挖掘机典型故障案例汇编定稿A4 修改稿

Foreword
With the continuous promotion of company’s internationalization process, service, as the business
assurance at the present stage, has been playing more and more important roles in promoting market
development and product competitiveness. Service personnel are the actual executors of oversea
service, and their skill levels directly determine the service effects and customer satisfaction. In order
to promote skill levels of service personnel and share their service experience, we collect and
summarize typical faults of excavator appearing in domestic markets in recent years and compile A
Casebook of Excavator's Typical Faults.
All the fault cases in this casebook are summarized and refined by service personnel of excavator
business division during the frontline field service in domestic markets, which have extensive
representativeness and important roles of learning and reference. Combining theory with practice, all
the collected cases summarize fault diagnostic methods and eliminating skills through plenty of
detailed pictures and written analytical materials. Here, we express our sincere gratitude to relevant
personnel of excavator business division for their hard efforts!
We classify the collected contents so that readers can read clearly and understand easily, and the
contents include: cause analysis, judgment and eliminating methods for typical faults of power system,
hydraulic system and electrical system. Here, we also express our sincere gratitude to personnel of
collating fault cases for their arduous efforts!
In the compiling process of this casebook, we get guidance from leaders at all levels in business
division and many good suggestions from colleagues, and we take this opportunity to express our
thanks to them all!
Due to time and ability constraints, this casebook may contain certain omissions and mistakes
that may be inevitable, and we will appreciate those who help us to improve the casebook!
Editor’s note
March, 2011
CONTENTS
I. Power System ...................................................................................................................................1
II. Hydraulic system ............................................................................................................................. 11
III. Electrical System.............................................................................................................................32

A Casebook of Excavator's Typical Faults
I. Power System
As a main component of power system and an important component of excavator, diesel engine
is a device to produce and output energy for excavator and its main function is to achive
transformation of energy.
The main faults of power system are: engine start diffuculty; oil pressure too low or too high; oil
level rise in oil sump; discharging blue smoke, black smoke or white smoke; engine overheat, diesel
engine no idling; galloping; diesel engine unstable running; insufficient horsepower; abnormal sound
and etc.
Fault causes of diesel engine are various, different faults have different symptoms. In order to find
out the exact fault causes, make full use of practical experience, find out the causes of diesel engine
disorder by the feelings such as look, listen, touch and smell, and thus eliminate the fault quickly.
Fault case no.: WP20110001 Fault classification: Power system
Fault case analysis record Record date: 2008.03.21 Recorder: Ma Guokai
Model Serial number Working hour(h) Service Location Working condition
FR60-7 RB100377S 1760 Beijing Plain, mountain land etc
Symptom of fault:
Engine is difficult to start.
Analyze the possible reasons:

1. Plunger wears out;
2. Oil tank blockage;
3. Oil line blockage;
4. Air filter blockage;
5. Poor atomization of nozzle;
6. Flywheel disk jamming;
7. Starting motor fault;
8. Compound relay fault;
9. Injection pump fault;
10. Poor contact of ground wire.
Check steps:
1. Listen to the sound of start-up to judge whether it is
normal, and it returns to normal after the check;
Conclusion Injection pump has internal faults
2. Check whether air filter is blocked;
3. Check oil line, both low pressure and high pressure
oil lines are normal;
Maintenance scheme Repair injection pump
4. Check whether atomization of nozzle is normal;
5. Check whether injection pump has faults, find there
is a falling bolt in the pump, and it returns to normal
Effect confirmation OK
after repair.
1
Fault case no.:WP20110002 Fault classification: Power system
Fault case analysis record Record date: 2008.12 Recorder: Zhu Dezhi
Model Serial number Working hours(h) Service Location Working condition
FR150-7 RJ200168S-G 100 Qingdao Public works
Symptom of fault:
Engine flames out automatically at idle speed.
1. The supply of low pressure fuel is insufficient;
2. The supply of high pressure fuel is insufficient;
3. Air channel is blocked;
4. Problem of flameout solenoid valve.
Check steps:
1. Check whether there is oil in oil tank and whether air
channel is blocked first;
2. Pump oil with manual oil pump to observe whether
Conclusion Oil line blockage
low pressure oil line is unblocked;
3. Unscrew air plug of injection pump and manual oil
pump has a sense of abnormal resistance, low Maintenance scheme Replace filter element
pressure oil line is deemed to be blocked, and it
proves that low pressure oil line blockage is caused
by fuel filter element blockage.
Fault case analysis record Record date: 2008.03.12 Recorder: Li Wenlong
FR85-7 RG100047CS 2002 Hubei Honghu city Plain
Symptom of fault:
Engine fails to start (starter has actions).
1. Diesel oil shortage, air filter element blockage or
insufficient starting voltage;
2. Insufficient oil supply of low pressure oil line;
3. Insufficient oil supply of high pressure oil line or oil
pumping failure;
4. Poor atomization of nozzle.
Check steps:
1. Diesel oil level is normal, air filter has just been
replaced, starter has good start-up, and circuit and
voltage are normal; Conclusion Injection pump plunger wears out
2. Check low pressure oil line, and oil supply is smooth;
3. Check high pressure oil line, injection quantity is
poor, and pressure is not enough to open oil nozzle,
high pressure oil pump plunger wear-out is judged, Adjust flow control screw to increase
Maintenance scheme
adjust oil supply screw to 180°, and then injection oil supply of injection pump
quantity increases, but pressure is still insufficient,
plunger wear-out is judged to be too serious, adjust
oil supply screw to 270°, and engine starts normally,
there is no stalling fault after trial run, and excavator Effect confirmation OK
returns to normal.
2
Fault case analysis record Record date: 2008.3.5 Recorder: Wang Zezhong
FR60-7 None 100 Guizhou Mountain land
Symptom of fault:
Engine flames out once or twice a day, restart immediately
sometimes, but sometimes several starting is needed,
there is no stalling fault, and exhaust color is normal.

1. Low pressure oil line is blocked or leaks air;
2. Electronic oil delivery pump works poorly;
3. Oil supply of high pressure oil line is insufficient;
4. Holding coil circuit of flameout solenoid valve is in poor
contact.
Check steps:
1. Wash low pressure oil line and replace diesel filter to
eliminate air leakage etc;
2. Check electronic oil delivery pump and it pumps oil Holding coil circuit of flameout
Conclusion
normally; solenoid valve is in poor contact
3. Remove flameout solenoid valve after engine stops to
find it can suck and draw normally, engine starts again
after putting it on, check the circuit of solenoid valve to Maintenance scheme Recover the state of power strip
find power strip at the bottom of driver’s cab is
deformed due to heat, which causes that holding coil
circuit is in poor contact and engine flames out
frequently.
Fault case analysis record Record date: 2008.8 Recorder: Wang Zezhong
FR75-7 RL100668N-G 500 Jiangsu Excavation
Symptom of fault:
The machine still fails to start after 500 hours of maintenance,
but starting motor can drive the engine normally.
1. There is air in oil line;
2. The blockage of intake passage causes intake
deficiency;
3. Flameout solenoid valve doesn’t work;
4. The compression ratio of cylinder is reduced, which
causes compression ignition failure.
Check steps:
1. Check flameout motor is normal;
2. Air in oil line has been emptied; Wrong oil filling method causes the
3. Air passage is not blocked; Conclusion oil to enter the combustion
4. Fluids inject while the engine starts, it is guessed chamber
preliminarily that wrong oil filling method causes the oil
to enter the combustion chamber; Wash and replace the damaged
Maintenance scheme
parts
5. Obvious oil traces are found after crankcase
ventilation apparatus on the intake pipe is open, and it
is judged that oil entering the combustion chamber Effect confirmation OK
causes the fault.
3
Fault case analysis record Record date: 2008.9 Recorder: Wang Zezhong
FR75-7 RL100568M-G 97 Anhui Public works
Symptom of fault:
Oil pressure gives an alarm.

1. Problem of wiring;
2. Oil is insufficient and oil model is wrong;
3. Pressure loss is caused by oil line failure.
Check steps:
1. Check oil quantity is normal;
2. Check joints of oil pressure sensor are normal; Conclusion Oil pressure sensor is damaged
3. Replaced new oil pressure sensor is normal.
Maintenance scheme Replace oil pressure sensor
Fault case analysis record Record date: 2008.12 Recorder: Zhang Hongjun
FR260-7 RE300018XS-G 6 Mianyang Riverbed
Symptom of fault:
Black smoke emits when engine starts, and begins to
reduce after lasting for 10 minutes or so.

1. The powers of engine and hydraulic pump don’t
match;
2. Engine intake is blocked;
3. Engine has internal faults;
4. Diesel label is wrong or oil quality is too poor.
Check steps:
1. Engine runs normally during trial run and there is no
abnormal occurrences such as stalling fault; Conclusion Fuel model is wrong
2. Check intake pipeline is normal;
3. Putting aside the internal faults of engine because it
is a new one, and replace fuel based on the
Maintenance scheme Replace fuel
temperature and things are getting better after trial
run, so it is judged to be a problem of fuel.
Note: Fuel model used is inconsistent with the Effect confirmation OK
specification, which causes the fault.
4
Fault case analysis record Record date: 2008.11 Recorder: Zhang Hongjun
FR150-7 RJ200018Z-G 700 Weifang Public works
Symptom of fault:
Engine is in high temperature after two hours’ work.

