.
sieve blocked
High/low pressure Leak of refrigerant Check for leak and repair it.
values excessively
Failure of the
expansion valve's Check, repair or replace it.
temperature sensing
pack
Defective compressor Check, repair or replace it.
Compress Defective electromagnetic clutch Check, repair or replace it.
or working
abnormally Driving belt damaged or sliding Check, repair or replace it.
Defective pressure switch Check, repair or replace it.
4-8
4.3.3 Abnormal Noise in Refrigeration System
Causes: it is generally caused by mechanical

faults, including looseness of fastening pieces,
abrasion of moving parts to the limit and bad
lubrication of relative moving parts. See Table 4-6.
Table 4-6 Troubleshooting the Fault of Abnormal Noise
Fault Cause Remedy

Too loose drive belt Adjust tightness of belt.
Heavy wear at drive belt Replace it.
Drive belt Loose supporting shoes Repair it.
Damaged tensioning pulley bearing Replace it.
Check blower for foreign materials, or repair or
Blower with abnormal noise
Blower replace it.
Heavy wear at motor Repair or replace it.
Sliding of electromagnetic clutch Repair it.
Inappropriate installation of coil Repair it.
Electromagnetic Inclined belt pulley Adjust it.
clutch
Excessive refrigerant Exhaust it.
Insufficient refrigerant lubricant Add lubricant.
Defective compressor Remove it for check.
4.3.4 Faults of Heating Device
For the air conditioning system with air warming

function, faults are always that there is no warm air
or the warm air cannot be stopped completely. See
Table 4-7.
4-9
Table 4-7 Troubleshooting the Fault of Air Warming
Fault Cause Remedy
Check and replace fuse and

Blown-off of fuse or
check lines with a universal
damage of lines
meter.
No wind
Check, repair or replace blower
Damage of blower
with a universal meter.
No heating Failure to open the

Check lines with a universal
electromagnetic valve
meter.
due to lack of power
Normal wind
Open warm-air switch to feel the
Electromagnetic valve
movement of electromagnetic
damaged and cannot be
valve; check, repair or replace
opened
electromagnetic valve.
Electromagnetic valve
Normal wind with Check, repair or replace
Switch loose blocked inside and
warm air electromagnetic valve.
cannot be closed
4.3.5 Other Faults
Besides the above faults, unstable refrigeration

effect and frost of the evaporator may occur to the
air conditioning system. See Table 4-8.
4-10
Table 4-8 Troubleshooting Other Faults
Fault Cause Remedy
The system has good

refrigeration effect at first, but Leak due to loose joints
cannot last for a long period; caused by vibration.
Find out the leak with leak detector;
bubbles can be detected in the Inappropriate operation. The
carefully screw down the loose parts
inspection hole of the liquid valve hole is closed due to the
and fill R134a.
receiver; the high-pressure and damage of expansion valve's
low-pressure gauges have low temperature sensing pack.
“reading”.
The system has no refrigeration

Thin frost or “sweating”
effect; warm air comes from the
appears on the expansion
wind mouth; there is no
valve due to blocked Replace expansion valve and refill
temperature difference at the
expansion valve's filter screen R134a.
inlet and outlet of expansion
because of foreign materials in
valve and the low pressure
the system.
gauge has low “reading”.
The wind out of the wind outlet is Start the air conditioning system at
not cool, and the compressor's intervals. If the blockage is not
temperature rises. The low serious, the instantaneous blockage
No effect of the throttle hole in
pressure gauge's hand drops can be eliminated; or dismantle the
the expansion valve.
quickly, almost approaching 0; expansion valve and clean it with
and the high pressure gauge has alcohol, and refill R134a after
high “reading”. exhausting the system.
The refrigerating output is

insufficient, and the evaporator
Dryer in liquid receiver Exhaust the system, replace the
frosts; both high-pressure and
saturated expansion valve and re-fill R134a.
low-pressure gauges have low
“reading”.
After operating for a period of

