Chapter Ⅶ

APPENDIX
 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Table of Contents
1. OPERATION MANUAL FOR ROBWAY CRANE LIMITER RCI1550 ....................... 4

1.1 D ESCRIPTIONS OF P USHBUTTON & O PERATION I NTERFACE ........................................ 4

1.2 O PERATION I NSTRUCTIONS .................................................................................... 5
1.2.1 Startup & Duty Modifying ............................................................................... 5
1.2.2 Calculating of Empty Hook.............................................................................. 6
1.2.3 Time & Date Setting........................................................................................ 7
1.3 O THERS ............................................................................................................... 8
2. OPERATION INSTRUCTIONS FOR DISPLAY OF HL-LCD064(C) ....................... 8

2.1 S TARTUP I NTERFACE ............................................................................................. 8

2.2 M AIN M ENU I NTRODUCTION .................................................................................. 8
2.2.1 Interface Logo ................................................................................................ 9
2.2.2 Oil Content Indicating ..................................................................................... 9
2.2.3 Voltage Indicating ......................................................................................... 10
2.2.4 Working Hours of Engine .............................................................................. 10
2.2.5 Engine Rotating Speed Indicating .................................................................. 10
2.2.6 Oil Pressure Indicating .................................................................................. 10
2.2.7 Water Temperature Indicating ........................................................................ 10
2.2.8 Servo Pressure of Hydraulic System ............................................................... 10
2.2.9 Hydraulic Oil Temperature Indicating............................................................. 11
2.2.10 Relative position of Top Crane & Down Crane .............................................. 11
2.2.11 Level Indicating .......................................................................................... 11
2.2.12 Wind Speed Indicating ................................................................................. 11
2.2.13 Lockup Indicating ....................................................................................... 11
2.2.14 Lockup & Unlock of Swing .......................................................................... 12
2.2.15 Lockup & Unlock of Main Boom .................................................................. 12
2.2.16 Lockup of Free Fall ..................................................................................... 12
2.2.17 Mode Indicating .......................................................................................... 12
2.2.18 Descriptions of Handle Pushbuttons ............................................................. 13
2.2.19 Total Unload State Indicating ....................................................................... 13
2.2.21 Emergency Stop .......................................................................................... 13
2.2.22 Alarm Logos of Engine Fault ....................................................................... 13
2.2.23 Alarm Logos of System Fault ....................................................................... 14
2.3 I NTERFACE S ETTING ............................................................................................ 14
2.4 S ETTING OF T IME M ODIFICATION I NTERFACE ......................................................... 14
2.5 I NQUIRY I NTERFACE OF C ONTROLLER & E LECTRIC S IGNAL ..................................... 14
2.5.1 Inquiry of I/O State of Main Controller U1 ..................................................... 15
2.5.2 Inquiry of I/O State of Main Controller U2 ..................................................... 16
2.5.3 Inquiry of I/O State of Main Controller U3 ..................................................... 17
2.6 I NQUIRY I NTERFACE OF FAULTS ............................................................................ 18
2.7 B UTTON OF A LARM C ONFIRMING ......................................................................... 21
2.8 S YSTEM I NFORMATION ........................................................................................ 21
3． USE, MAINTENANCE AND KEEPING OF AIR CONDITIONER .......................... 25

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

3.1 O VERVIEW ......................................................................................................... 25

3.2 T ECHNICAL PARAMETERS .................................................................................... 25
3.3 S YSTEM C OMPOSITION ........................................................................................ 25
3.4 W ORKING P RINCIPLE ........................................................................................... 26
3.4.1. Refrigeration System................................................................................. 26
3.4.2. Heating System (Optional) ........................................................................ 26
3.4.3. Electric Schematic Diagram ....................................................................... 27
3.4.4. System Auto Control ................................................................................. 28
3.5.O PERATION M ETHOD OF D IGITAL A IR C ONDITIONER C ONTROLLER .......................... 28
3.5.1 Panel Profile............................................................................................. 28
3.5.2 Operation Method ..................................................................................... 29
3.6.I NSTALLATION .................................................................................................... 29
3.6.1. Installation of Compressor......................................................................... 30
3.6.2. Installation of Evaporator .......................................................................... 30
3.6.3. Installation of Condenser .......................................................................... 30
3.6.4. Installation of Liquid Vessel ...................................................................... 30
3.6.5. Installation of Refrigerating Pipeline ......................................................... 30
3.6.6. Installation of Apparatus Cables ................................................................ 31
3.7.D EBUGGING ....................................................................................................... 32
3.7.1. Vacuum .................................................................................................... 32
3.7.2. Leakage check: ......................................................................................... 32
3.7.3. Refilling refrigerating medium: ................................................................. 32
3.7.4. Table of pressure parameters of the system at different ambient temperatures33
3.8.M AINTENANCE AND K EEPING ............................................................................... 33
3.8.1. Routine Maintenance of the Air Conditioner ............................................... 33
3.8.2. Preventive Keeping of Air Conditioner ....................................................... 34
3.9.R EMOVAL OF COMMON FAULTS ............................................................................. 35

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

1. Operation Manual for ROBWAY Crane Limiter

RCI1550

This manual is available only for SCC500E cranes equipped with ROBWAY crane limiter,

bellowing is the operation interface:

