SA-YQ-80

Hydraulic Winch Operating Manual

1. Overview

The SA-YQ-80 Hydraulic Tractor is one of the earliest tractor models produced by our
company, primarily designed for the construction of 330kV and below transmission lines.
Additionally, it can also be used in conjunction with ultra-high voltage transmission line
construction projects of 500kV and above for the laying of traction ropes. Compared to the
SA-YQ-50 or similar equipment, it boasts a wider range of applications. Especially in
situations where the traction force frequently exceeds 40kN, the SA-YQ-80 exhibits superior
performance due to its greater operational margin, resulting in faster traction speed and
enhanced reliability. The SA-YQ-80 adopts a single-axle trailer structure, making the overall
machine compact.

Our SA-YQ-80 tractor stands out for its high reserve power, compact structure, convenient
operation, and excellent safety and reliability. The hydraulic system employs threaded
cartridge valves, maximizing system efficiency, integration, and reliability. It adopts a
proportional control method to achieve electronic control of the entire machine, ensuring
convenient and comfortable operation.

It's worth noting that the SA-YQ-80 is a tractor equipped with an intelligent control system.
Its control system is centered around the MC-050 processor from Danfoss, paired with the
DM430E color display also from Danfoss. Coupled with an electronically controlled diesel
engine from Weichai, the basic control system is formed through a bus connection. Combined
with high-performance components like the original cartridge valve block system, the overall
technology and performance of the equipment have been significantly enhanced.

All critical parameters or statuses of the SA-YQ-80 can be digitally displayed on the monitor,
achieving complete constant speed control and tail rope pressure loss protection. The preset
traction force and real-time traction speed can be simultaneously and intuitively displayed. In
case of control system failures, it accurately indicates the fault conditions, surpassing the
capabilities of traditional tractors.

The SA-YQ-80 is equipped with a remote control port that can be connected to our standard
control device via a control cable, enabling remote or centralized remote control, further
enhancing its performance and versatility.

Moreover, as we continually gather experience from practical use, the control software
(programming) for the processor and display will undergo continuous updates. These updated
software versions can not only be directly applied to newly manufactured equipment but can
also easily upgrade the software of already-shipped devices, thereby improving their
performance.

With the continuous advancement of the equipment, its safety and reliability have been
steadily improved. However, on the other hand, the increasing utilization of the equipment
makes it crucial to use and maintain it properly. Improper use or maintenance during
prolonged and frequent operation can compromise the equipment's integrity, potentially
 leading to significant losses due to project delays. Therefore, operators are required to
carefully read the equipment's operating manual, ensuring correct usage while performing
necessary maintenance on time. This is the only way to maximize the equipment's integrity
and performance.
2. Performance Parameters

2.1. Performance Parameters

 Maximum intermittent traction force: 96kN
 Maximum continuous traction force: 80kN - Corresponding speed: 2.5km/h
 Maximum traction speed: 5km/h - Corresponding traction force: 40kN

2.2. Performance Description

1. The traction wheel can rotate in both directions, and the traction force and speed can
be controlled smoothly and steplessly. The traction force can be displayed visually and preset
according to actual needs, never exceeding the preset value under any circumstances.
2. All critical parameters or statuses can be digitally displayed on the monitor. Complete
constant speed control and tail rope pressure loss protection are achieved. The preset traction
force and real-time traction speed can be simultaneously and intuitively displayed.
3. In case of control system failures, the fault conditions are accurately displayed,
facilitating troubleshooting.
4. The tail rope wheel is matched with the traction speed. The tail rope wheel speed can
be automatically adjusted to accommodate changes in the diameter of the wire coil, ensuring
that the tail rope maintains the predetermined tension and wraps neatly on the tail rope wheel.
5. The tail rope pendulum system is controlled through an independent circuit, linked
with the main traction wheel, achieving fully automated pendulum functionality.
6. It is equipped with a remote control port that can be connected to our standard control
device through a control cable, enabling remote or centralized remote control, further
enhancing its performance and versatility.
7. It is equipped with a wire rope clamping device with anti-misoperation protection,
making the replacement of tail ropes safer and more reliable.
8. The cooling system automatically starts and stops based on the hydraulic oil
temperature, regulating the cooling pressure.
9. It boasts simple operation and reliable performance. The main transmission system
features dual braking, ensuring reliable braking in case of sudden engine shutdown or
unexpected situations.

