三一旋挖钻机SR285RC10维修手册电路图2023款
大小:247.41MB
格式:PDF
语言:英语
品牌:三一
机器类型:旋转钻机
手册类型:服务手册、电气和液压图表
型号:三一SR285RC10旋挖钻机
出版日期:二零二三年
页数:792页
内容:
1前言
1.1服务手册阅读指南
1.2标准维修术语的解释
1.3维护的基本原则
1.4电气和液压元件的搬运注意事项
1.4.1概述
1.4.2电气零件的搬运注意事项
1.4.3液压件的搬运注意事项
1.5拧紧管接头时的注意事项
1.5.1概述
1.5.2管件类型
1.5.3管件紧固扭矩
1.5.4O形环连接
1.6拧紧螺栓和螺母的注意事项
1.6.1螺栓类型
1.6.2螺栓拧紧顺序
1.6.3螺栓和螺母拧紧扭矩
1.7拧紧裂纹法兰的注意事项
1.7.1概述
1.7.2分裂法兰螺栓的拧紧扭矩
1.8单位换算表
2 安全
2.1安全标志
2.2一般性注意事项
2.2.1概述
2.2.2安全规则
2.2.3保持工作区域清洁
2.2.4流体储存注意事项
2.2.5零件清洗的注意事项
2.2.6清洗机的注意事项
2.2.7保养服的注意事项
2.2.8维修工具的使用注意事项
2.2.9熟悉灭火器和应急出口位置
2.3降低悬臂振幅前的准备工作
2.3.1维修前的准备工作
2.3.2警告信号
2.3.3自我准备
2.4维修时的注意事项
2.4.1发动机或电机运行过程中的维护注意事项
2.4.2电动机及电气控制维修注意事项
2.4.3拆除机器附件的注意事项
2.4.4对齐零件的注意事项
2.4.5机下维修注意事项
2.4.6使用锤子的注意事项
2.4.7使用压缩空气的注意事项
2.4.8焊接的注意事项
2.4.9轨道维护的注意事项
2.4.10添加或更换油液的注意事项
2.4.11高压软管维修的注意事项
2.4.12小心高压液体
2.4.13小心热冷却液
2.4.14空调器维修注意事项
2.4.15检修时的电气安全
2.4.16蓄电池维修注意事项
2.4.17累加器检修注意事项
2.4.18避免火灾和爆炸危险
2.4.19正确处理废物
2.4.20起重作业的注意事项及信号
2.4.21移动式和桥式起重机使用注意事项
2.4.22选择钢丝绳
2.4.23其他注意事项
2.5故障诊断的注意事项
2.5.1故障排除前的检查
2.5.2故障排除的注意事项
2.5.3故障排除程序
2.5.4故障排除类别和步骤
3电气系统
3.1工作原理
3.1.1主泵
3.1.2 试点
3.1.3深度测量
3.1.4接通电源-启动-延迟断电
3.1.5空调和收音机
3.1.6 擦拭器和洗衣机
3.2端子的插入和拆卸
3.3 DTC
3.3.1服务代码列表
3.3.2 E001-液压风扇1号信号的断路
3.3.3 E033—节气门旋钮信号的断开
3.3.4 E037-主泵功率控制阀的断路
3.3.5 E049-主绞车销轴张力开路
3.3.6 E051-平整手柄Y轴的开路
3.3.7 E053—拥挤压力传感器的开路
3.3.8 E055-桅杆X轴的开路
3.3.9 E057-桅杆左收缩比例阀的开路
3.3.10 E059-最大左伸出比例阀打开电路
3.3.11 E061-桅杆右收缩比例阀的开路
3.3.12 E063-桅杆右伸比例阀的开路
3.3.13 E065-拥挤调节比例阀的开路
3.3.14 E091-旋转驱动转矩的开路
3.3.15 E093-左操纵杆推拉信号开路
3.3.16 E095-右侧操纵杆推拉信号开路
3.3.17 H001-主泵1压力过低
3.3.18 H003-主泵2压力过低
3.3.19 H023-工作装置压力过低
3.3.20 H025-过低的行进压力
3.3.21 DTC P0016（闪烁代码16）凸轮轴传感器相位不匹配
3.3.22 DTC P0087（闪烁代码225）压力限制阀打开
3.3.23 DTC P0089（闪烁代码151）普通轨道压力异常（泵超压输送）
3.3.24 DTC P0091（闪烁代码247）断开PCV1驱动系统或GND短路
3.3.25 DTC P0092（闪烁代码217）PCV1驱动系统短路+B
3.3.26 DTC P0093（闪烁代码227）普通轨道压力异常低（冷态下无压力泵送货）
3.3.27 DTC P0112（闪烁代码22）异常进气温度传感器（异常低电压）
3.3.28 DTC P0113（闪烁代码22）异常进气温度传感器（异常高压）
3.3.29 DTC P0117（闪烁代码23）异常水温传感器（异常低电压）
3.3.30 DTC P0118（闪烁代码23）异常水温传感器（异常高压）
3.3.31 DTC P0182（闪烁代码211）异常燃油温度传感器（异常低电压）
3.3.32 DTC P0183（闪烁代码211）异常燃油温度传感器（异常高压）
3.3.33 DTC P0192（闪烁代码245）异常共轨压力传感器（异常低电压）
3.3.34 DTC P0193（闪烁代码245）异常共轨压力传感器（异常高压）
3.3.35 DTC P0201（闪烁代码271）喷射器#1驱动系统的断开
3.3.36 DTC P0202（闪烁代码272）喷射器2驱动系统的断开
3.3.37 DTC P0203（闪烁代码273）喷射器3驱动系统的断开
3.3.38 DTC P0204（闪烁代码274）喷射器4驱动系统的断开
3.3.39 DTC P0205（闪烁代码275）喷射器5驱动系统的断开
3.3.40 DTC P0206（闪烁代码276）喷射器6驱动系统的断开
3.3.41 DTC P0217（闪烁代码542）过热
3.3.42 DTC P0219（闪烁代码543）超速驾驶
3.3.43 DTC P0237（闪烁代码32）异常升压传感器（异常低电压）
3.3.44 DTC P0238（闪烁代码32）异常升压传感器（异常高压）
3.3.45 DTC P0335（闪烁代码15）曲轴传感器异常（无信号）
3.3.46 DTC P0336（闪烁代码15）曲轴传感器异常（异常信号）
3.3.47 DTC P0340（闪烁代码14）凸轮轴传感器异常（无信号）
3.3.48 DTC P0380（闪烁代码66）预热继电器异常
3.3.49 DTC P0381（闪烁代码67）预热指示器异常
3.3.50 DTC P0404（闪烁代码45）EGR阀控制异常
3.3.51 DTC P0409（闪烁代码44）EGR位置传感器异常
3.3.52 DTC P0522（闪烁代码295）发动机机油压力传感器异常（异常低电压）
3.3.53 DTC P0523（闪烁代码295）发动机机油压力传感器异常（异常高压）
3.3.54 DTC P0563（闪烁代码35）电池电压异常高
3.3.55 DTC P0601（闪烁代码53）异常ROM
3.3.56 DTC P0602（闪烁代码154）异常二维码
3.3.57 DTC P0604（闪烁代码153）异常RAM
3.3.58 DTC P0606（闪烁代码51）异常CPU/异常IC用于CPU监控
3.3.59 DTC P060B（闪烁代码36）异常A/D切换
3.3.60 DTC P0615（闪烁代码19）起动电机异常断路继电器
3.3.61 DTC P0641（闪烁代码55）5V电源电压异常1
3.3.62 DTC P0650（闪烁代码77）异常故障指示器
3.3.63 DTC P0651（闪烁代码56）5V电源电压异常2
3.3.64 DTC P0685（闪烁代码416）主继电器异常（无法连接）
3.3.65 DTC P0687（闪烁代码416）主继电器异常（无法断开连接）
3.3.66 DTC P0697（闪烁代码57）5V电源电压异常3
3.3.67 DTC P1062（闪烁代码257）异常PCV1 返回
3.3.68 DTC P1063（闪烁代码258）异常PCV2 返回
3.3.69 DTC P1093（闪烁代码226）普通轨道压力异常低（冷态下泵送液无压力1\）
3.3.70 DTC P1112（闪烁代码295）异常升压温度传感器（异常低电压）
3.3.71 DTC P1113（闪烁代码295）异常升压温度传感器（异常高压）
3.3.72 DTC P1261（闪烁代码34）充电电路异常（第1组）
3.3.73 DTC P1262（闪烁代码34）充电电路异常（第2组）
3.3.74 DTC P1293（闪烁代码211）异常燃油滤清器堵塞传感器（异常低电压）
3.3.75 DTC P1294（闪烁代码221）异常燃油滤清器堵塞传感器（异常高压）
3.3.76 DTC P1404（闪烁代码45）异常EGR零学习
3.3.77 DTC P1621（闪烁代码54）异常EEPROM