1.1 Descriptions of Pushbutton & Operation Interface

1) Descriptions for Pushbuttons

1. “KEY” indicates limiting disarm;
2. “HORN” indicates sound alarm;
3. “HOOK” indicates the hook crashing the boom;
4. “！ ” indicates approaching the rated load;
5. “！！ ” indicates exceeding the rated load;
6. “hand” indicates switching off the dangerous operation;

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

7. “Rectangular code of Green, Yellow, Red” indicates percentage of rated load;

8. The switching buttons of main & auxiliary hook of “R, F1, F2, F3” are buttons of
special functions;
9. “T” indicates flaying;
10. “R, F1, F2, F3” are buttons of special functions;
11. “×”± indicates canceling, “√”± indicates confirming;
12. Time display;
13. Swl29.2 indicates rated load;
14. main load10.5 indicates current work load;
15. length 7.0 indicates length of main boom;
16. height 4.6 indicates perpendicular height of main boom;
17. angle45.6 indicates angle of main boom;
18. radius3.1 Indicates work scope.

1.2 Operation Instructions

1.2.1 Startup & Duty Modifying

1. After machine startup, the scream will be displayed as “Communication connection,

please wait”, it will last a few seconds.
2. The information interface with certain items of Edition NO., chip NO. and etc. will be
displayed automatically. Note down the chip no. #, find “press ok” in the last line
(press the button of √¡).
3. When entering the interface of duty modifying, the items of DUTY, WINCH, BOOM
LENGTH, JIB LENGTH, JIB-ANGLE and etc. will be displayed, if any modification is
needed, press the canceling button of ¡°×¡±, enter the needed duty no. # with the
keyboard, press “up” and “down” to turn over. Press the confirming button of ¡°√¡± to
finish the modification.
4. After modifying the duty, the interface will be the modifying of the number of the main
falls. Press the button of ¡°×¡± to implement modification, enter the needed number of
main falls; press the button of ¡°√¡± to finish the operation.
5. After modifying the number of the main falls, the interface will be the modifying of the
number of the Aux Falls. Press the button of ¡°×¡± to implement modification, enter
the needed number of main falls; press the button of ¡°√¡± to finish the operation.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

1.2.2 Calculating of Empty Hook

1. After changing the duty, one button of ▲¡± will be displayed with characters of ACK,
press it to enter the main working interface.
2. Press the “MENU” button above the button of ▲¡± at the right bottom to enter a new

interface. Press the button of “PAGEDOWN” and select the “function codes”, press the

button of ¡°√¡± and the interface of pin:_ will display, the password is the chip NO. +

first two digit of the current time, press ¡°√¡± after entering.

3. The following interface will be displayed:

Function code

F01:
VIEW MAIN LOAD

hh:mm

Diagram 6: Function code screen

Calculating of Empty Hook

Press the “PAGEDOWN” and select the 02Cal.active winch, press the button of ¡°√¡±.

4. The following interface will be displayed:

CAL ACTIVE WINCH
F02:

Enter Load + hook

Edit : 234.89

hh:mm

Diagram 8: Cal active winch

Calculating of Empty Hook

Enter the hook weight at the flashing frame of “Edit” and press the button of ¡°√¡±.

Hoist the angle of the main boom from 30°to 65°, or low from 65°to 30°, then press the

confirming button to finish the calculating of empty hook.

5. Press the canceling button continuously to back to the working interface, trail lifting a

heavy block to validate its accuracy.

6. If the accuracy is not high enough, find 37 with the “DOWNPAGE” button in item 3 and

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

press the button of ¡°√¡± to enter, then select “08 Amplified 1” and press ¡°√¡±, the

following interface will be shown:

RAW LO (initial signal value of sensor without load)

RAW HI 980 （ signal limit value）

CAL LO 0 （ No-load value）

CAL HI （ maximum tonnage value of sensor）

Press the “DOWNPAGE” to find the line of “cal hi” and modify the latter digits; if the

value displayed is bigger than the actual tonnage, minish the value; vice versa.

1.2.3 Time & Date Setting

When modifying the system time with this function, the condition as shown in the

following figure will appear, the time displayed will be in the standard mode (HH:MM:SS);

improper input will result to the display of “Error”.

Caution: the value of seconds cannot be set and is always been displayed as “00”, the

second value will start counting after pressing the confirming button.

When modifying the system date with this function, the condition as shown in the

following figure will appear, the date displayed will be in the ISO mode (YYYY-MM-DD);

improper input will result to the display of “Error”

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

1.3 Others

For other operations, please refer to the Operation Manual of Limiter.

2. Operation Instructions for Display of HL-LCD064(C)

2.1 Startup Interface

After power connection, the following display will last 3 seconds and then enter into the
main menu.

Shanghai SANY Science & Technology

Personality decides success

Quality perfects world

Welcome to use crawler crane of SCC series

2.2 Main Menu Introduction

The main menu will be：

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

（ Main

Menu Ⅰ）

Detailed information of Main Menu:

2.2.1 Interface Logo

Main Menu logo, as shown:

Crawler Crane of SCC Series 2006-8-18 8:31:18

Time

Display Area

Display current date & time (adjustable) at the right side of interface logo;

2 0 0 6 -8 -1 8 8 :3 1 :1 8
18%

System Time Oil Content Percentage

2.2.2 Oil Content Indicating

When the fuel oil percentage is smaller than 10%, the rate of process will be red;
when bigger than 10% and smaller than 20%, it will be yellow; when bigger than 20%,
it will be green.