2.3. Structural Parameters

1. Traction wheel groove bottom diameter: Φ550mm
2. Maximum allowable steel wire rope diameter: Φ22mm
3. Maximum allowable coupler diameter: Φ60mm
4. Air-cooled diesel engine performance: Domestic Weichai air-cooled: WP4G160
118kW-2300r/min
5. Electrical system: 24V
6. Battery: 6-QA-105(D) × 2
7. Transmission system: Closed hydraulic transmission with control and cooling devices
8. Display: Color digital display DM430E
9. Tail rope wheel frame: Hydraulic lifting type, suitable for rope coils with a maximum
diameter of Φ1400mm
10. Machine weight: 4600kg
11. Overall dimensions (length × width × height): 4000 × 2080 × 2150mm
12. Tire model: 825-15
13. Minimum ground clearance: 330mm

2.4. Oil Level Control

1. Hydraulic oil level: Approximately 160 liters
2. Diesel engine oil level: Check the oil level scale and oil pressure gauge,
approximately 9 liters
3. Gearbox lubricating oil level: Approximately 3.7 liters
4. Brake oil level: Check the brake oil level indicator, approximately 0.3 liters
5. Fuel tank capacity: Approximately 120 liters, check the diesel fuel level gauge

3. Operation of the Traction Machine

3.1. Digital Display Instructions

When the main power switch is turned on, the display lights up and first shows the company's
welcome screen for approximately 3 seconds before entering the main screen. The main data
of the traction machine is displayed on this screen.

3-1-1: Main Screen of the Display

Below the display are 4 buttons. While on the main screen, pressing the first button will
switch the screen to the "Pay-off Mileage Setting" screen. Pressing the "Count/Reset" (third
button) will record or reset the pay-off mileage. Pressing the "Return" (first button) will return
the screen to the main screen.

3-1-2: Pay-off Mileage Screen

While on the main screen, pressing the second button will switch the screen to the "Diesel
Engine Main Parameters" screen.

3-1-3: Diesel Engine Main Parameters Screen

On the "Diesel Engine Main Parameters" screen, pressing the "Query" button (second button)
will enter the "Diesel Engine Fault Query" screen. When a fault occurs with the engine, the
"Diesel Engine Fault" icon on the main screen will flash, as shown in 3-1-1. At this point, you
can enter the "Diesel Engine Fault Query" screen to check the current fault conditions of the
diesel engine, including the number of current faults and fault frequencies. When the number
of faults is greater than 1, press the "↓" and "↑" (third and fourth buttons) to query the engine
fault codes, namely SPN and FMI codes. Corresponding attachment code tables can be used
to query fault types. When the "Clear" button is pressed and the corresponding fault
disappears, it represents that the fault once occurred but has disappeared. If the fault count
quickly recovers after pressing the "Clear" button, it means that the fault still exists.

When a fault occurs with the diesel engine, simple troubleshooting can be performed based on
the fault conditions found in the attachments. If necessary, please contact our company's
after-sales service directly or call Weichai's after-sales service hotline at 400-6183066.

Note: Users must be cautious when dealing with any contact information provided, as there is
a risk of network fraud and malicious phone calls. Always verify the authenticity and
legitimacy of any contact information before proceeding.

3.2. Description of Main Control Elements

3.2.1. Power Switch

3-2-1: Control Panel

There is a "Main Power Switch" used for turning on and off the electrical system. The power
switch is a two-position switch. When moved to the "Power On" position, it is in the on state.
When moved to the "Power Off" position, it is turned off.

Before using the equipment, the power switch should be switched to "Power On". The power
switch can be turned off when the equipment is not in use for a long time.

It is strictly prohibited to turn off the power switch during normal use of the equipment.

3.2.2. Start Key

The start key is used to start, run, and stop the diesel engine. To start the engine, move the
start key from the vertical position to the right by one position, which is the "Energized"
position. At this point, the main bus instrumentation will light up, and the diesel engine will
be in a state of readiness for starting. Continue to move the key clockwise by one position,
and the starting motor will engage, initiating the starting of the diesel engine. Immediately
release the key once the engine has started successfully.

3.2.3. Jacket Water Heating Switch

The "Jacket Water Heating" switch is primarily used to heat the engine's antifreeze. In high
altitude or low-temperature environments, when the start key is in the "Run" position, press
the "Jacket Water Heating" switch to initiate heating. The heating time should be determined
based on actual conditions, as specified in the jacket water heating instructions.

After heating is complete, turn off the "Jacket Water Heating" switch. The diesel engine can
then be started normally. Once the "Jacket Water Heating" switch is turned off, the diesel
heating device will stop working. To ensure that the jacket water heating device is not
damaged due to high temperatures, the water pump will continue to operate, maintaining the
circulation of coolant. After approximately 2-3 minutes, the water pump will automatically
stop working. Therefore, it is prohibited to turn off the "Main Power Switch" immediately
after turning off the jacket water heating switch.