time, the refrigerating output
gradually declines, the high
Throttle hole of expansion Exhaust the system, replace the liquid
pressure gauge has high
valve blocked by ice receiver and re-fill R134a.
“reading”, and the low pressure
gauge has a reading of less than
0.2MPa.
After starting the refrigeration
Bad contact of the
system, there is wind but no Check the temperature-controlled
temperature-controlled switch
refrigeration effect coming; switch for damage with universal
or damage of the
readings of both high-pressure meter; replace the electromagnetic
electromagnetic clutch coil of
and low-pressure gauges keep clutch of the compressor
the compressor
unchanged.
The electromagnetic clutch of the Too small opening of the

compressor moves frequently temperature-controlled switch
Check the temperature-controlled
with short contact time; no automatically forces the
switch and turn it to the position of
refrigeration effect, but both high- compressor to stop running,
coldest effect.
pressure and low-pressure resulting in insufficient
gauges have normal “reading”. refrigeration.
4-11

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TABLE OF CONTENTS

PNEUMATIC TYRE ROLLER MAINTENANCE MANUAL

Chapter 2 Mechanical Part…………………………………………………………………………………2-1

Chapter 3 Hydraulic Part……………………………………………………………………………………3-1

Chapter 4 Electrical Part……………………………………………………………………………………4-1

1.1 About this Manual

This Manual must be put in the file of cab or the file

This Manual covers the information on routine

Some photos or details in figure or optional parts in

Some modifications as a result of constant

All instructions described in this Manual are about

The operator's technique and skills will be

If you have any queries about the machine or this

Presently, we have two series of pneumatic tyre

1.2 Overall Structure

1-Frame 2-Air conditioning system 3-Electrical system 4-Covering parts assembly

Chapter 2 Mechanical Part

2.1 Maintaining the Rear Wheel Assembly

The rear wheel assembly is already

2.1.1 Filling Oil into Driving Axle

Undo the bolt at the oil level port on axle housing

Oil level port

2.1.2 Removing and Maintaining the Rear Wheel

1) Preparation: Jack up the rear part of the

3) Rotate the two adjusting bolts to loosen the

4) Undo the M6 bolt and washer on the cover to

5) Undo the bolts (2 kinds) connecting the rear

M24 bolt and washer

6) Separate such parts as the rear wheel support

7) Undo the fixing nut and washer unit on the

8) If you wish further maintenance, you must

9) Remove the flat key. Undo the fixing bolt unit

11) Undo the bolt on the sprocket wheel cover

12) Successively remove the parts as shown in

13) Remove such parts as clipping key to

2.2 Maintaining the Tyre

2.2.1 Removing the Tyre

1) Discharge the air in the tyre. Screw off the

2) Insert a tyre lever between the tyre flange and

3) Insert the second tyre lever around the first

2.2.2 Fitting the Tyre

1) Check the rim for distortion and crack, the

2) To fit the tyre: first, fasten the lining band of

3) When inserting the lever into the tyre, do not

4) After fitting the tyre onto the rim, check and

5) The tyre flange and rim should be evenly in

6) You must inflate the tyre slowly. The tube is

7) For the sake of safety, you must insert a thick

2.2.3 Inflating the Tyre

The tyres of pneumatic tyre roller are inflated by

After overhaul of pneumatic system, you can carry

1) Adjust the pressure of unloading valve: the

e) Start the engine up. Engage the rated gear

2) Turn the adjusting screw of air pump control

3) Fit and tighten the control valve cover of air

4) Set the handle of manual valve to the neutral

5) Check the air tightness:

d) Check the air tightness of tyre: shut down the

2.3 Maintaining the Diesel Engine

Table 2-1 describes the common faults in diesel

Table 2-1 Troubleshooting the Diesel Engine

Fault Cause Remedy

Dirty dry-type air filter Clean or replace dry-type air filter.