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2.2.3 Voltage Indicating

The voltage display will be shown as the red signal of alarm signal;

123456.5
12.3V h

System Voltage Machine Working Hours

2.2.4 Working Hours of Engine

The machine working hours will be the same as the accumulated engine working
hours;

2.2.5 Engine Rotating Speed Indicating

2.2.6 Oil Pressure Indicating

20kPa 12.3℃

Oil Pressure Water Temperature

2.2.7 Water Temperature Indicating

2.2.8 Servo Pressure of Hydraulic System

56.6℃

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Servo Pressure Hydraulic oil temperature

2.2.9 Hydraulic Oil Temperature Indicating

The indication of hydraulic oil temperature will be shown as overheat alarm signal
of hydraulic oil.

2.2.10 Relative position of Top Crane & Down Crane

Positive location Inverse location

2.2.11 Level Indicating

The level will be indicated with coordinate and rings. When the dangerous angle is not
reached, the color of side angle point will be orange; the valid inclining angle of alarm
signal will be -5.0°——+5.0°.

Y:1.0°

X:1.0°

Gradienter Wind Speed

2.2.12 Wind Speed Indicating

2.2.13 Lockup Indicating

Indications of lockup and unlock of main & auxiliary winch.

M M

（ Main winch unlock ） （ Main winch lockup ）

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Aux Aux

（ Auxiliary winch unlock） （ Auxiliary winch lockup）

2.2.14 Lockup & Unlock of Swing

Swing lockup Swing unlock

2.2.15 Lockup & Unlock of Main Boom

BOOM BOOM

Main boom lockup Main boom unlock

2.2.16 Lockup of Free Fall

This crane is equipped with the function of Free Fall Lockup, when the alarm

happens, the logo will be yellow flashing.

Free Fall Unlock Free Fall Lockup

2.2.17 Mode Indicating

The models of installing & working are shown as follows， when 0X10 B1.1isat high

position, it is installing mode, at low position is working mode.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Installing Mode Working Mode

2.2.18 Descriptions of Handle Pushbuttons

Left pushbutton Right pushbutton

Left pushbutton ： combination （ REXROTH configuration ）， free rotating （ KAWASAKI

configuration），

Right pushbutton： Swing braking

Down pushbutton： Temporary no special meaning

2.2.19 Total Unload State Indicating

If no unload is available, the bellow figure will not display.

Total unloading indicating Emergency stop

2.2.21 Emergency Stop

Appears only at emergency conditions, at normal condition this logo will not

display.

2.2.22 Alarm Logos of Engine Fault

Indication of Engine Fault Indication of System Fault

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2.2.23 Alarm Logos of System Fault

The alarm will be indicated when the Electronic Control faults happen.

2.3 Interface Setting

Interface of System Setting (System Setting):

Press F1 at the main menu to System Setting interface, the entrance screen will be

password validating; enter the password which is set during machine manufacturing and

unchangeable.

2.4 Setting of Time Modification Interface

Press F4 at the main menu to the setting interface of time modification (as following).

Tim e Setting 2006-8-18 8:31:18

07-04-25 15:42

Confirm after adjusting

Back Confirm

F1 F2 F3 F4 F5 F6

Modification method: Press F2, F3 to move the cursor, the digits at where the cursor stops

will turn into red, press F4, F5 to increase or minish the value. After setting the digits,

press F6 to confirm, and then press F1 to back to interface of system setting.

2.5 Inquiry Interface of Controller & Electric Signal

The inquiry interface of electric input & output signal of controller & I/O module:

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Press F2 at main menu to enter;

2.5.1 Inquiry of I/O State of Main Controller U1

The current electric state of input & output of main controller (RC6-9) and the signal

definition is shown in the attached sheet.

Inquiry of I/O State of Main Controller U1 2006-8-18 8:31:18

NO NO
Pin Item Value Pin Item Value
. .
1 44 Overlaod X 11 60 Reverse Operation X
2 19 Upper limit of Main Boom X 12 73
Crawler ON/ jib upper
limit X
3 64 Lower limit of Main Boom X 13 53 Swing pin ON X
4 65 Upper limit of Aux boom X 14 18 A-Frame ready X
5 63 10
Main winch over
Lower limit of Aux boom X 15 expend X
6 61 Charging Error X 16 11 Aux winch over expand X
17 29
Safety valve for main
7
Upper limit of main
37 winch
X winch hoisting
X
18
Safety valve for main
48 15
Upper limit of Aux
8 winch
X winch lowing X
9 23 Main boom upper limit
81 X 19 5
Safety valve for aux
X
winch hoisting
10
Safety valve for aux
12 Main boom upper limit
88
X 20 6 winch lowing X

Next
Main Menu U2 U3
Page

F1 F2 F3 F4 F5 F6

Press F6 to the next page.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Inquiry of I/O State of Main Controller U1 2006-8-18 8:31:18