3.2.4. Indicator Lights

Above the right side of the instrument panel, there are two red indicator lights: the preheat
indicator and the charging indicator.

The preheat indicator, also known as the diesel engine start indicator, should not be ignored.
When it is illuminated, starting the diesel engine is not allowed. The engine can only be
started once the indicator has turned off.

The charging indicator shows the status of the charging system. When the diesel engine is
stopped, the charging indicator should be on. Once the engine starts normally and its speed
exceeds approximately 800r/min, indicating that the charging voltage meets the requirements,
the charging indicator should turn off.

3.2.5. Tractive Force Preset

There is a "Tractive Force Setting" potentiometer.

The tractive force setting potentiometer is used for presetting the maximum tractive force.
Rotate the knob and observe the tractive force meter on the main display. The red indicator
represents the real-time preset tractive force.

Under any circumstances, when the actual tractive force value (indicated by the green needle)
reaches or exceeds the preset tractive force value (indicated by the red needle), the traction
machine will automatically stop traction (the main pump will stop working and the brakes
will engage).

To resume traction operations, the control lever must be repositioned to the neutral position
before traction can be resumed.

As long as the actual tractive force value (green needle) is less than the preset tractive force
value (red needle), the traction operations will not be affected.

To ensure construction safety, it is crucial to carefully inspect and set the preset tractive force
before each traction operation.

3.2.6. Operating Modes

Above the left side of the panel, there is a dust-proof self-resetting switch labeled "Operating
Modes".

The traction machine has two operating modes: manual and automatic. This switch is used to
toggle between the two modes. Pressing the switch once switches the operating mode. When
the traction machine is in automatic mode, the word "Auto" appears in red in the top right
corner of the traction force meter on the main screen. In manual mode, this indication
disappears.

Switching between operating modes must be done when the control lever is in the neutral
position (when traction operations are stopped). If this condition is not met, the switch will be
inactive.

Manual mode works similarly to a conventional traction machine, with the operator
controlling the engine throttle and control lever in real-time to adjust the traction speed.

Automatic mode, also known as "Constant Speed Mode", allows the operator to set a "preset
traction speed" in real-time via the control lever. This speed is displayed as a black number in
the bottom left corner of the traction force meter on the main screen.

In automatic mode, when the control lever is moved for traction or wire feeding operations,
the system automatically controls the diesel engine throttle and main pump displacement to
match the actual traction speed with the preset traction speed (the diesel engine throttle
control is inactive during this time). The traction speed remains constant, unaffected by
factors such as traction force.

When the control lever is returned to the neutral position, the automatic control of the diesel
engine throttle is deactivated, and the diesel engine speed can be adjusted using the diesel
engine throttle potentiometer.

3.2.7. Control Modes

Above the left side of the panel, there is a dust-proof self-resetting switch labeled "Control
Modes".

This traction machine can be operated either locally or remotely using a remote control device.
These are referred to as the local mode and remote mode, respectively. This switch is used to
toggle between these two modes. Pressing the switch once switches the control mode.

When the traction machine is in remote mode, the traction machine's operating mode will
automatically switch to automatic mode. Therefore, when the traction machine is switched to
remote mode, the words "Remote" and "Auto" will appear in red in the top left and top right
corners of the traction force meter on the main screen, respectively. When switched back to
local mode, the red indications disappear.

Switching between control modes must be done when the control lever is in the neutral
position (when traction operations are stopped). If this condition is not met, the switch will be
inactive.
To use remote control mode, it is necessary to purchase the remote control device specifically
configured for this traction machine by our company (either a remote control box or a remote
control room). The remote control box provides remote control for one traction machine,
while the remote control room can provide remote control for 1-4 traction machines. Custom
remote control solutions can also be created based on the user's specific needs.

The remote control device is compatible with all intelligent traction machines of different
traction force specifications in the H series and offers excellent interchangeability.

3.2.8. Fan Control

There is a fan control button with an indicator light used to control the fan system.

During normal operation, pressing the "Fan Control" button will illuminate the green
indicator light, indicating that the fan system is active. The display will also show a fan
indication symbol (see 3-1-1). The fan system automatically controls the radiator's operation
and adjusts the cooling pressure based on the temperature of the hydraulic oil.

3.2.9. Tail Support Pressure Adjustment

There is a "Tail Support Pressure Adjustment" potentiometer.

Similar to traditional traction machines, the tail support pressure is controlled using an
open-loop control mode.

The current tail support pressure can be adjusted using the "Tail Support Pressure
Adjustment" potentiometer, and the displayed on the tail support pressure indicator.