1. Fan belt is too loose;
2. Cooler has external and internal blockage;
3. Wrong alarm is caused by circuit reason;
4. Water pump fault.
Check steps:
1. Check whether the belt is in normal state;
Rust inside the water tank
2. Check whether the external of cooler is blocked; Conclusion
causes blockage
3. Grounding the water temperature sensor to test
whether it is broken; Maintenance
Replace water tank
4. Drain water to observe whether there is rust inside scheme
the water channel. It proves that rust inside the
water tank causes blockage of water channel. Effect confirmation OK
Fault case analysis record Record date: 2008.03.10 Recorder: Tao Fengqing
FR85-7 RD101347X 1500 Yunnan, Luliang Mountain area
Symptom of fault:
Electronic throttle cannot be advanced.

1. Throttle knob needs to be reset;
2. Throttle controller fails;
3. Throttle motor fails;
4. Throttle knob fails;
5. Circuit has problems.
Check steps:
1. Reset throttle;
One wire of power stripe for
2. Check whether circuit is normal;
connecting throttle controller
3. Check throttle knob, throttle controller and throttle Conclusion
and harness from throttle knob
motor;
is in poor connection.
4. Check whether throttle cable falls off or breaks off.
It returns to be normal after
Maintenance scheme connecting two ends of power
stripe with wires
5
Fault case analysis record Record date: 2008 Recorder: Zhang Hongjun
FR60-7 None 101 Yunnan Chuxiong Mountain land
Symptom of fault:
Engine is in high temperature and boils.

1. Thermostat cannot open;
2. Water channel of engine is blocked;
3. Water pump is damaged and belt is loose;
4. The whole machine is overloaded for a long time;
5. Water temperature sensor is damaged;
6. Cooling fines are blocked.
Check steps:
1. Remove thermostat and it is normal after the test;
2. Check water channel of engine is not blocked; Conclusion Water tank radiator is blocked
3. Remove water pump of engine and check it is not
damaged; Maintenance scheme Replace water tank radiator
4. Belt is not loose;
5. Water temperature sensor is normal;
6. Check cooling fins to find they are blocked. Effect confirmation OK
Fault case analysis record Record date: 2008.2.29 Recorder: Shi Chengqiang
FR85-7 RD101067E-G 670 Sichuan, Yibin Plain, hill
Symptom of fault:
Engine emits white smoke, then flames out and cannot
be started, but starting motor runs normally.

1. Water is mixed into diesel oil;
2. Oil supply is not smooth;
3. Nozzle jamming;
4. Engine has internal faults.
Check steps:
1. Check oil supply at diesel pump is normal and front
Impurities in diesel oil cause
oil line is normal; Conclusion
the nozzle jamming.
2. Remove nozzle to check and find the nozzle jams;
3. Check oil tank to find there is water in the diesel oil Maintenance scheme Calibrate nozzle
and wash the oil tank.
6
FR60-7 3F803407W-G 1230 Sichuan Mountain area
Symptom of fault:
Engine emits black smoke, rotating speed drops,
diesel oil goes black and oil consumption
increases when the excavator works.

1. Diesel pump leaks oil;
2. Diesel oil is dirty and oil line is blocked.
Check steps:
1. Replace diesel pump;
Conclusion Diesel pump is damaged
2. Wash oil line, replace diesel filter element and
smoke color of engine becomes normal after Maintenance scheme Replace diesel pump
trial run and diesel oil doesn’t go black in a
short time. Effect confirmation OK
Fault case analysis record Record date: 2008.2.30 Recorder: You Qingshun
FR60-7 3F801096c 2750 Ganzhou Plain, mountain land, riverbed, sandlot etc
Symptom of fault:
Engine is easy to start at cold and big throttle
state but cannot start at hot state.

1. Engine can start, so circuit fault can be
excluded first;
2. In the aspect of oil line:
1) Problem of diesel oil;
2) Problem of low pressure oil line;
3) Problem of injection pump.
Check steps:
1. It still has no effect after checking oil
quality and washing low pressure oil line,
Conclusion Plunger of high pressure fuel pump wears out
oil-water separator, diesel filter and air
filter element;
2. Check flameout relay, flameout solenoid
valve and the circuit have no abnormal Maintenance scheme Replace pump and calibrate pump
faults;
3. Check high pressure oil pump and find
pump plunger wears out. Effect confirmation OK
7
FR85-7 RD201607X 540 Yunnan, Jinggu Mountain land

Symptom of fault:
Electronic throttle fails.
1. Throttle cable is damaged;
2. Throttle knob is damaged;
3. Throttle motor is damaged;
4. Intermediate circuit is shorted, broken or
grounded;
5. Throttle controller is damaged or needs to be
reset.
Check steps:
1. Check whether throttle cable is normal;
Throttle controller is damaged and
2. Check whether throttle controller can be reset; Conclusion
cannot be adjusted again.
3. If it can not be set, check whether circuit is normal;
4. If the circuit is normal, check electrical element, Maintenance scheme Replace throttle controller
knob, throttle controller and throttle step motor.
Fault case analysis record Record date: 2008.3.25 Recorder: Cao Jingchong
Plain, mountain land, riverbed,
FR85-7 RD100417M 1423H Shijiazhuang
sandlot etc
Symptom of fault:
Engine cannot be started after automatic flameout.
1. Hydraulic pump seizes up;
2. Flywheel seizes up;
3. Battery has power shortage;
4. Starting motor has faults;
5. Bearing seizure.
Check steps:
1. Check battery and starter; Engine oil is too dirty, which causes
2. Check engine flywheel; Conclusion
bearing seizure of the second cylinder.
3. Check hydraulic filter element;
Replace connecting rod bearing shell,
4. Check hydraulic pump;
Maintenance scheme grind shaft, bore cylinder and replace
5. Check oil to find oil is too dirty;
piston
6. Check engine to find connecting rod bearing of the
second cylinder is seized. Effect confirmation OK
8
Fault case analysis record Record date: 2008.1.15 Recorder: Wang Xuhui
FR60-7 3F804226E 2130 Guizhou Tongzi Mountain land

Symptom of fault:
Starter can work normally but engine fails to start.
1. Aspect of circuit:
1) Battery fault;
2) Flameout solenoid valve fault;
3) Starting compound time relay is damaged.
2. Aspect of oil line:
1) Low pressure oil line and diesel filter is
damaged;
2) Injection pump fault;
3) Engine has internal faults.
Check steps:
1. Check complete circuit and voltage are normal
and starting motor works normally. Conclusion Plunger of injection pump is jammed
2. Check oil supply of low pressure diesel oil line is
Replace injection pump head and
normal, without blockage. Maintenance scheme
calibrate pump
3. Check flameout solenoid valve works normally;
4. Check circuit fault;
5. Check high pressure oil pipe fails to supply oil and
distribute valve block (the position where valve Effect confirmation OK
spool of flameout solenoid valve withstands) with
manual injection pump to find it is jammed, and
plunger of injection pump is judged to be jammed.
Fault case analysis record Record date: 2008.6.18 Recorder: Du Pengcheng

FR65-7 RG100797Y-G 1360 Guizhou Mountain land
Symptom of fault:
Engine automatically flames out sometimes, or even
fails to start.
1. Engine has 5. Flameout solenoid valve
internal faults; has faults;
2. Starting switch has 6. Battery has faults;
faults; 7. Diesel oil line has faults;
3. Starting circuit has 8. The blockage of diesel tank
faults; cap causes negative
4. Starter has faults; pressure in the oil tank.
Check steps:
The sound of start-up is normal when start with a key,
which indicates starting control circuit is normal; Motor
has normal sound of start-up, which indicates battery is Conclusion Wire 30 at flameout solenoid valve
normal, with no loss of capacity; Check low pressure is damaged and grounded
diesel oil line is not blocked, open high pressure oil pipe
on top of pump head and there is no oil to inject, and it is
thus inferred that oil injection plunger or flameout
solenoid valve have faults. Remove flameout solenoid Maintenance scheme Put the circuit in order again
valve and push manually shift fork in oil pump and the
fork can move freely, which indicates oil pump has no
problems, open key switch and flameout solenoid valve
can withdraw, move the circuit on top of it aside to find
there is slight breakage, bind up the circuit and it returns Effect confirmation OK
to normal after trial run.
9
FR150-7 RJ100027XS-G 370 Rizhao Public works
Symptom of fault:
Engine is difficult to start.
1. Cause of circuit, such as problems of flameout
solenoid valve and preheating;
2. Causes of oil, oil line and air passage, such as air
filter and diesel filter are blocked and fuel quality is
poor;
3. Mechanical cause, such as deformation of
connecting rod;
4. High pressure oil pump or nozzle wears out.
Check steps:
Judge whether there is abnormal sound when engine
starts and then check step to step: Oil line is dirty, manual oil pump is
Conclusion
1. Check whether flameout solenoid valve has not tightened
actions;
2. Pump oil in low pressure oil line with manual oil Wash oil line and tighten manual
Maintenance scheme
pump to see whether it is blocked; oil pump
3. Check whether air passage is blocked; there are
foreign matters in oil-water separator and manual oil Effect confirmation OK
pump is not tightened after the check.
Fault case analysis record Record date: 2008.6 Recorder: Wang Shenglin
FR60-7 None None None Plain, mountain land, riverbed, sandlot etc
Symptom of fault:
Engine is difficult to start at the hot state, and still
fails to start after replacing pump head.
1. New pump head is not qualified;
2. Shift fork of speed regulating mechanism fails
to install in place;
3. Distributing shaft is installed reversely, which
causes oil injection timing faults.
Check steps:
1. Reinstall pump head and take care to install
Conclusion Oil injection is wrong
shift fork of speed regulating mechanism in
place; Adjust the angle of distributing
Maintenance scheme
2. Check angle of distributing shaft to find the valve
direction of it is wrong, and it starts normally
after rotating the angle of distribution valve for Effect confirmation OK
180°.
10
Fault case analysis record Record date: 2008.11.5 Recorder: Zhanghai
FR139-7 RJ200018Z-G 1020 Weifang Plain
Symptom of fault:
In the mode of automatic idling, the engine speed
cannot be reduced and with no automatic idle function.