3.3.78 DTC P1655（闪烁代码59）5V电源电压异常4
3.3.79 DTC P2122（闪烁代码121）异常油门开启传感器1（异常低电压）
3.3.80 DTC P2123（闪烁代码121）异常油门开启传感器1（异常高压）
3.3.81 DTC P2127（闪烁代码122）异常油门开启传感器2（异常低电压）
3.3.82 DTC P2128（闪烁代码122）异常油门开启传感器2（异常高压）
3.3.83油门开启传感器1和2比较时发现的DTC P2138（闪烁代码124）异常
3.3.84 DTC P2146（闪烁代码158）喷射器的异常驱动系统 COMMON 1
3.3.85 DTC P2149（闪烁代码159）喷射器的异常驱动系统 共同2
3.3.86 DTC P2228（闪烁代码71）异常大气压力传感器（异常低电压）
3.3.87 DTC P2229（闪烁代码71）异常大气压力传感器（异常高压）
3.3.88 DTC P2295（闪烁代码248）断开PCV2驱动系统或GND短路
3.3.89 DTC P2296（闪烁代码218）PCV2驱动系统短路+B
3.3.90 DTC U0001（闪烁代码84）异常ISO-CAN总线
3.3.91 DTC U0073（闪烁代码84）异常CAN总线
3.3.92 DTC U0101（闪烁代码85）异常CAN超时
3.3.93 DTC U2106（闪烁代码85）轮式装载机CAN超时异常
3.4故障案例
3.4.1 EVI平台上显示的施工数据均为0
3.4.2未显示EVI数据
3.4.3摄像头故障
3.4.4通讯故障，显示器一直开着
3.4.5筛网故障分析及解决方法
3.4.6张力显示故障分析及解决方法
3.4.7深度测量故障分析及解决方法
3.4.8机器不运动的分析及解决方法
4液压系统
4.1主油泵工作原理
4.2测试与调整
4.2.1主阀溢流压力的测试与调整
4.2.2辅助阀溢流压力的测试与调整
4.2.3释放液压油管中的残余压力
4.2.4器械的空气流失
4.3拆卸和安装
4.3.1液压泵总成拆卸及安装
4.3.2主阀总成拆卸及安装
4.3.3辅助阀组件的拆卸和安装
4.3.4液压油箱总成拆卸与安装
4.3.5八通电磁阀组的拆卸和安装
4.3.6四联电磁阀组的拆卸和安装
4.3.7先导过滤器的拆卸和安装
4.3.8呼吸阀-拆卸和安装
4.3.9吸油滤芯盖板的拆卸与安装
4.3.10回油滤清器盖板的拆卸与安装
4.3.11液压缸总成拆卸和安装
5旋转驱动系统
5.1概述
5.2机械原理
5.3电气工作原理
5.3.1旋转驱动正/反转
5.4液压原理:旋转驱动转向或倒车
5.5测试与调整
5.5.1旋转驱动正/反转卸压的测试与调整
5.5.2旋转驱动电动机充油压力试验
5.6拆卸和安装
5.6.1旋转驱动群众雪橇—拆卸和安装
5.6.2旋转驱动连接板—拆卸和安装
5.6.3旋转驱动缓冲键套的拆卸和安装
5.6.4旋转驱动电机减速器—拆卸和安装
5.6.5旋转驱动空气过滤器—拆卸和安装
5.6.6旋转驱动压力板—拆卸和安装
5.7故障案例
5.7.1旋转驱动低速故障
5.7.2旋转驱动器转速波动故障
5.7.3旋转驱动减速器的异常声音
5.7.4不显示旋转驱动速度
5.7.5不显示旋转驱动扭矩
6主/辅助绞车系统
6.1概述
6.2机械原理
6.3电气工作原理
6.3.1主绞车自由落体制动器和制动器释放
6.3.2主绞车升降
6.3.3主绞车自由落体
6.3.4辅助绞车升降
6.3.5主/辅助绞车限位
6.4液压工作原理
6.4.1主绞车升降
6.4.2主绞车自由落体
6.4.3辅助绞车升降
6.5测试与调整
6.5.1主绞车卸料压力的测试与调整
6.5.2主绞车电机制动阀油口Br压力试验
6.5.3辅助绞车卸料压力的测试与调整
6.5.4辅助绞车电机制动压力试验
6.6拆卸和安装
6.6.1主绞车总成拆卸与安装
6.6.2辅助绞车总成拆卸与安装
6.6.3绳压辊的拆卸与装配
6.7故障案例
6.7.1主绞车自由落体失效
6.7.2主绞车下料机无移动
6.7.3主绞车起重机无移动
6.7.4主绞车升降无动作
6.7.5主绞车上的钢丝绳制动不好
6.7.6 主绞车在凯利杆下降过程中摇晃
7 人群系统
7.1概述
7.2电气工作原理
7.2.1拥挤/拉挤
7.2.2拥挤限制（如有）
7.3液压原理:挤压/拉力
7.4人群气缸溢流压力的测试与调整
7.5拆卸和安装
7.5.1拥挤气缸总成的拆卸和安装
7.5.2挤压圆柱体的拆卸与组装
7.6故障案例
7.6.1人群气缸噪声异常及加压困难
7.6.2人群圆柱体无移动
7.6.3气缸收缩过程中的异常噪声
7.6.4人群气缸自动减压
8桅杆系统
8.1概述
8.2机械原理
8.3电气工作原理
8.3.1手动降低/升高桅杆
8.3.2自动吊杆降高/升高
8.3.3英寸桅杆调整
8.3.4自动调节
8.3.5桅杆极限
8.3.6桅杆头气缸伸长/收缩
8.4液压工作原理
8.4.1 降低桅杆和提高桅杆
8.4.2桅杆头气缸的伸缩
8.5测试与调整
8.5.1桅杆气缸溢流压力的测试与调整
8.5.2桅杆柱溢流压力的测试与调整
8.6拆卸和安装
8.6.1 桅杆头 - 拆卸和安装
8.6.2桅杆支座组件—拆卸和安装
8.6.3桅杆气缸-拆卸和安装
8.6.4桅杆气缸-拆卸和组装
8.7故障案例
8.7.1桅杆不得移动
8.7.2主右缸无移动
8.7.3桅杆左倾角
9 吸气系统
9.1概述
9.2机械原理
9.3电气工作原理
9.3.1吊杆机构的升降
9.3.2吊装限值
9.4液压原理:上下振动
9.5吊杆气缸溢流压力的测试和调整
9.6拆卸和安装
9.6.1三角形的拆卸和安装
9.6.2 Boom - 拆卸和安装
9.6.3支架臂和吊柱的拆卸和安装
9.6.4吊装气缸-拆卸和组装
9.7故障案例
9.7.1 轻微的推杆动作
9.7.2吊杆运动异常
9.7.3吊杆机构减压
9.7.4反向吊索运动
10上层建筑回转系统
10.1概述
10.2电气工作原理
10.2.1左右摆动
10.3液压工作原理
10.3.1上车厢左/右摆动和摆动缓冲
10.4测试与调整
10.4.1上车摆动溢流压力的测试与调整
10.4.2空调系统的测试与调整
10.5拆卸和安装
10.5.1摆动电机的拆卸和安装
10.5.2摆动减速器的拆卸和安装
10.5.3摆动接头总成的拆卸和安装
10.5.4中央摆动接头总成的拆卸与装配
10.5.5摆动轴承总成的拆卸和安装
10.5.6配重总成的拆卸和安装
10.5.7散热器盖的拆卸与装配
10.6故障案例
10.6.1 摆动角度未显示
10.6.2摆动机构不能锁定
10.6.3机器不能摆动
11电源系统
11.1各系统大纲图
11.2测试与调整
11.2.1排气烟度测量
11.2.2检查发动机的压缩压力
11.2.3皮带的试验和张力调整
11.3拆卸和安装
11.3.1燃油箱总成拆卸与安装
11.3.2散热器总成的拆卸和安装
11.3.3联轴器的拆卸和安装
11.3.4阻尼垫和发动机支架的拆卸和安装
11.3.5发动机机油滤清器总成的拆卸和安装
11.3.6燃油预滤器总成的拆卸和安装
11.3.7精细燃油滤清器总成的拆卸和安装
11.3.8水油分离器总成拆卸与安装
12轨道旅行系统
12.1概述
12.2电气工作原理
12.2.1爬虫旅行
12.2.2爬虫扩展/收回
12.3液压工作原理
12.3.1旅行
12.3.2爬虫的扩展和收回
12.4测试与调整
12.4.1延长筒溢流压力的测试与调整
12.4.2行走电机卸压的测试与调整
12.4.3轨道鞋张紧装置的检查与调整
12.4.4差旅抵销额的计量
12.5拆卸和安装
12.5.1旅行电机减速器的拆卸和安装
12.5.2载重辊的拆卸和安装
12.5.3惰轮和张紧器的拆卸和安装
12.5.4履带总成拆卸与安装
12.5.5链轮的拆卸和安装
12.5.6载重辊的拆卸和安装
12.6故障案例
12.6.1它不能行驶（只能在一边行驶）
12.6.2机器在行驶过程中会偏离轨道
13钻具
13.1 凯利酒吧介绍
13.1.1摩擦棒
13.1.2机械锁紧钻杆
13.2凯利棒的拆卸
13.3 凯利棒的组装
13.4凯利棒故障诊断
13.4.1维修清单
13.4.2维护技术要求
13.4.3消耗品清单
13.4.4常见故障及维修
13.4.5关键故障及维修
14附录
14.1 线束图
14.1.1束缚图:右平台束缚图
14.1.2束缚图:桅杆束缚图
14.1.3束缚图:上桅杆束缚图
14.1.4皮带图:驾驶室皮带
14.1.5束线图:桅杆头束线
14.1.6束线图:旋转驱动束线