N State N A/D
O. Pin Item Pin Item
value O. value
21 72
Safety valve for main luffing
X XX
hoisting 31 35 Water temperature
Safety valve for main luffing XX
XX
22 71 lowing X 32 46 Engine oil pressure
Safety valve for aux. luffing Position feedback of XX
XX
23 74 hoisting X 33 8
Safety valve for aux. luffing accelerator XX
XX
24 75 X 34 20 Fuel oil temperature
lowing XX
XX
25 12 Servo pressure unload X 35 34 Oil level of fuel
Combination of main
XX
XX
26 4 X 36 45 Servo pressure
valve
Wind speed of main
XX
XX
27 68 OFF valve for fuel X 37 9 boom XX
28 69 Engine pre-heating X 38 XX
21 Wind speed of jib
Flowrate adjusting of main XX
XX
29 16 Engine startup X 39 31 boom PWM X
30 40 30 Power limiting PWM XX
X

Main menu U2 U3 Back

F1 F2 F3 F4 F5 F6

Press the function button of F1 to back to the main menu, press F2 to enter controller U2,
press F6 to enter the second page of I/O state inquiry interface of controller U1.
Press the function button of F1 to back to the main menu, press F2 to enter the I/O state
inquiry interface of controller U2, press F3 to enter the I/O state inquiry interface of
controller U3, press F6 to enter the first page of I/O state inquiry interface of controller
U1.

2.5.2 Inquiry of I/O State of Main Controller U2

I/O State of controller U2 (HL-MC-A)

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Inquiry of I/O State of Main Controller U2 2006-8-18 8:31:18

NO State N State
. Pin Item Pin Item
value O. value
1 DI01 Emergency stop X 11 DI11 Locking of main winch X
2 DI02 Engine startup X 12 DI12 Lock of aux. winch X
3 DI03 Engine pre-heating Lock of main
X 13 DI13 X
luffing
4 DI04 Burn on left handle X 14 DI14 Lock of aux. luffing X
5 DI05 Swing lock-rotating X 15 DI15 Lock of swing X
6 DI06 Buttons of left X 16 DI16 Micro swing X
combination
7 DI07 Horn of right handle X 17 DI17 Micro input of main X
pump
8 DI08 Alarm eliminating X 18 DI18 Quick traveling X
Button of right X
9
DI09 combination X 19 DI19 Operating disarm
10 DI10 Operating/installing
mode
X 20 DI20 Interlock input X

Main
menu
U1 U3 Next

F1 F2 F3 F4 F5 F6

Inquiry of I/O State of Main Controller U2 2006-8-18 8:31:18

N State N State
Pin Item Pin Item
O. value O. value
21 DI21 Input of Free Fall X 31 DO07 X
DI2
22 Start of Free Fall X 32 DO08 X
2
DI2
23 Overlook of cab X 33 PWM1 X
3
DI2 PWM
24 Look of cab X 34 X
4 2
PWM
25 DO01 Buzzer X 35
DO0 Lamp of faults 3
PWM
26 X 36
2 4
27 DO03 X 37 AI01 Speed adjusting XXXX
28 DO04 X 38 AI02 Input of hand accelerator XXXX
DO0
29 X 39 AI03 Input of hand accelerator XXXX
5
DO0
30 40 AI04
6

Main menu U1 U3 Back

F1 F2 F3 F4 F5 F6

Requirements of interface logo, time display will be the same as the mentioned.
Press the function button F1 to back to the main menu, press F2 to enter the I/O
state inquiry of module RC6-9.

2.5.3 Inquiry of I/O State of Main Controller U3

I/O State of switch output module (HL-MC-B) and signal definition will be shown
in attached sheet.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

U3 I / 0 S t a t e 2006-8-18 8:31:18

N State N State
Pin Item Pin Item
O. value O. value
PLS0 11 X
1 Input of swing pressure X DO07 Valve 1 for traveling direction
1
PLS0 Solenoid valve for swing
2 Input of traveling pressure X 12 DO08 braking X
2
PLS0 Alarm of filter element of Solenoid valve for swing
3 X 13 DO09 unlock X
3
PLS0 oil suction
4 Stock of filter for servo oil X 14 DO10 Solenoid valve of swing X
4 pressure increase
5 DO01 Rachet valve of main winch X 15 DO11 Switch valve of free rotating X
6 DO02 Rachet valve of aux. winch X 16 DO12 Micro valve of swing X
7 DO03 Rachet valve of main luffing X 17 DO13 Micro valve of main pump X
DO0
8 Rachet valve of aux. luffing X 18 DO14 Valve 1 of fan motor X
4
DO0
9 Valve of quick traveling X 19 DO15 Valve 2 of fan motor X
5
10 DO06 Valve 1 for traveling direction
X 20 DO16 Valve 1 of Fall/Pilot switching X

Main menu U1 U2 Next

F1 F2 F3 F4 F5 F6

U3 I / 0 S t a t e 2006-8-18 8:31:18

N State N State
Pin Item Pin Item
O. value O. value
22 DO18 Horn output X
23 DO19 Output of swing flashing lamp X
24 DO20
25 DO21
DO2
26 2
27 PWM01 Stretch of cylinder in cab X
PWM0 X
28 Draw back of cylinder in cab
2
PWM0
29 Auxiliary mode X
3
30

Main menu U1 U2 Back

F1 F2 F3 F4 F5 F6

Requirements of interface logo, time display will be the same as the mentioned.
Press the function button F1 to back to the main menu, press F2 to enter the I/O
state inquiry of module RC6-9, press F3 to enter the I/O state inquiry of module
HL-MC-A.