1. Short circuit fault;
2. Automatic idle selector switch becomes invalid;
3. Controller fault;
4. Automatic idle switch fault.
Check steps:
Check the circuit is normal first, and then automatic
Conclusion Automatic idle switch is damaged
idle switch because controller is generally difficult to
damage, and it returns to normal after replacing with a
Maintenance scheme Replace automatic idle switch
new idle switch. Such fault is caused by damage of
automatic idle switch in most cases. Effect confirmation OK
II. Hydraulic system
As an important component of excavator, excavator hydraulic system is to transform mechanical energy of engine
to hydraulic energy by means of oil pump via the medium of oil and transform back to mechanical energy through
hydraulic cylinder and hydraulic motor after delivery to achieve various actions. Excavator hydraulic system consists of
main oil pump, main control valve, rotary motor+reducer, travel motor+reducer, armrest valve, foot valve and pipelines
of pilot control circuit, and accessories.
The main faults of excavator hydraulic system are: hydraulic pump pressure shortage, running deviation, poor
gyroscopic force and etc. Fault causes of hydraulic system are various, different faults have different symptoms. Try to
find out the exact fault causes, and thus eliminate the fault quickly.
11
Fault case no.:WH20110001 Fault classification: Hydraulic system
Fault case analysis record Record date: 2009.3.1 Recorder: Zhao Mingyang
FR75-7 RL100848H-G 320 Guizhou Mountain area
Symptom of fault:
Left travel motor has no actions when advancing at
cold state and it is jammed when advancing at hot
state, and right travel motor works normally.
1. Main valve spool gets stuck;
2. Balance valve and check valve of travel motor
are damage;
3. Motor has inner leakage and is damaged.
Check steps:
1. Check main valve spool is normal;
2. Oil pipe has the same fault after left and right Check valve and core plug of
Conclusion
travel motors on the main valve are exchanged; travel motor are damaged
3. It is inferred that the fault should occur on the
travel motor after exchanging pipeline of main
Replace check valve and core
valve, disconnect motor balance valve is normal, Maintenance scheme
plug
disconnect one-way oil compensating valve of
the motor to find the check valve has a damaged
notch and scratch of round hole in the check Effect confirmation OK
valve core plug is serious.
Fault case analysis record Record date: 2008.3.20 Recorder: Du Pengcheng

FR60-7 None 680 Guizhou
sandlot etc
Symptom of fault:
Left travel motor cannot move back and forth.
1. Pilot oil line fault;
2. Left travel valve spool is jammed;
3. Central rotary joint has serious inner leakage;
4. Balance valve spool of travel motor is jammed.
Check steps:
1. The pilot pressure measured with pressure gauge
is 3.5MP, which indicates pilot pressure has no
problems; Balance valve spool of travel motor
2. Check left travel valve spool on the main valve is Conclusion
normal, and the main pressure measured on left seizes up
travel motor with pressure gauge is 28MP, which
indicates central rotary joint is normal; Maintenance scheme Wash balance valve spool
3. Open balance valve spool of left travel motor to
find a metal particle, take it out and left travel
motor works normally after washing balance valve Effect confirmation OK
spool.
12
Fault case analysis record Record date: 2008.3.21 Recorder: Ma Guokai
FR60-7 3F705357U-G 1760 Beijing Plain, mountain land etc
Symptom of fault:
Unilateral travel has no actions.

1. Pilot oil line is blocked;
2. Pilot handle is damaged;
3. Main valve seizes up;
4. Main oil line is blocked;
5. Crawler seizes up;
6. Travel motor is damaged.
Check steps:
1. Check the pressure of pilot oil line is normal;
There is no regular maintenance,
2. Pressure of main safety valve is normal;
Conclusion which causes internal ablation of
3. Crawler should not be jammed;
travel reducer
4. Check gear oil in travel reduction gearbox has
no internal ablation and jamming, and it returns Maintenance scheme Replace travel mechanism
to normal after replacing travel mechanism.
FR85-7 RD106767H-G 2500 Yunnan Mangshi City
Symptom of fault:
Complete excavator has no actions.

1. Travel switch is broken or invalid;
2. Pilot solenoid valve is broken or damaged;
3. Pilot oil pressure is low;
4. Pilot valve spool seizes up;
5. Problem of circuit.
Check steps:
1. Check travel switch is normal;
2. Check hydraulic system and pilot pressure; Conclusion Solenoid valve is not pulling-in
3. Check pilot valve spool is normal;

Maintenance scheme Replace pilot solenoid valve
4. Check pilot solenoid valve spool is normal;
5. Check pilot solenoid valve is not pulling-in.
13
Fault case analysis record Record date: 2009.2 Recorder: Cao Jingchong
FR150 RJ200528X-G 670 Ningxia Sandlot
Symptom of fault:
In the mode of automatic idling, engine has no automatic
idling occasionally.

1. Automatic idle switch fault;
2. Automatic idle circuit fault;
4. Pilot oil return back pressure is too high.
Check steps:
1. Measure automatic idle switch and circuit are
normal;
2. Automatic idle switch can be broken or shorted Pilot oil return back pressure is too
Conclusion
normally, thus controller fault can be excluded; high
3. The measured pilot oil return back pressure is 1MP,
and setting pressure of handle action switch is 1MP,
which is just at the critical value and causes Maintenance scheme Replace large diameter joint
automatic idling is irresponsive sometimes, and the
machine can return to normal after replacing large
diameter oil return joint. Effect confirmation OK
FR150-7 RJ30018ZS-G 1000 Linyi Car-loading
Symptom of fault:
Excavator swings to the right automatically after engine
starts.

There is oil supply to swing to the right and no oil
return resistance after the start, the possible reason is
that pilot handle or main valve spool is jammed.
Check steps:
1. Draw out control rotary valve spool to see whether
Conclusion Main valve spool is jammed
it is jammed;
2. Check whether pilot handle is jammed, which
Maintenance scheme Wash valve spool
causes pilot to promote right rotary: rotary valve
spool is jammed by foreign matters, which causes
rotary after the start. Effect confirmation OK
14
Fault case analysis record Record date: 2008.3.6 Recorder: Sun Ming
FR60-7 3F706767H-G 2440 Dalian General
Symptom of fault:
The movable arm falls automatically when is fully up,
and returns to normal when rising to the half.

1. Hydraulic cylinder has inner leakage;
2. Overflow valve is jammed;
3. Valve spool is jammed.
Check steps:
1. Check overflow valve first;
2. Then check hydraulic cylinder; Conclusion Overflow valve is jammed
3. Check valve spool finally.
Maintenance scheme Washing
FR75-7 RL100388M-G 12 Henan Plain
Symptom of fault:
The complete excavator has slow actions.

1. Main valve fault;
2. Hydraulic oil deterioration;
3. Pressure shortage;
4. Hydraulic pump fault;
5. Pilot oil line fault.
Check steps:
1. Check hydraulic oil is normal;
Conclusion Pilot pressure is too low
2. Check pressure of main oil line is normal;
3. Check pilot oil source valve to find the pressure is
insufficient, and it returns to normal after adjusting Maintenance scheme Adjust pilot pressure
pilot pressure.
15
Model Serial number Working hours(h) Service Location 3F801527CWorking condition
FR60-7 3F801527C 1241 Sichuan, Mianyang Plain, mountain land
Symptom of fault:

1. Pressure of travel main oil line is low;
2. Travel pilot pressure is low;
3. System flow is small.
Check steps:
1. Check main oil line pressure and adjust travel
System has low pilot pressure
pressure;
Conclusion and small flow, pressure of
2. Check pilot pressure and adjust pilot pressure
after shimming; travel main oil line is low
3. Increase system flow and the unilateral travel of Maintenance scheme Adjust system pressure and flow
excavator is normal on hard surface.
Fault case analysis record Record date: 2006.11.21 Recorder: Liuyang
FR60-7 3F801296M 1500 Tripoli Sandy soil
Symptom of fault:
The movable arm cannot fall.