14.1.7束管图:旋转驱动机机身束管
14.1.8线束图:电柜线束
14.1.9束缚图:机身束缚图
14.1.10束缚图:机身管路束缚图
14.2电气原理图
14.3电气元器件编码表
14.4液压原理图（带制动阀的旋转驱动）
14.5液压原理图（无制动阀的旋转驱动）
14.6液压原理图（使用力士乐和川崎电机旋转驱动）
14.7电气元件.传感器
14.7.1深度测量传感器BG1
14.7.2桅杆倾角传感器BG3
14.7.3主绞车线拉力传感器BP19
14.7.4桅杆左限位开关SF2
14.7.5桅杆右限位开关SF3
14.7.6主绞车限位开关 SF4
14.7.7辅助绞车限位开关 SF5
14.8电气元件.电磁阀
14.8.1四阀组电磁阀DT10—DT11、DT13—DT14
14.9液压元件:液压泵
14.9.1 V1泵单元
14.10液压元件-阀门组
14.10.1 V2主阀组
14.10.2 V3辅助阀组
14.10.3 V4四通阀组
14.10.4 V5 踏板先导阀
14.10.5 V6左手柄导阀
14.10.6 V7 右手柄导阀
14.10.7 V11 十四通阀组
14.10.8 V18主绞车自由落体阀组
14.10.9 V19主绞车制动缸的开启阀组
14.10.10 V21 拥挤气缸平衡阀
14.10.11V22、V23、V24和V25主汽缸平衡阀
14.10.12 V26、V27、V28和V29铰接气缸平衡阀
14.10.13 V30桅杆气缸平衡阀
14.10.14 V64主绞车平衡阀组
14.11液压元件-马达
14.11.1V40和V41旋转驱动电机总成
14.11.2 V43主绞车电机总成
14.11.3 V45辅助绞车电机总成
14.11.4 V47摆动电机总成
14.11.5 V49和V50左行和右行电机总成
14.11.6 V51散热器电机总成
14.12液压件-气缸
14.12.1 MC1 拥挤气缸
14.12.2 MC2和MC3 左/右桅杆气缸
14.12.3 MC4 和 MC5 铰链气缸
14.12.4 MC6、MC7、MC8和MC9履带伸缩气缸
14.12.5 MC10 桅杆头气缸
14.13液压件-其他
14.13.1 EP1散热器
14.13.2 V52 中心摆动接头
14.13.3 V53旋转驱动油座总成
14.13.4 V54液压油箱总成
14.13.5 V58空气过滤器
14.13.6 V57 导频滤波器
Sany Rotary Drilling Rig SR285RC10 Service Manual 2023
Size: 247.41 MB
Format: PDF
Language: English
Brand: Sany
Type of Machine: Rotary Drilling Rig
Type of Manual: Service Manual, Electrical and Hydraulic Diagrams
Model: Sany SR285RC10 Rotary Drilling Rig
Publication Date: 2023
Number of Pages: 792 Pages
Contents:
1 Foreword
1.1 Service Manual Reading Guide
1.2 Explanation of Standard Maintenance Terminology
1.3 Basic Principles for Maintenance
1.4 Precautions for Handling Electrical and Hydraulic Components
1.4.1 Overview
1.4.2 Precautions for Handling Electrical Parts
1.4.3 Precautions for Handling Hydraulic Parts
1.5 Precautions for Tightening Pipe Connectors
1.5.1 Overview
1.5.2 Pipe Fitting Types
1.5.3 Pipe Fitting Tightening Torque
1.5.4 O-ring Connection
1.6 Precautions for Tightening Bolts and Nuts
1.6.1 Bolt Type
1.6.2 Bolt Tightening Sequence
1.6.3 Bolt and Nut Tightening Torque
1.7 Precautions for Tightening Split Flanges
1.7.1 Overview
1.7.2 Tightening Torque for Split Flange Bolts
1.8 Unit Conversion Table
2 Safety
2.1 Safety Signs
2.2 General Precautions
2.2.1 Overview
2.2.2 Safety Rules
2.2.3 Keep the Work Area Clean
2.2.4 Precautions for Fluid Storage
2.2.5 Precautions for Part Cleaning
2.2.6 Precautions for Cleaning Machine
2.2.7 Precautions for Maintenance Attire
2.2.8 Precautions for Using Maintenance Tools
2.2.9 Familiarize with Fire Extinguisher and Emergency Exit Location
2.3 Preparations before lowering the jib boom
2.3.1 Pre-Maintenance Preparations
2.3.2 Warning Signs
2.3.3 Self-Preparation
2.4 Precautions During Maintenance
2.4.1 Precautions for Maintenance During Engine or Motor Operation
2.4.2 Precautions for Motor and Electric Control Maintenance
2.4.3 Precautions for Removing Machine Attachments
2.4.4 Precautions for Aligning Parts
2.4.5 Precautions for Maintenance Under the Machine
2.4.6 Precautions for Using Hammers
2.4.7 Precautions for Using Compressed Air
2.4.8 Precautions for Welding
2.4.9 Precautions for Track Maintenance
2.4.10 Precautions for Adding or Replacing Oils and Fluids
2.4.11 Precautions for Repairing High-Pressure Hose
2.4.12 Beware of the High-Pressure Fluids
2.4.13 Beware of Hot Coolant
2.4.14 Precautions for Air Conditioner Maintenance
2.4.15 Electrical Safety During Maintenance
2.4.16 Precautions for Battery Maintenance
2.4.17 Precautions for Accumulator Maintenance
2.4.18 Avoiding Fire and Explosion Hazards
2.4.19 Proper Waste Disposal
2.4.20 Precautions for Lifting Operations and Signaling
2.4.21 Precautions for Using Mobile and Bridge Cranes
2.4.22 Selecting Wire Rope
2.4.23 Additional Precautions
2.5 Precautions for Fault Diagnosis