2.6 Inquiry Interface of Faults

There are 4 sub-interfaces in the fault inquiry. Press the button of “fault inquiry” at
the main menu to enter the interface of “Current fault inquiry of the system”, here
shows the figure.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

When the electric control engine (model: ) is adapted, the function buttons of
F3 and F4 is available, otherwise these two buttons will be hidden without any function.

Inquiry of system historical faults

Select the “inquiry of system historical faults” in the interfaces of “inquiry of
current system faults”, “inquiry of current engine faults” and “inquiry of engine
historical faults”, the interface will be shown as:

This interface shows the historical faults information about occurring time and

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

resolving time, all the faults will be listed by time sequence with the latest one at the
top.

Inquiry of current engine faults：

Select the “inquiry of current engine faults” in the interfaces of “inquiry of current
system faults”, “inquiry of historical system faults” and “inquiry of engine historical
faults”, the interface will be shown as:

If the number of current engine faults is 0, the interface will be shown as “no current
engine faults”; meanwhile, the buttons of “PAGEUP” AND “PAGEDOWN” are useless.

Inquiry of historical engine faults:

Select the “inquiry of historical engine faults” in the interfaces of “inquiry of
current system faults”, “inquiry of historical system faults” and “inquiry of current
engine faults”, the interface will be shown as:

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

The number of engine historical faults, serial NO., SPN, FMI, OC.
If the number of engine historical faults is 0, the interface will be shown as “no engine
historical faults”; meanwhile, the buttons of “PAGEUP” AND “PAGEDOWN” are useless.

2.7 Button of Alarm Confirming

At the main menu, F5 indicates “alarm confirming”. When faults happen, there will
be sound alarm, press F5 to eliminate the sound.

2.8 System Information

Press F6 at the main menu to enter the interface of System Information Inquiry, as
follows:

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Crawler Crane of SCC series 2007-10-18 8:31:18

Software edition：SCC-LCD064C V1.0

SHANGHAI SANY SCIENCE & TECHNOLOGY CO., LTD.

No.319chuanda Rd, Chuansha Economic Park, Pudong New Area,
Shanghai 201200, P.R.China.
www.sanygroup.com

Main menu

F1 F2 F3 F4 F5 F6

While at the interface of System Information Inquiry, press F1 to back to the main
menu.

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 Chapter Ⅶ APPENDIX SCC500E Operation Manual

Attached sheet: Inquiry of Faults Information:

NO. CODE NO. CODE DESCRIPTION
DESCRIPTION
1 0 Overwinding of main winch 27 26 Air filter blocked

2 1 Overexpanding of main winch 28 27 Anemometer faults of main boom

3 2 Overwinding of aux. winch 29 28 Anemometer faults of aux. boom

4 3 Overexpanding of aux. winch 30 29 Faults of water temperature sensor

5 4 Upper limit of main boom 31 30 Faults of engine oil pressure

6 5 Upper limit of Aux. boom 32 31 Faults of accelerator position

7 6 Overload alarm 33 32 Fault s of rot at in g sp eed s enso r o f engin e

8 7 Upper limit of main boom luffing 34 33 Fault s of h yd raul i c oil t e m per atur e

9 8 Lower limit of main boom luffing 35 34 Faults of servo pressure sensor

10 9 Upper limit of aux. boom luffing 36 35 Faults of fuel oil content

11 10 Lower limit of aux. boom luffing 37 36 Faults of speed regulating trimmer

12 11 Decline of crane 38 37 Faults of foot accelerating trimmer

13 12 Engine oil pressure too low 39 38 Faults of hand accelerating

Water temperature of engine too 40 39 Saf et y v alv e faul ts of mai n win ch

14 13
high 41 40 Saf et y v alv e f au lts o f main win c h lo win g

15 14 Engine faults
42 41 Saf et y v alv e faul ts of aux . winch

16 15 fuel oil content too low

43 42 Saf et y v alv e f au lts of aux . w in c h lo wing

17 16 Temperature of hydraulic oil too

44 43 Saf et y v alv e f ault s of main luffing

18 17 Servo pressure too low

45 44 Saf et y v alv e f ault s of main luffing

19 18 System voltage too low

46 45 Saf et y v a lv e faul ts of aux . luffing

20 19 Wind speed to high

47 46 Saf et y v a lv e faul ts of aux . luffing

21 20 Suction filter element 1

48 47 Faults of unload valve
22 21 Suction filter element 2
49 48 Faults of combination valve
23 22 Return filter element 1
50 49 Faults of engine startup relay
24 23 Return filter element 2
51 50 Faults of engine fuel relay
25 24 Servo filter blocked
52 51 Faults of engine pre-heat relay
26 25 Swing filter blocked

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NO. CODE DESCRIPTION NO. CODE DESCRIPTION

53 52 Flow regulating faults of PWM1 of main 74 73 Faults of swing braking valve

54 53 Power limit faults of PWM2 75 74 Faults of swing lock valve

55 54 Co mmun i ca tion faul ts o f eng ine 76 75 Faults of swing pressure valve

56 55 Co mmun i ca tion fau lts of g radi en t er 77 76 Free rotating valve

57 56 Co mmun i ca tion faul ts of con trol modul e 78 77 Faults of swing micro valve