1. Pilot handle is jammed;
2. Main valve spool is jammed;
3. Shuttle valve is jammed and has inner leakage.
Check steps:
1. Check pilot handle is normal;
2. The fault still exists after exchanging movable arm
on pilot control valve and bucket pilot oil pipe;
3. Movable arm is normal but bucket has no actions Conclusion Shuttle valve is invalid
after exchanging movable arm on main valve and
bucket pilot oil pipe, so it is inferred that the shuttle
Maintenance scheme Replace shuttle valve
valve may have problems;
4. It returns to normal after replacing shuttle valve.
16
Fault case analysis record Record date: 2009.8 Recorder: Sun Ming
FR60-7 3F706957H-G 2500 Dalian Seaside
Symptom of fault:
Breaking hammer cannot move.
1. Breaking hammer has low nitrogen pressure;
2. Hydraulic oil is too little;
3. Safety valve of P3 pump main valve has low
pressure;
4. Main valve has inner leakage.
5. Solenoid valve of hydraulic hammer is jammed.
Check steps:
1. Check hydraulic oil is normal;
2. Measure pressure of hammer is normal; Pressure of safety valve is
Conclusion
3. Pressure of main valve safety valve is too low. low
Adjust pressure of main
Maintenance scheme
safety valve
Fault case analysis record Record date: 2006.08.21 Recorder: Lan Zhengshen

FR60-7 3F8011366M 1630 Jiangsu, Changshu
sandlot etc
Symptom of fault:
Travel deviation.
1. The tension degree of crawler;
2. Travel pressures at the two sides are
inconsistent;
3. Central rotary joint has inner leakage;
4. Motor has inner leakage and is damaged;
5. Travel reversing valve is jammed;
6. Pressure of travel pilot control valve is low or
left and right pilot control valves have
inconsistent travels.
Check steps:
1. Check whether tension degrees of crawler are
consistent;
2. Check whether pressures at two sides are Conclusion Inner leakage of motor
consistent;
3. Exchange oil pipes of left and right motors on
main valve; Maintenance scheme Replace travel motor
4. Check pressure of travel pilot control valve or
travels of left and right pilot control valves;
5. Short-circuit the central rotary joint; Effect confirmation OK
6. Determine whether motor has faults.
17
Fault case analysis record Record date: 2009.2 Recorder: Lan Zhengshen
FR39-7 RB100158Y 1700 Zhejiang Mire
Symptom of fault:

1. Pilot pressure is low;
2. Main overflow valve leaks;
3. Main pump has inner leakage;
4. LS signal is abnormal.
Check steps:
Test pilot pressure is only 2.2MPa, which is lower
Conclusion Pilot pressure is low
than the standard pressure of 3.5MPa, and it returns
to normal after adjusting upward the pilot overflow
valve on oil source valve. Maintenance scheme Adjust pilot pressure
FR210-7 RH100098VS-G 720 Jiangsu Public works
Symptom of fault:
Bucket arm cylinder falls automatically.

1. Overload valve leaks;
2. Valve spool has poor retraction;
3. Bucket arm cylinder has serious inner leakage.
Check steps:
Bucket arm cylinder will not fall automatically after
Overload valve of bucket arm
exchanging two overload valves of bucket arm, and it Conclusion
cylinder leaks
returns to normal after washing overload valve of
bucket arm cylinder small cavity. Maintenance scheme Wash overload valve
18
FR60-7 3F703628M 900 Beijing Public works
Symptom of fault:
Both deviations of travel motor in front and rear travels
exceeds the standard.

1. Valve spool travel is not enough because of pilot;
2. Motor has inner leakage or balance valve travel is
not enough;
3. Main pump has inner leakage;
4. Central rotary joint has inner leakage;
5. P1 and P2 overflow valves have different
pressures.
Check steps:
During actual operation, rotary speed is too fast, the
Conclusion Hoses are connected reversely
speed of dozer blade is too fast, because P2 and P3
hoses have just been replaced, it is doubted that the
Maintenance scheme Exchange hoses
two hoses may be connected wrongly, and it returns to
normal after exchanging two hoses. OK
Effect confirmation
Fault case analysis record Record date: 2008.03.10 Recorder: Wang Tan
Plain, mountain land,
FR65-7 None 1750 Guangxi Nanning
riverbed, sandlot etc
Symptom of fault:
Hydraulic oil is in high temperature.
1. External part of oil radiator has blockage;
2. Hydraulic oil is too little;
3. Oil line of oil radiator is blocked;
4. Bypass oil return check valve is jammed and oil
returns to oil return tank directly without passing
radiator;
5. Temperature sensor fault.
Check steps:
1. Observe whether external part of oil radiator has
blockage; Conclusion Check valve is jammed
2. Check whether hydraulic oil level is appropriate;
3. Check temperatures of oil radiator and oil tank, oil
Maintenance scheme Replace check valve
radiator temperature is low, and oil tank temperature
is high;
4. Open check valve to find it is jammed.
19
Fault case analysis record Record date: 2009.1 Recorder: Wang Tan
Symptom of fault:
Slewing braking is poor (the rotary motor has braking
delay valve)
1. Safety valve of rotary motor is jammed;
2. Oil supply check valve is jammed;
3. Volumetric efficiency of the motor drops because
inner leakage is serious;
4. Inner leakage of reversing valve is serious.
Check steps:
1. Check rotary pressure and safety valve is normal if
the pressure is at 20MPa or so;
2. Wash check valve; Volumetric efficiency of rotary
Conclusion
3. Prop up the front excavator with a dozer blade, motor drops
install the working device on the front side, pull
bucket arm (rotary mechanical braking has been
released) to see rotary glide quantity, if the glide
Maintenance scheme Replace rotary motor
quantity exceeds 100MM in a minute, then the inner
leakage of rotary motor is serious and volumetric
efficiency is too low.
Fault case analysis record Record date: 2009.1 Recorder: Wang Xuhui
FR75-7 RL100239C-G 118 Wuxi Public works
Symptom of fault:
The complete excavator has slow actions, and rotating
one circle needs 12 seconds.

1. Pilot pressure is low;
2. LS feedback has leakage;
3. Main pump displacement is unable to ascend;
4. Main pump has leakage.
Check steps:
Pilot pressure at overflow is 3.3, pressure of main Stroking mechanism of main
system is 24.5, both achieve the delivery standard, Conclusion
pump seizes up
feedback is normal after checking 1 second, it is
judged that variable piston of main pump is jammed Maintenance scheme Replace main pump
and it returns to normal after replacing main pumping
hole. Effect confirmation OK
20
FR60-7 3F8A00467Z 1350 Guizhou Mountain land
Symptom of fault:
When the excavator works, movable arm cannot fall
and work normally after lifting.
1. Pilot oil line fault;
2. Valve spool of main valve movable arm is
jammed;
3. Shuttle valve has internal faults;
4. Boom cylinder has faults itself.
Check steps:
1. Wash valve spool of main valve movable arm to Shuttle valve spool is jammed or
Conclusion
find no abnormal faults; has internal damage.
2. Check pilot oil line has no abnormal faults;
3. Replace bucket pilot pipeline and movable arm Maintenance scheme Replace shuttle valve
pilot pipeline on the main valve, movable arm
works well after trial run, and it is concluded to be Effect confirmation OK
shuttle valve fault.
Fault case analysis record Record date: 2008.03.01 Recorder: Zhu Dezhi
FR139-7 RJ20008ZS-G 130 Shandong Weifang
sandlot etc
Symptom of fault:
Bucket arm cylinder will fall automatically at the small
cavity state, that is, it will change to the big cavity
state automatically.
1. Bucket arm overload valve is jammed; 2. Bucket
retaining valve fails;
3. The sealing between main valve spool and valve
cavity is poor;
4. The sealing parts of bucket arm overload valve
fail, oil flees inside;
5. Oil sealing inside the bucket arm cylinder fails, at
the overflow state.
Check steps:
1. It is unlikely because it is a new excavator and
imported hydraulic cylinder; Sealing O-ring of bucket arm
Conclusion
2. The quality of imported valve should be OK; overload valve fails
3. Remove and check bucket arm overload valve,
and there are no impurities and jamming;
Replace sealing O-ring of bucket arm
4. Remove and check the main valve body of Maintenance scheme
bucket arm overload valve, and sealing O-ring at overload valve
this place has been flushed seriously, which
causes oil seal here is untight, and finally causes
bucket arm cylinder presents a state of Effect confirmation OK
automatic falling.
21
FR60-7 3F801096C 3500 Fenyi
Symptom of fault:
Power drops.
1. Output power of diesel engine is insufficient;
2. Oil pump wears out;
3. Distribution valve or main overflow valve is
adjusted improperly;
4. Working oil quantity is insufficient;
5. Oil suction pipeline sucks in air.
Check steps:
1. Check whether output power of diesel engine is
normal; Conclusion Hydraulic pump wears out
2. Check whether working (hydraulic) oil quantity is Maintenance scheme Replace hydraulic pump
sufficient;
3. Check leakage of oil quality system, abrasion of
elements, and etc;
4. Oil suction pipeline sucks in air and discharge air
in the system;
5. Distribution valve or main overflow valve is Effect confirmation OK
adjusted improperly, and adjust the pressure to
the suitable value; 6. Oil pump wears out, check
and replace it, check tightening joint and replace
sealing.
Fault case analysis record Record date: 2008.05.01 Recorder: Yang Yajun
FR65-7 RB100097MS 1721H Nanyang city, Xixia county Mountain land