In automatic mode, when the "Lift-Stop-Rotate" switch is in the "Rotate" position and the
control lever is in the "Traction" position, normal traction operations can proceed if the tail
support pressure is greater than 40 bar. If the pressure drops below 40 bar, the tail support
pressure loss protection is activated, and the traction operation will automatically stop to
ensure safety against potential risks caused by pressure loss.

3.2.10. Lift-Stop-Rotate

There is a three-position switch labeled "Lift-Stop-Rotate" for controlling the tail support.

When the switch is in the middle position, the tail support is inactive. Switching the switch to
the left position, labeled "Lift", activates the lifting cylinder, which is used to raise the wire
rope drum. The lifting pressure can be adjusted using the "Tail Support Pressure"
potentiometer. Switching the switch to the right position activates the tail rope winding motor,
and the tail rope tension can also be adjusted using the "Tail Support Pressure" potentiometer.

3.2.11. Release-Hold-Clamp

There is a three-position switch labeled "Release-Hold-Clamp" for controlling the tail rope
clamping device.
To use the tail rope clamping function, first, set the "Lift-Stop-Rotate" switch to the "Rotate"
position to maintain tension on the tail rope. Then, by switching the "Release-Hold-Clamp"
switch, you can control the action of the cylinder to clamp or release the tail rope. After the
clamping or releasing operation is complete, return the switch to the middle position.

When the control cylinder is in the "Clamp" position, the "Clamp" icon on the main screen
will flash. At this point, the control lever becomes inactive, and the traction wheel remains in
the "Brake" position, preventing traction or wire feeding operations.

3.2.12. Pendulum Switch

There is a two-position switch labeled "Pendulum Switch" used to turn the pendulum system
on or off. When the switch is in the left position, the pendulum system is inactive. When the
switch is in the right position, the pendulum system becomes active and operates in
conjunction with the control lever's movements.

3.2.13. Pendulum Reversal

There is a self-resetting switch labeled "Pendulum Reversal" used for manual reversal of the
pendulum system. Each time the "Pendulum Reversal" switch is toggled, the pendulum
direction changes once.

3.2.14. Control Lever

3-2-2: Schematic Diagram of Lever Return Operation

There is a "Control Lever" used to control the main pump during traction or active wire
feeding operations. In manual mode, the greater the angle at which the control lever is pulled,
the faster the traction speed. In automatic mode, the control lever is used to set the traction
speed, with the set value displayed in black text in the lower left corner of the main screen.
When the control lever is placed in the neutral position, the main pump stops working.

3.2.15. Diesel Engine Throttle Control

There is a throttle control potentiometer used to adjust the diesel engine's throttle. Rotating
the throttle clockwise increases the engine's throttle, while rotating it counterclockwise
decreases it. The current engine speed is displayed on the monitor. In automatic mode, when
the control lever is moved away from the neutral position, the "Throttle Control"
potentiometer becomes inactive. When the control lever returns to the neutral position, the
"Throttle Control" potentiometer becomes active again.

3.2.16. Pendulum Speed Regulation

There is a pendulum speed control valve available for adjusting the speed of the pendulum
movement.

3.2.17. Hoisting Cylinder Speed Regulation

 There is a hoisting cylinder throttle valve used to adjust the speed of lifting or descending a
multi-stage cylinder.

3.3. Tractor Startup and Shutdown

3.3.1. Tractor Startup Procedure

1. After securing the tractor, turn on the main power switch and inspect the display and
indicator lights.
2. Place the control lever in the neutral position, all three-position switches in the
middle position, and the engine throttle control lever in the minimum or lower position.
3. Wait for the "Preheat Indicator" light to go out, then turn the start key clockwise to
"Start". After the engine starts, release the start key.
4. Once the diesel engine starts, adjust the engine speed, and check if all indicator lights
are off.
5. During winter use, due to low temperatures, there may be difficulty starting the
engine. In such cases, the "Water Jacket Heating" feature can be used to improve starting
conditions. Press the water jacket heating switch, the green light will illuminate, and the filter
and fuel lines will preheat. The operator should control the preheat time based on the ambient
temperature, approximately 1 to 3 minutes. After preheating, turn off the water jacket heating
switch, and the green light will go out. Immediately proceed with the startup procedure
described in step 3).

3.3.2. Tractor Shutdown Procedure

1. Inspect all components on the control panel to ensure the control lever is in the
neutral position, and all diesel engine potentiometers are set to reasonable positions.
2. Set the throttle to a lower position.
3. Turn the "Start Key" to the "Stop" position to shut down the diesel engine.

3.4. Tractor Stabilization

3.4.1. Main Unit Stabilization

1. Position the tractor as much as possible in the direction of the traction line for
construction.
2. Start the tractor.
3. Pull out the rear leg pin, place the rear legs of the tractor in a suitable position, and
insert the leg pin.
4. Operate the mechanical rocker arm of the front leg to place the front legs of the
tractor in a suitable position.
5. Anchor the tractor with a pull line and adjust the tension of the anchor line
appropriately.