2.5.1 Pre-Troubleshooting Inspection
2.5.2 Precautions for Troubleshooting
2.5.3 Procedures for Troubleshooting
2.5.4 Troubleshooting Categories and Steps
3 Electrical system
3.1 Working Principle
3.1.1 Main pump
3.1.2 Pilot
3.1.3 Depth measurement
3.1.4 Power-on - start - delayed power off
3.1.5 A/C and radio
3.1.6 Wiper and washer
3.2 Terminal insertion and removal
3.3 DTC
3.3.1 Service code list
3.3.2 E001-Open circuit of hydraulic fan 1 signal
3.3.3 E033-Open circuit of throttle knob signal
3.3.4 E037-Open circuit of main pump power control valve
3.3.5 E049-Main winch pin shaft tension open circuit
3.3.6 E051-Open circuit of leveling handle Y axis
3.3.7 E053-Open circuit of crowding pressure sensor
3.3.8 E055-Open circuit of mast lever X axis
3.3.9 E057-Open circuit of mast left retraction proportional valve
3.3.10 E059-Mast left extension proportional valve open circuit
3.3.11 E061-Open circuit of mast right retraction proportional valve
3.3.12 E063-Open circuit of mast right extension proportional valve
3.3.13 E065-Open circuit of crowding adjusting proportional valve
3.3.14 E091-Open circuit of rotary drive torque
3.3.15 E093-Left joystick push/pull signal open circuit
3.3.16 E095-Right joystick push/pull signal open circuit
3.3.17 H001-Main pump 1 pressure too low
3.3.18 H003-Main pump 2 pressure too low
3.3.19 H023-Excessively low pressure of working device
3.3.20 H025-Excessively low traveling pressure
3.3.21 DTC P0016 (flashing code 16) phase mismatching of camshaft sensor
3.3.22 DTC P0087 (flashing code 225) pressure limiting valve open
3.3.23 DTC P0089 (flashing code 151) abnormal common rail pressure (pump overpressure delivery)
3.3.24 DTC P0091 (flashing code 247) disconnection of PCV1 driving system or GND short circuit
3.3.25 DTC P0092 (flashing code 217) short circuit of PCV1 driving system + B
3.3.26 DTC P0093 (flashing code 227) abnormally low pressure of common rail pressure (pump delivery without pressure 2\in cold state)
3.3.27 DTC P0112 (flashing code 22) abnormal intake air temperature sensor (abnormally low voltage)
3.3.28 DTC P0113 (flashing code 22) abnormal intake air temperature sensor (abnormally high voltage)
3.3.29 DTC P0117 (flashing code 23) abnormal water temperature sensor (abnormally low voltage)
3.3.30 DTC P0118 (flashing code 23) abnormal water temperature sensor (abnormally high voltage)
3.3.31 DTC P0182 (flashing code 211) abnormal fuel temperature sensor (abnormally low voltage)
3.3.32 DTC P0183 (flashing code 211) abnormal fuel temperature sensor (abnormally high voltage)
3.3.33 DTC P0192 (flashing code 245) Abnormal common rail pressure sensor (abnormally low voltage)
3.3.34 DTC P0193 (flashing code 245) Abnormal common rail pressure sensor (abnormally high voltage)
3.3.35 DTC P0201 (flashing code 271) disconnection of injector #1 driving system
3.3.36 DTC P0202 (flashing code 272) disconnection of injector #2 driving system
3.3.37 DTC P0203 (flashing code 273) disconnection of injector #3 driving system
3.3.38 DTC P0204 (flashing code 274) disconnection of injector #4 driving system
3.3.39 DTC P0205 (flashing code 275) disconnection of injector #5 driving system
3.3.40 DTC P0206 (flashing code 276) disconnection of injector #6 driving system
3.3.41 DTC P0217 (flashing code 542）overheating
3.3.42 DTC P0219 (flashing code 543）overdriving
3.3.43 DTC P0237 (flashing code 32）abnormal boost pressure sensor (abnormally low voltage)
3.3.44 DTC P0238 (flashing code 32）abnormal boost pressure sensor (abnormally high voltage)
3.3.45 DTC P0335 (flashing code 15）abnormal crankshaft sensor (no signal)
3.3.46 DTC P0336 (flashing code 15）abnormal crankshaft sensor (abnormal signal)