Symptom of fault:
Left and right travel motors have no actions suddenly.
1. Motor fault; 2. Travel control valve;
3. Multiple valve fault; 4. Central rotary joint.
Check steps:
1. Replace travel pilot valve first, and fault still exists;
2. Because there are no bilateral travels, the
simultaneous damage probability of the motors is
very little;
3. If rotary joint has faults, four hydraulic fluid ports
all have inner leakage, and the probability is also
little;
4. Measure the pressure of main system is normal
(the normal overflow pressure of B system is
24.5Mpa), but single control travel pressure is
extremely low, inner leakage of valve is Conclusion Pressure compensated valve
impossible. The only possibility is certain valve of multiple valve is blocked
spool in the valve body is blocked. As shown in
the structural drawing, every valve has a pressure
compensated valve and a check valve, main oil
line achieves the pressure requirements through
the pressure compensated valve, check valve Maintenance scheme Clearing, cleaning and
needs to be opened in the process of flowing into installing
the valve body, and if any of the two valve spools
is blocked, then hydraulic oil cannot pass and thus
actions fail;
5. Remove and check the pressure compensated Effect confirmation OK
valve, there are ends of the wire blocked at the oil
hole, and it returns to normal after cleaning.
22
Fault case analysis record Record date: 2008.05.01 Recorder: Zhang Qiang
FR60-7 3F8A06986H 2010 Ningdun village, Ningguo city, Anhui Mountain land
Symptom of fault:
The complete excavator has no actions.
1. Pilot solenoid valve fault;
2. Oil source valve fault;
3. Power supply fault of pilot solenoid valve (travel
switch\fuse\circuit break etc);
4. Main pump fault.
Check steps:
1. Measure power supply of pilot solenoid valve with
a universal meter is normal, but the valve is not
pulling-in;
2. The newly replaced pilot solenoid valve is still not
pulling-in, and solenoid valve produces
magnetism;
Conclusion Valve spool seizes up
3. Remove pilot valve spool, energized pilot
solenoid valve has normal pulling-in, pilot valve
spool is still not pulling-in after pilot valve spool is
installed on the oil source valve;
Wash oil source valve and
4. Wash pilot valve spool and remove the hose from Maintenance scheme discharge air
oil source valve to pilot filter element, and the
complete excavator returns to normal after
discharging the air.
Fault case analysis record Record date: 2008.6.1 Recorder: Gu Changbao
FR65-7 RG100197M 2721H Shandong, Qingdao Plain

Symptom of fault:
The excavator has no actions in the rotary operation (left
and right rotations fail).
1. Rotary motor fault;
2. Left and right control valves;
3. Multiple valve faults;
4. Shuttle valve blockage.
Check steps:
1. Open and check oil source valve pilot pipeline at
the bottom of accumulator, there is oil on the pilot
part and it returns to normal after changing to other
actions, and it is concluded that pilot braking Conclusion Rotary motor has faults itself.
release oil line is normal;
2. Check rotary release signal pipe, there is also oil,
and it is concluded that release signal pipe is also
normal; Maintenance scheme Replace rotary motor
3. Check main valve spool is also normal;
4. Overhaul the motor assembly to find motor brake
seizes up, and it returns to normal after replacing Effect confirmation OK
rotary motor.
23

Fault case analysis record Record date: 2006.9.3 Recorder: Ren Chunjie
FR60-7 3F802876N 48H Henan Yuzhou Plain, mountain land, riverbed etc
Symptom of fault:
The excavator travels slackly and oil cylinder of
bulldozing plate drops.
1. Oil is too dirty, which causes valve spool is jammed;
2. Problem of central rotary joint.
Check steps:
1. Check oil in return oil filter element is not
Central rotary joint has inner
deteriorated or polluted; Conclusion
leakage
2. Check overload valve and valve spool are not
jammed;
3. Touch rotary joint with hand to find it produces a lot Maintenance scheme Replace central rotary joint
of heat and has abnormal sounds, short-circuit the
rotary joint to the dozer blade cylinder, and cylinder
is normal and the complete excavator is normal Effect confirmation OK
after replacing central rotary joint.

FR60-7 3F805586X 1800 Xinyu
sandlot etc
Symptom of fault:
Pilot hydraulic system has no oil.
1. Oil pump cannot suck in oil;
2. Driving device of oil pump fails;
3. The connection between oil pump and driving
mechanism is cut off;
4. Motor of driving oil pump is connected reversely;
5. Inlet and outlet of oil pump are connected reversely;
6. Oil overflows from safety valve;
7. Oil pump is damaged.
Check steps:
1. Motor or diesel engine should be repaired or replaced,
check the electrical circuit;
2. Driving device of oil pump fails; Conclusion Pilot oil source valve is blocked
3. The connection between oil pump and driving
mechanism is cut off;
4. Oil pump cannot suck in oil, replace filter, wash the
blocked inlet pipe and air breather of accumulator, Maintenance scheme Replace pilot oil source valve
replace system oil and adjust pump speed;
5. Oil returns from safety valve;
6. Adjust pressure of safety valve, check or replace the
components; Effect confirmation OK
7. Oil pump is damaged.
24
FR139-7 RJ100017XS-G 260 Guizhou Mountain land

Symptom of fault:
Left and right rotations are jammed and slack.
1. Pilot control handle fault;
2. Main valve spool fault;
3. Rotary motor has problems itself.
Check steps:
Seen from the fault symptom, terminal components should
Overflow valve of rotary
be checked first:
Conclusion valve has clamping
Analysis: it is unlikely that pilot handle and main valve spool
stagnation
have clamping stagnation simultaneously in two directions;
Disassemble and it returns
check two overflow valves of rotary motor and find overflow
Maintenance scheme to normal after washing with
valve has clamping stagnation.
clean diesel
FR85-7 RWE201148Y-G 1456 Guizhou Mountain land
Symptom of fault:
Movable arm, bucket arm and bucket of the excavator have
no actions occasionally after three hours of continuous work;
pilot handle is operated heavily.
1. Pilot valve problem;
2. Air enters the hydraulic system;
3. GPS safety locking problem;
4. Accumulator problem;
5. Main safety valve problem;
6. Neutral position unloading valve;
7. Power adjuster of main pump is jammed;
8. Valve spool of load feedback valve is jammed;
9. Main pump problem.
Check steps:
1. The measured pilot pressure is 2.8MPa, which should
be adjusted to 3.5MPa;
2. Because excavator cannot release pressure, replace Adjustor in the pump is
Conclusion
accumulator; jammed
3. Supply system discharges air;
4. Disassemble main safety valve, neutral position
unloading valve, and power adjuster of main pump are
not jammed, and the result is still bad after the above Maintenance scheme Replace main pump
work;
5. Measure the actual pressure of action failure is 9 MPa,
and the threshold pressure for adjustment is 9-11MPa
learned from technical center, but the pump hasn’t been
adjusted, and it is inferred that the adjustor in the pump
is jammed.
25

FR60-7 3F704027V-G 600 Ganzhou
Symptom of fault:
Hydraulic cylinder has slow actions.

1. Flow is too low;
2. Oil viscosity is low;
3. Pressure is insufficient;
4. Lubrication of linkage is poor;
5. Hydraulic cylinder and hydraulic motor wear out or
damage.
Check steps:
1. Check whether the viscosity of hydraulic oil is
Pressure of hydraulic cylinder is
normal; Conclusion
too low
2. Check whether pressure is normal;
3. Flow is too low and the pump flow should be Maintenance scheme Adjust pressure
adjusted;
4. Check whether lubrication of linkage is normal;
5. Hydraulic cylinder and hydraulic motor wear out or Effect confirmation OK
damage.
FR60-7 3F703506V 800 Ganzhou
sandlot etc
Symptom of fault:
Travel deviation.
1. The tension degrees of crawler are inconsistent;
2. Safety valve has different pressures;
3. Central rotary joint is damaged;
4. Main valve is jammed;
5. Main pump is damaged.
Check steps:
1. Check whether tension degrees of crawler at the Safety valve jamming causes
two sides are consistent; Conclusion pressures at two sides are
2. Check whether pressure of safety valve is normal; inconsistent.
3. Determine whether main pump is in good condition
Maintenance scheme Wash safety valve
after exchanging hoses at the main pump;
4. Check whether main valve is jammed;
5. Short-circuit the central rotary joint to make a test.
26
FR139-7 RJ100017XS-G 378 Guizhou Fuquan city Mountain land
Symptom of fault:
No braking at right rotation sometimes.