58 57 Co mmun i ca tion faul ts of con trol modul e 79 78 Faults of pump micro valve

59 58 Co mmun i ca tion faul ts of mo me n t l i mi t er 80 79 Fault of motor valve Ⅰ

60 59 Engin e st ar tup f ault , r et r y aft er 10 81 80 Fault of motor valve Ⅱ

61 60 Engin e st ar tup f ault , r et r y aft er 30 82 81 Faults of free fall valve Ⅰ

62 61 Engin e st ar tup f ault , r et r y after 120 83 82 Faults of free fall valve Ⅱ

63 62 A-Frame un-hoisted 84 83 Faults of horn

64 63 Crawler locked 85 84 Faults of swing alarm lamp

65 64 Swing lock-pin locked 86 85 Power fault of sensor

66 65 Faults of general wire of 87 86 Faults of green signal lamp

67 66 Rachet valve fault of main 88 87 Faults of yellow signal lamp

68 67 Rachet valve fault of aux. 89 88 Faults of red signal lamp

69 68 Rachet valve fault of main luffing 90 89 Faults of power supply

70 69 Rachet valve fault of aux. luffing 91 90 Faults of up-warding valve in cab

71 70 Faults of fast-travel valve 92 91 Faults of down-warding valve in

72 71 Faults of travel direction valve Ⅰ 93 92 Faults of auxiliary switching valve

73 72 Faults of travel direction valve Ⅱ 94 93 Faults of swing sound alarm

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3．Use, Maintenance and Keeping of Air Conditioner

3.1 Overview
Air conditioning system of CD series engineering vehicles is composed of evaporator, condenser,
compressor and pipeline. The compressor is provided with auxiliary drive through belt by the
vehicle’s engine while power to the air conditioner is provided by the vehicle’s power supply. This
system selects optimal parts with stable and reliable performances and excellent anti-vibration,
proper for the driving cabs of all vehicles, such as engineering vehicle, truck, special vehicle at the
airport, medium-size bus.

3.2 Technical Parameters

Refrigeration volume: 4600W Wind volume: 550m³/h
Working voltage: 12V or 24V Overall power consumption: 500W
Refrigerating medium: R134a Refrigerating oil: PAG100
Compressor: SE5H14 Shaft power: 2000W
Refilling volume: 1Kg Heating volume: 5000W (optional)

3.3 System Composition

Air conditioning system of CD series engineering vehicles is composed of compressor, evaporator,
condenser, liquid vessel and pipeline. The body of the air conditioner includes such parts as
condenser, liquid vessel, expansion valve and evaporator.
The working principle is shown below:

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3.4 Working Principle

3.4.1. Refrigeration System

This system adopts vapor compressed refrigeration cycling system, mainly including 4 processes.

A． The process of compression

The refrigerating medium at low temperature and low pressure is absorbed in by the compressor,
and is compressed into refrigerating medium gas at high temperature and high pressure to be sent
into the condenser.

B． The process of condensing

After being sent into the condenser, the refrigerating medium gas at high temperature and high
pressure shall force heat dissipation to become refrigerating liquid at high temperature and high
pressure gradually.

C． The process of throttling expansion

After the refrigerating liquid is dried and filtered in the liquid vessel, it is sent to the expansion
valve where it is transformed into a liquid at low temperature and low pressure through throttling
expansion. This process features dramatic decrease of pressure and temperature.

D． The process of evaporation

The refrigerating liquid enters the evaporator after its temperature and pressure are reduced by the
expansion valve. The evaporated liquid shall absorb the heat to become gas at low temperature and
low pressure sent into the compressor. Heat and temperature of air inside the vehicle shall be
absorbed and reduced by the evaporator through the fan to realize the aim of refrigeration.

3.4.2. Heating System (Optional)

Heating is achieved circularly through use of hot water or other hot oil in the engine.

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3.4.3. Electric Schematic Diagram

A: Electric Schematic Diagram

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3.4.4. System Auto Control

A． Pressure Control
Pressure of this system is controlled by high-low pressure switch with a pressure scope of
0.169MPa-3.14MPa. The system pressure can disconnect the compressor when there is a little
medium or no medium; the compressor can be disconnected when the system pressure is
abnormally high to protect the system.

B． Fuse of the Power Supply

The system is equipped with three fuses to prevent short circuit and overload, respectively of 20A,
10A, 10A.

C． Fusible Plug (High Temperature) Control

When the system pressure exceeds 2.9MPa or the system medium reaches 102-110℃, the fusible
plug shall be smelted to release medium in the system into the air to prevent the entire system
from being damaged.

3.5. Operation Method of Digital Air Conditioner Controller

3.5.1 Panel Profile Working indicators

Power-off Button

Power-on Button Temp. Adjust & Refrigerating Heating Wind Speed Adjust
Set Button Button Button

: panel switches. Press to connect the power supply and the power indicator shall
be on; press to disconnect the power supply and the power indicator shall be off.

: adjust and set temperature. Each time is pressed, the temperature to be set shall
increase by 1 degree; each time is pressed, the temperature to be set shall decrease by 1
degree.

: refrigerating button. After is pressed down, the refrigerating light shall be on and the
system shall start to refrigerate.

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: heating button. After is pressed down, the heating light shall be on and the system
shall start to heat up.