3.4.2. Use of Tail Rope Sheave Frame

 When installing or replacing the tail rope reel, it is recommended to first set the working
mode switch to manual mode. Due to the tail rope pressure loss protection feature, it may not
be possible to replace the tail rope reel normally in automatic mode.

3.4.3. Tail Rope Reel Installation

1. Start the tractor.
2. For safety reasons, adjust the tail rope lifting throttle valve to a lower position. This
will effectively reduce the speed of the tail rope sheave frame's ascent or descent, ensuring a
safe and controlled operation.
3. Switch the "Lift-Stop-Rotate" three-position switch to the "Lift" position. Coordinate
with the tail rope pressure adjustment and lock the tail rope sheave frame with the latch.
4. Switch the "Lift-Stop-Rotate" three-position switch to the "Stop" position. Allow the
tail rope sheave frame to slowly descend under its own weight. The descent speed can be
adjusted using the throttle valve.
5. Install the wire reel onto the wire reel shaft.
6. Open the tail rope sheave shaft pressure plate.
7. Place the installed wire reel with the shaft onto the tail rope sheave frame.
8. Switch the "Lift-Stop-Rotate" three-position switch to the "Lift" position. Coordinate
with the tail rope pressure adjustment to slowly raise the tail rope sheave frame support until
the mechanical support can be positioned correctly. Then, switch the "Lift-Stop-Rotate"
three-position switch to the "Stop" position.
9. Tighten the tail rope sheave shaft pressure plate.
10. Place the shifting block mechanism's lever into the cross chuck of the wire reel shaft,
ensuring proper engagement. After completion, conduct a check to ensure the lever is securely
locked to prevent movement during operation and potential safety accidents.
11. Tighten the locking pin.

3.4.4. Replacement of Tail Rope Sheave

1. Switch the "Lift-Stop-Rotate" three-position switch to the "Rotate" position.
2. Check the tail frame pressure gauge and adjust the tail frame tension control valve to
ensure that the tail rope pressure is above 5MPa.
3. Set the "Loose-Hold-Clamp" switch to the clamp position. At this point, the clamping
cylinder will start to actuate. When the upper and lower top plates of the cylinder clamp the
wire tightly, make sure to set the "Loose-Hold-Clamp" switch to the hold position. Adjust the
tail rope pressure to the lowest setting and manually rotate the tail rope reel in the opposite
direction until the joint is loosened. Then, switch the "Lift-Stop-Rotate" three-position switch
to the "Stop" position to proceed with the disassembly of the rotary connector.
4. Loosen the locking pin.
5. Open the rope sheave shaft pressure plate.
6. Detach the shifting block.
7. Switch the "Lift-Stop-Rotate" three-position switch to the "Lift" position and raise the
tail rope sheave frame slightly. Detach the mechanical support, then switch the
"Lift-Stop-Rotate" three-position switch to the "Stop" position. Allow the tail rope sheave
frame to descend under its own weight. The descent speed can be adjusted using the throttle
valve.
8. Replace the tail rope sheave.
9. After the replacement is complete and the rope reel is in position, manually
pre-tension the tail rope first. Then, switch the "Lift-Stop-Rotate" three-position switch to the
"Rotate" position and adjust the tail frame tension control valve to increase the tail rope
pressure to above 5MPa. Move the "Loose-Hold-Clamp" switch to the loose position. At this
point, the clamping cylinder will start to actuate until the lower top plate of the cylinder
presses against the limit switch. Then, move the "Loose-Hold-Clamp" switch to the hold
position. The tail rope sheave replacement is now complete.

Notes:
1. If the stroke valve is not pressed fully into position by the lower top plate of the
cylinder, even if the main traction lever is actuated, the traction wheel will not work.
2. During the wire payout process, make sure not to randomly move the tail rope clamp
switch; it should be maintained in the hold position.

3.4.5. Cycloidal Mechanism Operation

The cycloidal mechanism of this machine is intelligently linked with the main pump control
lever. To engage the cycloidal operation, the "Cycloidal Switch" should be set to the working
position (right position). When not required, it should be placed in the stop position (left
position). The cycloidal operation has the following characteristics:
1. The start and stop of the cycloidal mechanism are linked with the main pump control
lever, requiring no manual intervention.
2. The cycloidal direction has a memory function. When the lever is reversed, the
cycloidal direction also changes automatically.
3. When the cycloidal system is not in use, it can be turned off via the "Cycloidal
Switch".
4. If manual intervention is needed to change the cycloidal direction, the "Cycloidal
Direction Change" switch can be used. Pressing this self-resetting switch once will switch the
cycloidal direction once.
5. The "Cycloidal Speed Adjustment Lever" allows for infinite adjustment of the
cycloidal speed to match the speed of the tail rope sheave, ensuring uniform winding of the
wire on the reel.