1. Pilot control handle fault;
2. Main valve spool fault;
3. Rotary motor has problems itself.
Check steps:
1. Remove and check safety valve, check valve
and anti-reverse valve of rotary motor are not
jammed, the fault still exists after exchanging the
above valves from left to right;
2. Because both left rotary starting and braking are
normal, exchange the pilot hoses from left to
Conclusion Pressure loss in rotary motor
right, and no braking at right rotation still exists;
exchange high pressure hose on the main valve
from left to right, the fault still exists;
Replace one rotary motor
3. The measured retaining pressure of rotary motor Maintenance scheme
assembly
at right rotation braking failure is 0-0.2Mpa, there
is no pressure basically. Measure the retaining
pressure of normal left rotation is 6MPa, and it is Effect confirmation OK
inferred to be internal faults of motor.

FR65-7 RG100397Y 2000 Shangrao
sandlot etc
Symptom of fault:
Rotary braking is too slow.

1. Braking pipeline is damaged;
2. Braking control valve is adjusted improperly;
3. Oil pressure of the system is too low;
4. Oil level of the system is too low.
Check steps:
1. Check whether hydraulic oil is sufficient; Conclusion System pressure is too low
2. Check whether braking pipeline is damaged;
3. Pressure of hydraulic system is too low; Maintenance scheme Adjust pressure to normal value
4. Braking control valve is adjusted improperly. Effect confirmation OK
27
Fault case analysis record Record date: 2008.5.19 Recorder: Liuyang
FR60-7 3F700677Z 1200 Ningxia Lingwu Plain, sandlot etc
Symptom of fault:
Left travel has slow actions, without high speeds.

1. Central rotary joint is damaged;
2. Left travel pilot valve is damaged;
3. High and low-speed pilot pipe is blocked;
4. Travel motor has inner blockage.
Check steps:
1. Faults still exist after replacing pilot pipes of left
and right travels, the possibility of pilot valve Conclusion Travel motor has inner blockage
damage is excluded;
2. Faults still exist after replacing two high and low Maintenance scheme Replacing
speed hoses from the bottom of chassis to motor;
and it is inferred to be motor fault, and the faults
are eliminated after replacing the motor.
Fault case analysis record Record date: 2006.08.21 Recorder: Zhang Hai
FR65-7 RG302398M-G 15 Linyi General
Symptom of fault:
During rotary compound action, it continues to rotate
after releasing the compound action, but the rotary
speed is low.

1. Rotary pressure is not enough;
2. Overload valve is jammed;
3. Pilot pipeline is connected wrongly;
4. Pressure compensated valve fault.
Check steps:
1. Rotary pressure is normal; Pressure compensated valve is
Conclusion
2. It fails after washing overload valve; damaged
3. Check pipeline is normal; Replace pressure compensated
Maintenance scheme
4. Pressure compensated valve wears out and valve
needs to be replaced. Effect confirmation OK
28
FR85-7 None 1900 Guangxi Heshan
sandlot etc
Symptom of fault: Bucket arm has serious deadlock and
failure.
1. Main valve spool of bucket arm has inner leakage;
2. Handle is jammed or flees oil;
3. Bucket arm cylinder has serious inner leakage;
4. Exchange small and big cavities of main valve bucket
arm valve block or exchange small and big cavities of
corresponding high pressure pipe;
5. Pilot pressure is unstable;
6. Overflow pressure is sometimes big and sometimes
small, or even none occasionally.
Check steps:
1. Check pilot pressure; Small and big oil supply cavities of
2. Check overflow pressure; main valve bucket arm valve block
Conclusion
and bucket arm cylinder are
3. Check whether handle plunger flees oil and control inconsistent
flexibility;
Exchange bucket arm valve spool
4. Check whether bucket arm cylinder is powerful or Maintenance scheme
or high pressure pipe
drops quickly;
5. Exchange valve spool of bucket arm or check Effect confirmation OK
whether high pressure pipe is normal.
FR75-7 None None Shanxi
Symptom of fault: Hydraulic cylinder shakes.
1. Oil level is too low;
2. Gasket of piston rod is too tight;
3. The fitness between piston and hydraulic cylinder is
too loose;
4. Piston rod is bent.
Check steps:
1. Oil level is too low and oil is added to proper
position;
2. Gasket of piston rod is too tight and adjusted
properly; Conclusion Oil level is too low
3. The fitness between piston and hydraulic cylinder is
too loose, check, repair or replace; Maintenance scheme Add oil to appropriate position
4. Piston rod is bent, and make overhaul after
dismantling hydraulic cylinder. Effect confirmation OK
29

FR60-7 3F805626U 2500 Xinyu
Symptom of fault:
The engine speed is reduced.
Check whether fuel filter element is blocked, whether air leaks
in fuel line, whether plunger in fuel pump, nozzle tip and oil
outlet valve wear out seriously, whether air intake of air filter is
smooth, whether temperature of engine rises rapidly, whether
viscosity of engine oil is reduced, which causes loose sealing of
cylinder wall and reduction of compression ratio, whether
cylinder liner assembly wears out, which causes air flees
severely in the cylinder and loose sealing of engine valve etc,
and check the matching between flow of hydraulic pump and
output power of engine.
Check steps:
Check whether fuel filter element is blocked first, whether air
leaks in fuel line, whether plunger in fuel pump, nozzle tip and
oil outlet valve wear seriously, whether air intake of air filter is Conclusion Power doesn’t match
smooth, whether turbocharger is damaged for the engine with
turbocharger, whether temperature of engine rises rapidly,
whether viscosity of engine oil is reduced, which causes loose
sealing of cylinder wall and reduction of compression ratio,
whether cylinder liner assembly wears out, which causes air Maintenance scheme Adjust power of main pump
flees severely in the cylinder and loose sealing of engine valve
etc, all of theses are factors seriously affect engine power. If
output power of the engine itself is excluded, then consider the
matching between flow of hydraulic pump and output power of Effect confirmation OK
engine.
FR139-7 RJ100017X－G 26 the Southwest Plain
Symptom of fault:
Excavator bucket falls back automatically after retracting in place.

1. Valve spool of main valve seizes up;
2. Hydraulic cylinder has inner leakage;
3. Overload valve has inner leakage;
4. Valve spool of main valve has inner leakage.
Check steps:
1. Check hydraulic cylinder is normal, without inner leakage;
O-ring of overflow valve is
2. Check valve spool of main valve is normal, without clamping Conclusion damaged
stagnation;
3. Check another action of bucket is normal, so it may be a
Maintenance scheme Replace O-ring
problem of overflow valve, check it to find leakage is caused
by damage of O-ring, and it returns to normal after replacing
O-ring. Effect confirmation OK
30
Fault case analysis record Record date: 2008.6.15 Recorder: Yang Wangjun

FR139-7 RJ200258E-G 115 Ankang
sandlot etc
Symptom of fault:
Rotary actions have abnormal sounds.

1. Rotary bearing or motor has collision of teeth;
2. Rotary support ring gear lacks of butter, which
causes abrasion;
3. Reducer of rotary motor has collision of teeth or
abnormal abrasion;
4. Rotary motor has internal faults;
5. Bolt hole on the frame has machining errors.
Check steps:
1. Check butter in rotary bearing is sufficient, without
abrasive iron filings, so ring gear has no collision of
Reducer wears out because
teeth; Conclusion
rotary motor doesn’t have gear oil
2. Check rotary swing clearance compiles with the
standard after stopping the engine, it is confirmed
that frame clearance is normal;
Maintenance scheme Replace rotary motor
3. Check reducer of rotary motor doesn’t have gear oil,
open oil outlet, there is no gear oil flowing out, and it
is inferred that reducer of rotary motor wears out, and
it returns to normal after replacing rotary motor.
FR85-7 None 2288 Yunnan, Yongde Mountain area
Symptom of fault:
The complete engine has no actions.
1. Pilot travel switch is broken;
2. Pilot solenoid valve is broken;
3. Pilot oil pressure is insufficient;
4. Pilot valve spool seizes up;
5. Circuit fault;
6. Drive shaft of main pump is broken;
7. Coup-link is damaged.
Check steps:
Check whether main pump can supply oil first, and then
Conclusion Coup-link is damaged
check coup-link and drive shaft of main pump, and finally
Maintenance scheme Replace connecting disk
check circuit and hydraulic pressure.
31
III. Electrical System
Electrical system is generally composed of power circuit, starting circuit, lighting circuit, signal circuit, instrument
and alarm circuit and auxiliary circuit, and the main functions are to achieve lighting, engine starting, various signal
indicating and solenoid valve control and etc.
Main faults of electrical system are: start-up slack of starter, battery charging failure, various lights don’t work,
generator doesn’t work or has charging failure, instrument panel and sensor are damaged etc.
Fault case no.:WE20110001 Fault classification: Electrical system
Fault case analysis record Record date: 2008.02.24 Recorder: Lv Qingguang
Zhumadian city, Suiping

FR60-7 3F803946V 1556 Mountain area
county
Symptom of fault:
The excavator fails to start, and there is no response after
starting the key to power on.