: adjust wind speed. The fan is at low speed shift when the system is powered on. Press
continually to change between low, medium and high wind speed with related indicator on.

3.5.2 Operation Method

A． Refrigerating
z Start the engine.

z Press down to switch on power supply switch with the power indicator on.

z When is pressed, the fan indicator shall be on. Press continually to change
between low, medium and high wind speed with related indicator on.

z Press or to set proper temperature (The temperature set up should be lower than
the ambient temperature).

z After is pressed down, the refrigerating light shall be on and the system shall start to
refrigerate;

z After the temperature is set properly, adjust the wind speed as required.

B． Heating
z Start the engine.

z Press down to switch on power supply switch with the power indicator on.

z When is pressed, the fan indicator shall be on. Press continually to change
between low, medium and high wind speed with related indicator on.

z Press or to set proper temperature (The temperature set up should be lower than
the ambient temperature).

z After is pressed down, the heating light shall be on and the air conditioner shall start to
heat up.

z After the temperature is set properly, adjust the wind speed as required.

3.6. Installation
Notice:
The installer shall possess knowledge of vehicle air conditioning system.
This manual is required to be read through before installation.
No part is hurt or damaged. All parts are well sealed, dry and clean internally.
The operation circumstance should be clean and humidity proof. Make sure to prevent
matters such as pollutant and water from entering the loop.

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3.6.1. Installation of Compressor

a) Belt slot of the compressor clutch shall be at the same plane with the belt slot of the engine.
b) A tensioning unit is added on the compressor belt. The tension degree shall be properly set to
enforce a force of 98N onto the belt with the belt decreased by about 10-12mm.
c) Interface of the compressor should face upward, able to rotate to left and right by between 90
degrees.
d) The gap between the compressor’s foot and the fixing foot of the supporting frame shall be
below 0.1mm.

3.6.2. Installation of Evaporator

a) The evaporator should be moved slightly to prevent damaging the paint on the surface.
b) It is required to consider preventing condensed water, wind leakage and it should be well
sealed.
c) It should be installed securely with a tightening moment of 20Nm; generally the box is power
negative, so it should be well grounding.
d) When installing, pay attention to keep the inlet and outlet vented to avoid affecting the wind
quantity.

3.6.3. Installation of Condenser

a) If the condenser carries a fan, it is required to pay attention to wind directions at its inlet and
outlet. Generally, wind at the inlet is air outside the vehicle.
b) If the condenser does not carry a fan, that is, when placed in front of the water tank, it should
be unobstructed.
c) Connector of the inlet pipe (the thick pipe) should be on the above to prevent over-high
system pressure, which may affect the refrigerating effect.
d) The condenser should be installed securely without hurt to its wings and the fan. The cable
connector should be well connected.

3.6.4. Installation of Liquid Vessel

The liquid vessel should be installed at a well vented position, placed vertically and its cover
should be opened at final stage of the installation to connect with the pipeline.
Notice: Pay attention to inlet and outlet directions of the liquid vessel. Hose from the
condenser should be connected to inlet of the liquid vessel, which should not be wrongly
connected.

3.6.5. Installation of Refrigerating Pipeline

a) Connector of the pipeline and the O-ring should be coated with cooling oil before installation.
b) First screw tight the nut and then use the wrenches. If the nut cannot be screwed manually or
is not well positioned, it is not allowed to screw it in forcefully. When screwing it tight, it is
required to use two wrenches, with the wrench screwing the nut rotated and the other wrench
keeping unmoved.
c) Tightening moment 3/4 thread 16-18Nm
7/8 thread 16-28Nm
9/16 thread 15-18Nm
d) If necessary, the thread should be added with some thread glue (which cannot enter the
pipeline system).
① Caution: The pipeline should avoid heat source and sharp objects as much as possible.
② When bending radius of the pipeline is larger than 90mm, it is not allowed to have twist.
③ The pipeline should be fastened with pipe clamps at the middle to prevent vibrating
wear.

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3.6.6. Installation of Apparatus Cables

a) The power supply should pay attention to identify voltage required by the air conditioner.
b) The cabling space should avoid heat source and sharp objects.
c) The plug-ins should be connected firmly.

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3.7. Debugging
After the system installation is completed or system repair is finished, it is required to carry out
system debugging (debugging should be implemented by professionals).
Notice:
A． The operation circumstance should be clean and humidity proof. Make sure to prevent
matters such as pollutant and water from entering the loop. Avoid operation in rainy
weather as much as possible.
B． The refrigerating medium should be correspondent. R12 and R134a cannot be mixed.

3.7.1. Vacuum
The purpose of vacuum is to release water inside the system. It is a critical step in repairing the air
conditioner.
Connect vacuum pump, vacuum meter and connection pipe and open the high-low pressure valve.
It is required to vacuum for 15 minutes first so that the vacuum degree is -0.1MPa.

3.7.2. Leakage check:

Shut down the manual valve and pointer of the pressure meter indicates stable which indicates the
system has no leakage. Otherwise, it indicates there is leakage, which should be checked and
repaired. If the pointer keeps unmoved, open the manual valve to continuum vacuuming for 15-20
minutes.
Notice: The time to vacuum should be implemented as required to ensure that water inside
the system is emptied sufficiently. On humid days it is necessary to vacuum repeatedly.