3.3.47 DTC P0340 (flashing code 14）abnormal camshaft sensor (no signal)
3.3.48 DTC P0380 (flashing code 66) abnormal preheating relay
3.3.49 DTC P0381 (flashing code 67) abnormal preheating indicator
3.3.50 DTC P0404 (flashing code 45) EGR valve control abnormality
3.3.51 DTC P0409 (flashing code 44) abnormal EGR position sensor
3.3.52 DTC P0522 (flashing code 295) abnormal engine oil pressure sensor (abnormally low voltage)
3.3.53 DTC P0523 (flashing code 295) abnormal engine oil pressure sensor (abnormally high voltage)
3.3.54 DTC P0563 (flashing code 35) abnormally high voltage of battery
3.3.55 DTC P0601 (flashing code 53) abnormal ROM
3.3.56 DTC P0602 (flashing code 154) abnormal QR code
3.3.57 DTC P0604 (flashing code 153) abnormal RAM
3.3.58 DTC P0606 (flashing code 51) abnormal CPU/abnormal IC for CPU monitoring
3.3.59 DTC P060B (flashing code 36) abnormal A/D switching
3.3.60 DTC P0615 (flashing code 19) abnormal disconnection relay of starter motor
3.3.61 DTC P0641 (flashing code 55) abnormal voltage of 5 V power supply 1
3.3.62 DTC P0650 (flashing code 77) abnormal fault indicator
3.3.63 DTC P0651 (flashing code 56) abnormal voltage of 5 V power supply 2
3.3.64 DTC P0685 (flashing code 416) abnormal main relay (unable to be connected)
3.3.65 DTC P0687 (flashing code 416) abnormal main relay (unable to be disconnected)
3.3.66 DTC P0697 (flashing code 57) abnormal voltage of 5 V power supply 3
3.3.67 DTC P1062 (flashing code 257) abnormal PCV1 FLY BACK
3.3.68 DTC P1063 (flashing code 258) abnormal PCV2 FLY BACK
3.3.69 DTC P1093 (flashing code 226) abnormally low pressure of common rail pressure (pump delivery without pressure 1\in cold state)
3.3.70 DTC P1112 (flashing code 295) abnormal boost temperature sensor (abnormally low voltage)
3.3.71 DTC P1113 (flashing code 295) abnormal boost temperature sensor (abnormally high voltage)
3.3.72 DTC P1261 (flashing code 34) abnormal charging circuit (Bank 1)
3.3.73 DTC P1262 (flashing code 34) abnormal charging circuit (Bank 2)
3.3.74 DTC P1293 (flashing code 211) abnormal fuel filter clogging sensor (abnormally low voltage)
3.3.75 DTC P1294 (flashing code 221) abnormal fuel filter clogging sensor (abnormally high voltage)
3.3.76 DTC P1404 (flashing code 45) abnormal EGR zero learning
3.3.77 DTC P1621 (flashing code 54) abnormal EEPROM
3.3.78 DTC P1655 (flashing code 59) abnormal voltage of 5 V power supply 4
3.3.79 DTC P2122 (flashing code 121) abnormal throttle opening sensor 1 (abnormally low voltage)
3.3.80 DTC P2123 (flashing code 121) abnormal throttle opening sensor 1 (abnormally high voltage)
3.3.81 DTC P2127 (flashing code 122) abnormal throttle opening sensor 2 (abnormally low voltage)
3.3.82 DTC P2128 (flashing code 122) abnormal throttle opening sensor 2 (abnormally high voltage)
3.3.83 DTC P2138 (flashing code 124) abnormality upon comparison between throttle opening sensors 1 and 2
3.3.84 DTC P2146 (flashing code 158) abnormal driving system of injector COMMON 1
3.3.85 DTC P2149 (flashing code 159) abnormal driving system of injector COMMON 2
3.3.86 DTC P2228 (flashing code 71) abnormal atmospheric pressure sensor (abnormally low voltage)
3.3.87 DTC P2229 (flashing code 71) abnormal atmospheric pressure sensor (abnormally high voltage)
3.3.88 DTC P2295 (flashing code 248) disconnection of PCV2 driving system or GND short circuit
3.3.89 DTC P2296 (flashing code 218) short circuit of PCV2 driving system + B
3.3.90 DTC U0001 (flashing code 84) abnormal ISO-CAN Bus
3.3.91 DTC U0073 (flashing code 84) abnormal CAN Bus
3.3.92 DTC U0101 (flashing code 85) abnormal CAN timeout
3.3.93 DTC U2106 (flashing code 85) abnormal Wheel Loader CAN timeout
3.4 Fault Cases