1. Battery power shortage;
2. Battery relay doesn’t work;
3. Wiring power strip falls off;
4. Electric lock has internal damage;
5. Starting compound relay is damaged;
6. Time relay of flameout valve is damaged;
7. Flameout solenoid valve is damaged;
8. Flameout valve relay is damaged.
Check steps:
1. Check voltage of battery; Control harness of battery relay
Conclusion
2. Check starting key; failure
3. Check battery relay;
Maintenance scheme Replace battery relay
4. It returns to normal after replacing battery relay and
repairing harnesses of excavator body. Effect confirmation OK
32
Fault case analysis record Record date: 2009.1 Recorder:
FR150-7 RJ200118M-G 238 Guangxi Public works
Symptom of fault:
The meter shows communication error, the complete
excavator has slow actions, and power mode doesn’t
function after selected.

1. Plug connector is poor, which causes loose
connection and circuit fault of oil contamination
alarm;
2. Both power control and signal alarm of Isuzu engine
are processed by controller, and it may be ECU fault.
Conclusion ECU plug connector release

Check steps:
Many functions in such cases fail, and it is obvious that Simple release is determined
ECU is damaged or plug connector is loose, and ECU Maintenance scheme after the check, and tighten the
joint release is found after the check. plug connector
FR85-7 RD100227S-G 1830 Yunnan, Baoshan Mountain area
Symptom of fault:
Instrument panel gives charging alarm and has no speed
display at the same time.

1. Circuit is shorted or broken or has poor grounding;
2. Instrument panel has faults itself;
3. Adjuster of generator is damaged.
Check steps:
1. Check grounding has no problems;
Adjuster of generator is
2. Check the circuit from generator to the meter is normal; Conclusion
damaged
3. Lead a wire from point B of generator to L neutral point
joint, and charging alarm of the meter disappears,
Maintenance scheme Replace generator
which indicates the meter is normal.
Note: the speed indication of Yanmar engine is obtained by
measuring the output pulse signal of engine neutral point P.
33

FR39-7 RB100607U-G 190 Guangxi Nanning
Symptom of fault:
All the actions fail instantaneously at times.

1. Travel switch is in poor contact;
2. Pilot valve spool is jammed;
3. Circuit connectors are in poor contact;
4. Pilot solenoid valve is loose;
5. GPS problem.
Check steps:
1. Detect whether travel switch is good with a universal
meter and observe visually whether safety mechanism Conclusion GPS card is in poor contact
is closed after pressing down;
2. Wash pilot valve spool;
Maintenance scheme Reset GPS card
3. Check and refasten the joint by plug connection;
4. Check whether coil of solenoid valve is pulling-in;
5. Short-circuit GPS to observe the running condition.
Fault case analysis record Record date: 2008.12 Recorder: Wang Tan
FR150-7 RJ200018Z -G 1020 Weifang Excavation
Symptom of fault:
The engine speed cannot be reduced and with no
automatic idle function after spot inspection.
1. Circuit causes, there is a handle action switch at the
pilot oil line, and throttle should be reduced
automatically if all handles have no actions for a
time;
2. Circuit is open;
3. Handle action switch is damaged;
4. ECU is damaged.
Check steps:
1. Check whether connecting wires on the handle
Conclusion Handle action switch is damaged
action switch alive;
2. Whether ECU plug connection is good;
Maintenance scheme Replace handle action switch
3. If all the above are normal, and it can be judged that
handle action switch is damaged. Effect confirmation OK
34
FR85-7 RWE201148Y -G 495 Guizhou Mountain land
Symptom of fault:
Air conditioner has no refrigeration function.
1. Circuit fault;
2. Control panel fault;
3. Refrigerant loss;
4. Drying bottle fault;
5. Expansion valve fault;
6. Compressor has faults itself;
7. Blower and evaporator of air conditioner faults.
Check steps:
1. Check and maintain circuit to make circuit control return to
normal;
2. Hardware is checked in the following steps: Conclusion Instrument fault
■ Check pressure gauge to find the high pressure is lower
than normal value (normal value: 9—20KG/CM3), then
check refrigerant to find it loses seriously, check the pipe
joints one by one to find pipe joints at the entrances of
condenser of compressor and drying bottle, and retighten Replace instrument
the joints; Maintenance scheme
assembly
■ There is pressure values on the gauge, and it is inferred that
drying bottle has no ice block;
■ Seen from pressure on the low pressure gauge (normal
value: 0.7-2.6KG/CM3), expansion valve has no ice block
either;
■ Check resistance of air conditioner blower to find it is Effect confirmation OK
infinity, and it indicates internal coil has been blocked, which
causes damage of blower.
Fault case analysis record Record date: 2008.3.28 Recorder: Tong Fasheng
FR85-7 RD100517N 1100 Xinjiang Korla Gobi

Symptom of fault:
High temperature alarm.
1. The tension degree of water pump belt is not enough;
2. Cooling water in water tank is insufficient;
3. Water temperature sensor is in poor contact or invalid;
4. Thermostat fails;
5. Scale in water channel is too much;
6. Instrument panel fault;
7. Cooling fines are blocked.
8. Circuit faults.
Check steps:
1. Check water tank doesn’t lack water;
2. Press water pump and the tension degree of water pump Water temperature sensor is
Conclusion
belt is within the range; invalic
3. Water temperature sensing line is grounded directly, and
Replace water temperature
the instrument panel gives an alarm, which indicates Maintenance scheme
sensor
instrument panel is in good condition;
4. It returns to normal after replacing water temperature
sensor.
35
Fault case analysis record Record date: 2009.1 Recorder: Ma Guokai
FR150-7 RJ200258E-G 126 Guangxi Mountain land
Symptom of fault:
The engine speed displays unsteadily.

Problem of circuit connection, wrong installation of speed
sensor and the meter problem itself cause the display is
inaccurate.
Check steps:
1. Check whether circuit is open;
Speed sensor is installed
2. Check whether meter has other fault displays at the Conclusion
improperly
same time;
3. Whether the sensor is installed loosely; speed display
Maintenance scheme Reinstall speed sensor
failure in this case is because speed sensor on flywheel
is installed out of place, rotate the speed sensor to touch
the flywheel, and then screw it out for 1 millimeter.
Fault case analysis record Record date: 2008.3 Recorder: Ma Guokai
FR150-7 RJ200128M-G 400 Jinan Public works
Symptom of fault:
The engine speed reaches 2000 rpm instantaneously
when the throttle knob is increased and returns to normal
if go on knobbing.

1. Throttle motor fault;
2. Throttle knob fault;
4. Circuit fault;
5. Injection pump fault.
Check steps:
1. Because the engine speed can returns to normal, the
possibility of injection pump damage is little; Conclusion Throttle knob is damaged
2. Measure the circuit is normal;
3. Measure the output current is imbalance when
turning the knob, the current increases suddenly at Maintenance scheme Replace throttle knob
the 2-gear, and returns to normal at the latter gears, it
is concluded that throttle knob has faults, and it
returns to normal after replacing knob.
36
Fault case analysis record Record date: 2008.06 Recorder: Anhui Bason
FR150-7 RL100448M-G 450 Anhui Mountain land
Symptom of fault:
Speeds at 1-gear to 4-gear are unstable when engine speeds
up.

1. Throttle motor damage;
2. Throttle knob damage;
3. Circuit is in poor contact;
4. Engine injection pump fault.
Check steps:
1. Check circuit is normal, and output current of throttle
knob rises regularly; Conclusion Throttle motor is damaged
2. Check throttle motor to find motor retracts automatically

Maintenance scheme Replace throttle motor
at the fixed gears, and it is inferred to be throttle motor
faults;
3. It returns to normal after replacing throttle motor. Effect confirmation OK
FR150-7 RJ200038YS-G 1769 Qingdao Public works
Symptom of fault:
Travel has no high and low speeds, and relay is damaged
after the check.