3.5. Operating Procedures for Traction Conditions

3-5-1 Winding Method for Traction Sheave

1. Start the traction machine.
2. Check that the pressure indicated on the oil supply pressure gauge is greater than
2Mpa. If not, stop the machine for inspection.
3. Switch the "Lift-Stop-Rotate" three-position switch to the "Rotate" position.
4. Adjust the engine speed using the throttle control lever. Then, adjust the tail rope
tension as needed using the "Tail Frame Pressure Adjustment" potentiometer, ensuring a
pressure of at least 5Mpa on the tail frame pressure gauge.
Note: The tail rope tension should be set to prevent slippage of the steel wire rope wound on
the traction sheave. Insufficient tail rope pressure can cause slippage, posing a safety risk and
leading to wear on the drum. When the traction machine is reversing for extended periods, it
is advisable to adjust the tail rope pressure to be slightly less than 5Mpa.
5. Press the "Fan Control" button. The green indicator light will illuminate, indicating
that the cooling system is operational.
6. Operate the control lever to rotate the traction sheave and observe the traction force
through the traction force gauge.
7. When using the cycloidal function, set the "Cycloidal Control" to the working
position. Adjust the cycloidal speed using the cycloidal speed control valve located on the
lower left side of the instrument box.
Note: The position of the control lever determines the speed of the traction sheave. The more
it deviates from the neutral position, the faster it will rotate. When the control lever returns to
the neutral position, it automatically engages the brake, stopping the traction machine. When
the control lever is moved to the traction position, it automatically disengages the brake,
allowing normal traction operation.
When stopping the traction and returning the control lever to the neutral position, avoid rapid
movement as it may cause the brake to engage prematurely, leading to hydraulic impact and
potential damage to system components. To avoid this, move the control lever quickly
towards the neutral position and then slow down as it approaches the neutral position. This
ensures a smooth stop and avoids hydraulic impact.

3.5. Oil Temperature Control for the Hydraulic System

3.5.1. Description

During normal traction operations, the "Fan Control" button should be pressed, indicated by a
green indicator light and a gray fan icon on the main screen, indicating that the cooling
system is activated. When the cooling system is operating, the fan icon turns green.

The temperature of the fan cooling system on this machine is measured by a sensor, which
automatically controls the fan's operating state and working pressure. Under various operating
conditions, the fan automatically starts when the temperature rises above 40°C and shuts
down when the temperature drops below 35°C. The temperature of the hydraulic oil can be
observed through the hydraulic oil temperature gauge.

3.5.2. Precautions
 Compared to traditional mechanical transmissions, hydraulic transmission systems offer
numerous advantages that mechanical transmissions cannot match. However, it cannot be
overlooked that the normal operation and performance of a hydraulic transmission system are
greatly influenced by the transmission medium, typically hydraulic oil. Controlling the
temperature of the hydraulic oil is crucial to ensuring reliable operation of the hydraulic oil
and other hydraulic components while optimizing the performance of the hydraulic system.
For traction machines, the use of a hydraulic closed-loop system places high demands on
lubrication and oil cleanliness, making this point particularly important.

From recent practical usage on construction sites, even in the hottest climates of the south, the
cooling capacity of the equipment poses no issues. This means that as long as it is used
correctly, the hydraulic oil can be maintained within a normal operating range. Here are some
instructions for operators to consider:
1.It is absolutely necessary to turn on the fan switch during actual use. Failure to do so may result
in the fan not working and cause the hydraulic oil temperature to rise excessively.

2.The hydraulic oil temperature gauge indicates the temperature of the hydraulic oil inside the
tank, which is approximately 20 degrees lower than the temperature of the hot oil in the
closed-loop circuit.

3.The optimal operating temperature of the hydraulic oil when using hydraulic equipment is
related to the type of hydraulic oil. When using the original hydraulic oil provided for this
machine, it is recommended to maintain the hydraulic oil temperature between 35-50 degrees
Celsius. If using a different brand of hydraulic oil, refer to its usage instructions or consult the
manufacturer or seller. It is important to note again that the temperature displayed on the
hydraulic temperature gauge is the temperature of the hydraulic oil in the tank, and there is
approximately a 20-degree difference between this temperature and the main system's
operating temperature.

4.The maximum pressure that the cooling system can adjust is related to the diesel engine speed.