3.4.1 The construction data displayed on EVI platform are all 0
3.4.2 EVI data not displayed
3.4.3 Camera fault
3.4.4 Communication fault and display stays on all the time
3.4.5 Analysis and solution of screen fault
3.4.6 Analysis and solution of tension display fault
3.4.7 Analysis and solution of depth measurement fault
3.4.8 Analysis and solution of no movement of the machine
4 Hydraulic System
4.1 Main oil pump operating principle
4.2 Testing and Adjustment
4.2.1 Test and adjustment of overflow pressure of main valve
4.2.2 Test and adjustment of auxiliary valve overflow pressure
4.2.3 Release the residual pressure in the hydraulic oil lines
4.2.4 Air bleeding of devices
4.3 Removal and Installation
4.3.1 Removal and installation of hydraulic pump assembly
4.3.2 Removal and installation of main valve assembly
4.3.3 Removal and installation of auxiliary valve assembly
4.3.4 Removal and installation of hydraulic oil tank assembly
4.3.5 Removal and installation of eight-way solenoid valve group
4.3.6 Removal and installation of quadruple solenoid valve group
4.3.7 Removal and installation of pilot filter
4.3.8 Breather Valve - Remove and Install
4.3.9 Removal and installation of oil suction filter element cover plate
4.3.10 Removal and installation of oil return filter cover plate
4.3.11 Removal and installation of the hydraulic cylinder assembly
5 Rotary Drive System
5.1 Overview
5.2 Mechanical principle
5.3 Electrical Working Principle
5.3.1 Rotary drive positive/reverse rotation
5.4 Hydraulic principle: Rotary drive forwarding or reversing
5.5 Testing and Adjustment
5.5.1 Test and adjustment of rotary drive positive/reverse rotation relief pressure
5.5.2 Test of oil charge pressure of rotary drive motor
5.6 Removal and Installation
5.6.1 Rotary Drive Crowd Sledge - Remove and Install
5.6.2 Rotary Drive Connecting Plate - Remove and install
5.6.3 Removal and installation of rotary drive buffer key sleeve
5.6.4 Rotary Drive Motor Reducer - Remove and Install
5.6.5 Rotary Drive Air Filter - Remove and Install
5.6.6 Rotary Drive Pressure Plate - Remove and Install
5.7 Fault Cases
5.7.1 Rotary drive low speed fault
5.7.2 Rotary drive rotation speed fluctuation fault
5.7.3 Abnormal sound of rotary drive reducer
5.7.4 No display of rotary drive speed
5.7.5 No display of rotary drive torque
6 Main/auxiliary winch system
6.1 Overview
6.2 Mechanical principle
6.3 Electrical Working Principle
6.3.1 Main winch freefall brake and brake release
6.3.2 Main winch lifting/lowering
6.3.3 Main winch freefall
6.3.4 Auxiliary winch lifting/lowering
6.3.5 Main/auxiliary winch limit
6.4 Hydraulic Working Principle
6.4.1 Main winch lifting/lowering
6.4.2 Main winch freefall
6.4.3 Auxiliary winch lifting/lowering
6.5 Testing and Adjustment
6.5.1 Test and adjustment of main winch relief pressure
6.5.2 Test of brake valve oil port Br pressure of main winch motor
6.5.3 Test and adjustment of relief pressure of auxiliary winch
6.5.4 Auxiliary winch motor brake pressure test
6.6 Removal and Installation
6.6.1 Removal and installation of main winch assembly
6.6.2 Removal and installation of auxiliary winch assembly
6.6.3 Disassembly and assembly of rope hold-down roller
6.7 Fault Cases
6.7.1 Main winch freefall disabled
6.7.2 No movement of main winch lowering
6.7.3 No movement of main winch lifting
6.7.4 Main winch lifting/lowering has no movement
6.7.5 The wire rope on main winch is not well braked
6.7.6 The main winch shakes during the Kelly bar lowering
7 Crowd system
7.1 Overview
7.2 Electrical Working Principle
7.2.1 Crowding/pulling
7.2.2 Crowding limit (if any)
7.3 Hydraulic principle: Crowding/pulling