1. Circuit fault causes high and low-speed solenoid valve
has no electricity or is damaged;
2. High and low-speed solenoid valve is clamped at the low
speed position, and variable piston of travel motor seizes
up.
Check steps:
Because both the two motors don’t have high and low
speeds, the possibility of simultaneous damage is very little.
Check the following first:
1. Whether high and low-speed solenoid valve is pulling-in
Conclusion Solenoid valve is damaged
after connecting high speed gears;
2. Whether high and low-speed pilot pipeline has pressure
oil inside;
Maintenance scheme Replace solenoid valve
3. Check wiring point of high and low-speed solenoid valve
is alive and solenoid valve cannot be pulling-in and there
is damage on the appearance, and it returns to normal
after replacing solenoid valve.
37

FR65-7 RG100947Y -G 375 Lvliang, Xiaoyi
Symptom of fault:
Starting switch fuse is burnt out when the starting switch
opens.
1. Coil of battery relay is shorted;
2. Diode of battery relay is broken down;
3. Diode of flameout solenoid valve is broken down;
4. The circuit to meter is grounded;
5. The circuit to generator is grounded;
6. The circuit to solenoid valve is grounded;
7. Flameout relay is broken down;
8. Flameout solenoid valve relay is shorted;
9. Flameout solenoid valve is shorted;
10. Generator faults.
Check steps:
1. Check whether diode is broken down;
2. Check whether coil of battery relay is shorted; Diode of flameout solenoid
Conclusion
3. Check whether flameout solenoid valve is shorted; valve is broken down
4. Check whether flameout time relay is broken down;
5. Check whether flameout time relay is shorted;
Maintenance scheme Replace diode
6. Check whether generator is burnt out;
7. Check whether meter is burnt out;
8. If the above electrical appliances have no faults, check Effect confirmation OK
the relevant circuits.

FR60-7 3F8A00467Z 2760 Nankang
sandlot etc
Symptom of fault:
Air conditioner has no refrigeration function.
1. Fuse blowout; 2. Electrical circuit fault;
3. Air conditioner switch fault; 4. Refrigerant shortage;
5. Pressure switch fault; 6. Expansion valve fault;
7. Compressor fault.
Check steps:
1. Check fuse doesn’t blow out, and the circuit has no
poor contact;
2. Check control panel to find the refrigeration indicator Conclusion Control panel is damaged
light is not on, check the amplifier is normal; it returns to
normal after replacing control panel. Maintenance scheme Replace control panel
38

FR60-7 3F800917Z 1400 Shanggao
sandlot etc
Symptom of fault:
Instrument panel displays battery charging alarm after the
start.

1. Circuit problem;
2. Meter fault;
3. Generator fault.
Check steps:
1. Check there is no voltage at the central point of starting
compound relay, and it can be judged that there are
problems at the central point from generator to starting
compound relay;
Conclusion Generator has inner damage
2. Check the neutral point P of generator has no voltage
output;
3. Check the power strip of generator is normal and
without ablation, and it can be judged that the generator Maintenance scheme Replace generator
has inner faults, and remove and check the generator
to find the diode inside is damaged.
Fault case analysis record Record date: 2006.08.29 Recorder: Zhang Qiang
FR65-7 RG102267E-G 183h Anhui, Lai An Plain
Symptom of fault:
GPS monitoring platform indicate no positioning information
on that day.
1. GPS antenna is damaged;
2. Power supply circuit is damaged and fails to supply
power;
3. GPS instrument fault.
Check steps:
1. Check GPS blinking lights and instruments are normal
Conclusion GPS sleep mode works
on the site;
2. Place GPS antenna according to requirements and
circuit is normal; Maintenance scheme Reposition
3. GPS manufacturer rewires it and the positioning

information returns to normal. Effect confirmation OK
39
FR35-7 RA5100067WS 1431H Shijiazhuang
sandlot etc
Symptom of fault:
Starting motor doesn’t run when restart after flameout.
1. Starting motor faults;
2. Starting compound relay;
3. Battery relay;
4. Starting switch;
6. Engine flywheel seizes up.
Check steps:
1. Check battery voltage is normal;
2. Check ignition switch is normal;
3. Check whether grounding between starting
Conclusion Starter harness ablation
compound relay and pulling-in switch is good;
4. Check battery relay;
5. Check whether engine flywheel seizes up; Maintenance scheme Replace starter
6. Check the starter;
7. Grounding between starting compound relay and
pulling-in switch is bad and starter harness ablation.
FR150-7 RJ200018Z -G 516 Weifang Public works

Symptom of fault:
Air conditioner has poor refrigeration effect.
1. Air conditioner belt is too loose;
2. Air conditioner compressor is not pulling-in;
3. Refrigerant shortage;
4. Air outlet or inlet is blocked;
5. Circuit faults.
Check steps:
1. Check whether air conditioner belt is too loose, and
air quantity at air outlet of air conditioner is
sufficient;
2. Press needle valve by hand to see whether Conclusion Refrigerant shortage
refrigerant is sufficient, connect the meter to see
whether pressure of refrigerant satisfies the
standard;
3. Refrigerant shortage in air conditioning system is Maintenance scheme Add refrigerant
found after the check;
4. Check whether there is leakage, and the leaking
points are usually at the sealing point of joint and
refrigeration returns to normal after adding Effect confirmation OK
refrigerant.
40
Fault case analysis record Record date: 2008.4.10 Recorder: Lv Guangqing

FR60-7 3F803946V 1888 Zhumadian city, Luohe county Plain
Symptom of fault:
The machine has no response after starting the
switch but meter has normal indication.
2. Battery relay fails;
3. Wiring power strip falls off;
4. Fuses in the electrical box are burnt out;
5. Electrical components in the electrical box don’t
work;
6. Wiring power strips at all the positions fail;
7. Ignition switch has poor inner contact.
Check steps:
1. Check battery pressure is normal;
Starting switch has inner
2. Check battery relay works normally; Conclusion
breakage
3. Check fuse is not burnt out;
4. Check all working components in the electrical Maintenance scheme Replace starting switch
box are normal;
5. Check ignition switch to find there is inner
breakage. Effect confirmation OK
Fault case analysis record Record date: 2008.5.21 Recorder: Gu Changbao

sandlot etc
Symptom of fault:
Instrument panel indicates high temperature alarm.
Distinguish true high temperature and false high
temperature, the so called false high temperature
means instrument merely gives out an alarm, but water
tank doesn’t “boil up”, and at this times, check water
temperature sensor, circuit meters and etc; on the
contrary, it is true high temperature and check the
following aspects:
1. the tension degree of water pump belt is not
enough;
2. cooling water in water tank is insufficient;
3. thermostat fails;
4. scale in water channel is too much;
5. the surfaces of air conditioner, hydraulic cooler or
water tank are too dirty.
Check steps:
1. Check water tank doesn’t lack water;
2. Press water pump and the tension degree of water
pump belt is within the range; Conclusion Water temperature is invalid
3. It still fails after washing surfaces of condenser
and water tank.
4. Water temperature sensing line is grounded
directly, and the instrument panel gives an alarm, Maintenance scheme Replace water temperature sensor
which indicates instrument panel is in good
condition;
5. It returns to normal after replacing water
temperature sensor. Note: such fault is “false high Effect confirmation OK
temperature” fault.
41

挖掘机典型故障案例汇编 定稿A4 修改稿

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Foreword

I. Power System ...................................................................................................................................1

II. Hydraulic system ............................................................................................................................. 11

III. Electrical System.............................................................................................................................32

Fault case no.: WP20110001 Fault classification: Power system

Fault case analysis record Record date: 2008.03.21 Recorder: Ma Guokai

Model Serial number Working hour(h) Service Location Working condition

FR60-7 RB100377S 1760 Beijing Plain, mountain land etc

Analyze the possible reasons:

Fault case no.:WP20110002 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR150-7 RJ200168S-G 100 Qingdao Public works

Fault case no.:WP20110003 Fault classification: Power system

Fault case analysis record Record date: 2008.03.12 Recorder: Li Wenlong

Model Serial number Working hours(h) Service Location Working condition

FR85-7 RG100047CS 2002 Hubei Honghu city Plain

Fault case no.:WP20110004 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR60-7 None 100 Guizhou Mountain land

Analyze the possible reasons:

Fault case no.:WP20110005 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR75-7 RL100668N-G 500 Jiangsu Excavation

Fault case no.:WP20110006 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR75-7 RL100568M-G 97 Anhui Public works

Analyze the possible reasons:

Maintenance scheme Replace oil pressure sensor

Fault case no.:WP20110007 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR260-7 RE300018XS-G 6 Mianyang Riverbed

Analyze the possible reasons:

Fault case no.:WP20110008 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR150-7 RJ200018Z-G 700 Weifang Public works

Analyze the possible reasons:

Fault case no.:WP20110009 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR85-7 RD101347X 1500 Yunnan, Luliang Mountain area

Analyze the possible reasons:

Fault case no.:WP20110010 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR60-7 None 101 Yunnan Chuxiong Mountain land

Analyze the possible reasons:

Fault case no.:WP20110011 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR85-7 RD101067E-G 670 Sichuan, Yibin Plain, hill

Analyze the possible reasons:

Fault case no.:WP20110012 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR60-7 3F803407W-G 1230 Sichuan Mountain area

Analyze the possible reasons:

Fault case no.:WP20110013 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

Analyze the possible reasons:

Fault case no.:WP20110014 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR85-7 RD201607X 540 Yunnan, Jinggu Mountain land

Fault case no.:WP20110015 Fault classification: Power system

Fault case no.:WP20110016 Fault classification: Power system

Model Serial number Working hours(h) Service Location Working condition

FR60-7 3F804226E 2130 Guizhou Tongzi Mountain land

Fault case no.:WP20110017 Fault classification: Power system

挖掘机典型故障案例汇编定稿A4 修改稿

挖掘机典型故障案例汇编定稿A4 修改稿