5.When using the equipment in winter, before starting the equipment in the morning, if the
ambient temperature is below zero degrees, adjust the throttle to a lower position and start the
equipment for preheating. Once the preheating is complete, proceed with normal operation.
Generally speaking, before the hydraulic oil temperature rises to 20 degrees, the equipment
should be operated at a low speed. Once the hydraulic oil temperature exceeds 20 degrees, the
equipment can be operated at full speed.

6. Ensuring the normal operating temperature of the hydraulic oil is crucial for the proper
functioning of the hydraulic system. Although the use of the cooling system is relatively
simple, it cannot be neglected or overlooked, as the consequences can be severe. By following
the above requirements, the lifespan of the hydraulic oil and hydraulic system can be
significantly extended, reducing wear and aging of system components, improving system
efficiency and performance, and ultimately prolonging the lifespan of the equipment.

3.6. Tractor Transportation

3.6.1. Towing Transportation:

Connect the power vehicle to the towing hook ring at the front end of the tractor. The speed
on the highway should not exceed 15 kilometers per hour, and the speed on the access road
should not exceed 10 kilometers per hour.

3.6.2. Loading Transportation:

There is a single-point lifting ring on the main beam of the tractor, which can be used for
lifting and loading. The fixed binding points are the towing hook lever at the front and the two
anchor plates at the rear.

Tractor Maintenance
Proper and timely maintenance of the equipment is crucial to minimizing equipment failures
and extending its lifespan during actual use.

4.1. Operating Instructions for Dry Oil Pump

When refilling the dry oil pump, rotate counterclockwise and remove the end cap. Then, hold
the handle 1 shown in 6 and pull it upward to remove the sealing cap. Add grease after
removing the sealing cap, and then install the sealing cap and end cap in sequence.

To lubricate the split gears or bearings, operate the control handle of the dry oil pump. Each
dry oil pump has two working oil ports, which can be switched through the lever.

4.2. Routine Inspection and Maintenance

Check the working condition of the oil circuit filter. Hydraulic oil filters are equipped with
instrument indications and blockage alarm lights. If the light is on, it means the filter is
blocked, and the filter element should be cleaned or replaced.

Replace the hydraulic oil and filter element completely after 400 hours of operation for new
machines.

Replace the hydraulic oil and filter element annually or every 1500 hours of operation.
Replace the lubricating oil of the reduction gearbox after 50 hours of operation for new
machines.

Replace the lubricating oil of the reduction gearbox every 400 hours of operation.

Lubricate the split gear section every shift by switching the control lever on the dry oil pump
station to the "gear" position and operating the dry oil pump handle shown in 1-6
approximately ten times.

Lubricate the drum bearings every 100 hours of operation. There are two sets of drum
bearings, with the internal bearings lubricated by the dry oil pump. Pull out the dry oil pump
selection handle, and operate the oiling handle to complete the grease filling. The external
bearings are lubricated manually by removing the outer bearing cover plate of the drum and
directly injecting grease into the bearings using an oil gun or other suitable tools.

Regularly lubricate all joints and connections.

4.3. Diesel Engine Maintenance

Replace the diesel engine oil after the first 50 hours of use; thereafter, replace the diesel
engine oil and the three filters every 250 hours.

Replace at least once a year.

The recommended oil filling volume is 16.4 liters.

The diesel engine is equipped with a Chinese-language instruction manual provided by the
manufacturer, which provides detailed instructions for various maintenance tasks of the diesel
engine. It is essential to read the manual carefully before use.

4.4. Maintenance of Gearbox and Brake

The gearbox employs a two-stage planetary gear transmission. Critical components such as
gears inside the gearbox are made of high-quality alloy steel. The main gears are quenched
and ground, and the supports use high-capacity hydrostatic bearings. Except for the bearing
below the output shaft, which is lubricated with grease, the rest of the gearbox employs an
immersion lubrication method. The gearbox input end is equipped with a friction disc-type
wet brake operated by oil pressure.

When replacing the lubricating oil in the gearbox, first unscrew the oil drain plug to drain the
dirty oil and clean the oil residue inside the box. Then, seal the oil drain port, unscrew the oil
fill plug, and inject the specified clean lubricating oil. During the use of the gearbox, it is
essential to observe for any oil leaks, noise, and loosening of bolts or screws. Any abnormal
phenomena should be addressed promptly. This gearbox employs a splash lubrication system,
so it is normal for oil to leak from the air holes when the gearbox is operating at high speeds.

Replace the lubricating oil in the gearbox and brake within the first 100 hours of operation;
then replace it every 1500-2000 hours or every 12 months.

Regularly clean the magnetic plug.

The gearbox requires 100# industrial gear oil with a filling capacity of 3.7 liters.
The brake requires 46# hydraulic oil with a filling capacity of 0.35 liters.