7.4 Test and adjustment of overflow pressure of crowd cylinder
7.5 Removal and Installation
7.5.1 Removal and installation of crowd cylinder assembly
7.5.2 Disassembly and assembly of crowd cylinder
7.6 Fault Cases
7.6.1 Abnormal noise and difficult pressurization of crowd cylinder
7.6.2 No movement of crowd cylinder
7.6.3 Abnormal noise during cylinder retraction
7.6.4 Automatic pressure relief of crowd cylinder
8 Mast System
8.1 Overview
8.2 Mechanical principle
8.3 Electrical Working Principle
8.3.1 Manual lowering/raising the mast
8.3.2 Auto mast lowering/rasing
8.3.3 Inching mast adjustment
8.3.4 Auto adjusting
8.3.5 Mast limit
8.3.6 Masthead cylinder extension/retraction
8.4 Hydraulic Working Principle
8.4.1 Lowering mast and raising mast
8.4.2 Masthead cylinder extension and retraction
8.5 Testing and Adjustment
8.5.1 Test and adjustment of overflow pressure of mast cylinder
8.5.2 Test and adjustment of overflow pressure of masthead cylinder
8.6 Removal and Installation
8.6.1 Masthead - Remove and install
8.6.2 Mast Pivot Assembly - Remove and Install
8.6.3 Mast Cylinder - Remove and Install
8.6.4 Mast Cylinder - Disassemble and Assemble
8.7 Fault Cases
8.7.1 No movement of mast
8.7.2 No movement of mast right cylinder
8.7.3 Left tilt of the mast
9 Luffing System
9.1 Overview
9.2 Mechanical principle
9.3 Electrical Working Principle
9.3.1 Derricking mechanism lifting/lowering
9.3.2 Derricking limit
9.4 Hydraulic principle: Boom up and down
9.5 Test and adjustment of boom cylinder overflow pressure
9.6 Removal and Installation
9.6.1 Removal and installation of triangle
9.6.2 Boom - Remove and Install
9.6.3 Removal and installation of support arm and derricking cylinder
9.6.4 Derricking Cylinder - Disassemble and Assemble
9.7 Fault Cases
9.7.1 Weak derricking action
9.7.2 Abnormal derricking movement
9.7.3 Derricking mechanism pressure relief
9.7.4 Reverse derricking movement
10 Superstructure Slewing System
10.1 Overview
10.2 Electrical Working Principle
10.2.1 Left/right swing
10.3 Hydraulic Working Principle
10.3.1 Upper carriage left/right swing and swing buffering
10.4 Testing and Adjustment
10.4.1 Test and adjustment of upper carriage swing overflow pressure
10.4.2 Test and adjustment of A/C system
10.5 Removal and Installation
10.5.1 Removal and installation of swing motor
10.5.2 Removal and installation of swing reducer
10.5.3 Removal and installation of swing joint assembly
10.5.4 Disassembly and assembly of central swing joint assembly
10.5.5 Removal and installation of swing bearing assembly
10.5.6 Removal and installation of counterweight assembly
10.5.7 Disassembly and assembly of water radiator cover
10.6 Fault Cases
10.6.1 The swing angle not displayed
10.6.2 The swing mechanism cannot be locked
10.6.3 The machine can not swing
11 Power System
11.1 Outline diagram of each system
11.2 Testing and Adjustment
11.2.1 Exhaust smoke measurement
11.2.2 Check the compression pressure of engine
11.2.3 Test and tension adjustment of belt
11.3 Removal and Installation
11.3.1 Removal and installation of fuel tank assembly
11.3.2 Removal and installation of the radiator assembly
11.3.3 Removal and installation of coupling
11.3.4 Removal and installation of damper pad and engine support
11.3.5 Removal and installation of engine oil filter assembly
11.3.6 Removal and installation of fuel pre-filter assembly
11.3.7 Removal and installation of fine fuel filter assembly
11.3.8 Removal and installation of water oil separator assembly
12 Track Traveling System
12.1 Overview
12.2 Electrical Working Principle
12.2.1 Crawler travel
12.2.2 Crawler extension/retraction
12.3 Hydraulic Working Principle
12.3.1 Travel
12.3.2 Crawler extension and retraction
12.4 Testing and Adjustment
12.4.1 Test and adjustment of overflow pressure of extension cylinder
12.4.2 Test and adjustment of relief pressure of traveling motor
12.4.3 Inspection and adjustment of track shoe tensioning device
12.4.4 Measurement of traveling offset
12.5 Removal and Installation
12.5.1 Removal and installation of travel motor reducer
12.5.2 Removal and installation of carrier rollers
12.5.3 Removal and installation of idler and tensioner
12.5.4 Removal and installation of crawler assembly
12.5.5 Removal and installation of sprockets
12.5.6 Removal and installation of carrier roller
12.6 Fault Cases
12.6.1 It cannot travel (only on one side)
12.6.2 The machine has off-tracking during traveling
13 Drilling Tools
13.1 Introduction to Kelly bar
13.1.1 Friction bar
13.1.2 Mechanical locking drill pipe
13.2 Disassembly of Kelly bar
13.3 Assembly of Kelly bar
13.4 Kelly Bar Fault Diagnosis
13.4.1 Maintenance list
13.4.2 Requirements for maintenance technique
13.4.3 List of consumables
13.4.4 Common faults and maintenance
13.4.5 Key Faults and Maintenance
14 Appendices
14.1 Harness Diagram
14.1.1 Harness diagram: right platform harness
14.1.2 Harness diagram: mast harness
14.1.3 Harness diagram: upper mast harness
14.1.4 Harness diagram: cab harness
14.1.5 Harness diagram: masthead harness
14.1.6 Harness diagram: rotary drive harness
14.1.7 Harness diagram: rotary drive machine body harness
14.1.8 Harness diagram: electric cabinet harness
14.1.9 Harness diagram: machine body harness
14.1.10 Harness diagram: machine body pipeline harness
14.2 Electrical schematic diagram
14.3 Codes list of electrical components
14.4 Hydraulic schematic(rotary drive with brake valve)
14.5 Hydraulic schematic(rotary drive without brake valve)
14.6 Hydraulic schematic(rotary drive with Rexroth and Kawasaki motor)
14.7 Electrical components - sensor
14.7.1 Depth measurement sensor BG1
14.7.2 Mast inclination sensor BG3
14.7.3 Main winch line pull sensor BP19
14.7.4 Mast left limit switch SF2
14.7.5 Mast right limit switch SF3
14.7.6 Main winch limit switch SF4
14.7.7 Auxiliary winch limit switch SF5
14.8 Electrical components - solenoid valve
14.8.1 Quadruple valve group solenoid valve DT10-DT11, DT13-DT14
14.9 Hydraulic components: hydraulic pump
14.9.1 V1 Pump unit
14.10 Hydraulic components- valve group
14.10.1 V2 Main valve group
14.10.2 V3 auxiliary valve group
14.10.3 V4 four-way valve group
14.10.4 V5 pedal pilot valve
14.10.5 V6 left handle pilot valve
14.10.6 V7 right handle pilot valve
14.10.7 V11 Fourteen-way valve group
14.10.8 V18 Main winch freefall valve group
14.10.9 V19 Opening valve group of main winch brake cylinder
14.10.10 V21 Crowd cylinder balance valve
14.10.11 V22, V23, V24, and V25 mast cylinder balance valves
14.10.12 V26, V27, V28, and V29 derricking cylinder balance valves
14.10.13 V30 masthead cylinder balance valve
14.10.14 V64 Main winch balance valve group
14.11 Hydraulic components - motor
14.11.1 V40 and V41 rotary drive motor assembly
14.11.2 V43 main winch motor assembly
14.11.3 V45 auxiliary winch motor assembly
14.11.4 V47 swing motor assembly
14.11.5 V49 and V50 left and right travel motor assemblies
14.11.6 V51 Radiator motor assembly
14.12 Hydraulic parts - cylinder
14.12.1 MC1 crowd cylinder
14.12.2 MC2 and MC3 left/right mast cylinder
14.12.3 MC4 and MC5 derricking cylinders
14.12.4 MC6, MC7, MC8 and MC9 crawler telescopic cylinders
14.12.5 MC10 Masthead cylinder
14.13 Hydraulic parts- others
14.13.1 EP1 radiator
14.13.2 V52 center swing joint
14.13.3 V53 rotary drive oil seat assembly
14.13.4 V54 hydraulic oil tank assembly
14.13.5 V58 air filter
14.13.6 V57 pilot filter