4.5. Hydraulic System Maintenance

4.5.1. Instructions for Replacement and Maintenance of Hydraulic Filtration System

The hydraulic oil filter used in this machine is a self-sealing type, primarily used for fine
filtration of the hydraulic system, removing contaminants to maintain cleanliness of the oil.

The filter is installed at the bottom of the oil tank, with the cylinder submerged in the oil and
the filter head exposed outside the tank. To replace, clean, or repair the filter element or the
system, unscrew the filter end cap counterclockwise. The self-sealing valve will automatically
close, preventing oil from leaking out. Withdraw the filter element, replace, clean, or repair it,
and then reinstall it by screwing the end cap clockwise.

The oil filter is equipped with a contamination and blockage detector. The detector combines
instrument indication and electrical signaling, allowing for real-time monitoring of the filter
element's condition. If the detector signals (i.e., the filter alarm light comes on), the filter
element should be replaced or cleaned promptly.

There are two types of oil filters: suction filters and return filters. The suction filter element
models are ZX-100×50 (large) for the main pump and ZX-100×50 (small) for the auxiliary
and fan pumps. The return filter element model is TZ-250×20. The return filter comes with a
return oil hole. By unscrewing the small hole plug, contaminated oil inside the filter can be
drained, extending the filter element's lifespan and improving oil purification.

Check the working condition of the oil circuit filters. All hydraulic oil filters are equipped
with instrument indication and blockage alarm lights. If the light is on, it means the filter is
blocked, and the filter element needs to be cleaned or replaced.

4.5.2. Instructions for Replacing Hydraulic Oil

When replacing hydraulic oil, it is crucial to maintain cleanliness of the oil.

4.5. Hydraulic System Maintenance (Continued)

4.5.2. Instructions for Replacing Hydraulic Oil

To replace the hydraulic oil, follow these steps:

Unscrew the top cover of the hydraulic oil air filter.

Loosen the screws on the flange at the top of the oil tank.
Remove the air filter element.
Use an oil filtering cart or a small handheld oil filtering machine to drain the dirty oil. Ensure
to recover the dirty oil properly to avoid environmental pollution.
Clean the filter element and reinstall it.
Use the oil filtering cart to add clean hydraulic oil until the oil level reaches the upper limit
indicated by the oil level gauge.
Specific Replacement Timeline:

Replace the hydraulic oil and oil filter element completely after 400 hours of operation for a
new machine.
Replace the hydraulic oil and oil filter element every two years or after 1,500 hours of
operation.
4.6. Battery Maintenance

4.6.1. Daily Maintenance

Observe the battery casing for any electrolyte leaks.

Check that the battery is securely installed on the machine, and ensure tight connections
between the wire terminals and the battery.
Regularly remove dirt from the battery cover, rinse the electrolyte on the cover, and ensure
that the vent holes on the filling cap are unobstructed. Clean any oxides from the posts and
wire terminals.
Periodically check and adjust the density and level of the electrolyte. The density of the
electrolyte should be between 1.2 and 1.3 at 15°C (with a voltage of no less than 24V). The
liquid level should be 10-15mm above the separator. If the electrolyte level is low, add
distilled water.
Frequently check the battery's discharge level and recharge when the voltage drops below
22.5V.
4.6.2. Winter Usage Precautions

The battery should be used while fully charged to prevent freezing and potential casing
cracks.
Adding distilled water should be done before charging.
In non-freezing conditions, the concentration of the electrolyte should be as low as possible,
with a density generally not exceeding 1.285.
 4.7. Default Configurations of Hydraulic Oil and Lubricating Oil for the Traction Machine
upon Delivery
1. Hydraulic Oil: 46HM High Resistance and Wear-Resistant Hydraulic Oil
2. Gearbox and Gearbox Brake: 100# Industrial Gear Oil
3. Engine Oil: 15W/40 Oil (CD grade or above), such as Mobil Delvac 1330-15W/40
4. Diesel Fuel for Engine: Winter grades (-20 or -35 light diesel fuel) or Summer grades
(0 or 10 light diesel fuel) as per GB252-87
5. Lubricating Grease for Dry Oil Pump: ZN-3 Lithium-Based Grease

4.8. Additional Precautions Related to Maintenance and Servicing

1. Before starting the tensioning machine, inspect all oil level indicators to ensure
sufficient oil levels.
2. When using the machine after a long period of inactivity, ensure that the pump casing
(specifically the main pump R port) is filled with hydraulic oil.
3. Do not operate the machine when the hydraulic oil temperature exceeds 65°C.
4. When cleaning hydraulic system components, only use clean kerosene.