3.7.3. Refilling refrigerating medium:

a) After the work of vacuum is completed, shut down the manual valve. After no leakage is
checked, connect the middle hose with the refrigerating medium tank. (Notice that at this
time valve of the refrigerating medium tank should be opened to release part of the air inside
the pipe at the place where the vacuum meter is connected with the hose)
b) Refilling at high pressure side: Open the high pressure manual valve. The refrigerating
medium shall enter the system from the high pressure side. At this time, value read on the
pressure meter at the low pressure side shall rise slowly till regulated mass is refilled or the
pressure no longer rise.
Notice: At this time it is possible to fill in liquid refrigerating medium reversely. But it is
absolutely not allowed to start the engine to prevent liquid strike.
c) Refilling at low pressure side: when it is unable to refill more at the high pressure side though
the refrigerating medium has not reached the regulated volume, shut off high pressure manual
valve and put the refrigerating medium tank upright (prevent the liquid refrigerating medium
from entering the compressor to cause liquid strike and damage the compressor consequently
when starting the engine). Start the engine and open the air conditioner’s refrigerating system.
Set the wind volume at highest shift, turn on the refrigerating switch. The engine rotates at a
speed of about 1000RPM. Open the low pressure valve to enable the refrigerating medium
gas to enter the system till the refrigerating medium arrives at regulated volume.
Notice:
z During ordinary repair, refilling method for leakage of refrigerating medium adopts
refilling at low pressure side.
z When refilling refrigerating medium into the system, sometimes the refrigerating
quantity may vary due to different length of pipeline. At this time, it is required pay
close attention to observing window of the liquid vessel and refill till no bubble can be
seen in the observing window.
d) After completing the refilling, shut down low pressure manual valve, shut off the
refrigerating medium tank and remove the refilling pipe. Notice that the pipe should be
removed quickly to prevent too much refrigerating medium from flowing out. Refilling
interface of the compressor should be well sealed with the original plastic cover.
Notice:
z It is required to wear gloves when dismantling the pipes to prevent frostbite.

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3.7.4. Table of pressure parameters of the system at different ambient

temperatures

Ambient Value on low pressure meter Value on high pressure meter

Temp.
Refrigerating medium R134a Refrigerating medium R134a
25℃ 0.2MPa±0.02 MPa 1.4MPa±0.2 MPa

30℃ 0.21MPa±0.02 MPa 1.6MPa±0.2 MPa

35℃ 0.23MPa±0.02 MPa 1.8MPa±0.2 MPa

40℃ 0.27MPa±0.02 MPa 2.2MPa±0.2 MPa

Conditions: rotating speed of the compressor is 2000RPM; maximum wind
volume; humidity is 60%

3.8. Maintenance and Keeping

To a great degree, life span of Chuangdao air conditioners for engineering vehicle depends on
correct maintenance and keeping by the user.

3.8.1. Routine Maintenance of the Air Conditioner

a) Check and clean condenser of the air conditioner. The radiating fins should be clean inside
without obstruction inside. It is required to clean with cold water or compressed air instead of
hot water and heated air.
b) Check quantity of refrigerating medium in the refrigerating system, by observing the
observing window of the liquid vessel. Normally there is no bubble in the observing window
and a few bubbles in it when changing rotation speed of the engine.
c) Check tension degree of the compressor’s transmission belt.
d) Check whether outer appearance of the hose is normal and whether all connections are
secure.
e) Check whether cable connections of the refrigerating system are firm and whether there is a
phenomenon of circuit break or short circuit.
Notice:
z No matter whether the air conditioner is used, the pipeline and other devices should be
regularly checked and maintained.
z If the air conditioner is not used for several months, each month it is required to run the
air conditioner for about 10 minutes continually to ensure the system can operate
normally.
z During the winter, the heating system should be added with anti-frost liquid to prevent
the core from frost crack.

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3.8.2. Preventive Keeping of Air Conditioner

Items and Period of Regular Maintenance of the Air Conditioning System

Maintenance cycle
System parts Maintenance
Monthly Biannually Annually
Refrigerating Check wear and completeness
※
pipe of the pipeline
Check whether there is
Connections leakage (there is usually oil ※
stain at where leaks)
Condenser Check the radiating fins ※

Refrigerating Liquid vessel Check its use or replace ※

system
Check the refrigerating
Refrigerating
medium through the ※
medium
observing window
Check fixed installation of the
Body of the air
main body (there should be ※
conditioner
nothing loosened)
Check sealing of the vehicle
System sealing ※
body and the air conditioner
Electromagnetic
Check pick-up of the clutch ※
clutch
Check belt completeness and
Belt ※
tension degree
Compressor
Fixing support Check the fixed installation ※
Check whether there is
Operation of
abnormality in operation ※
the compressor
sound
Check cable wear and
Cables ※
completeness
Circuit Check contact and
system Plug-ins ※
completeness
Control Check contact and
※
switches completeness

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3.9. Removal of common faults

Table of Common Faults Removal
Fault Phenomena Cause Measures
1. Water inside the system, causing the Replace liquid vessel
expansion valve blocked by ice Re-vacuum to refill
Refrigerate at

The refrigerating
intervals

2. Temperature controller not adjusted medium and adjust

system is turned on
3. The grounding is not good Check and repair
or off abnormally.
4. The control switch contacts badly Check and repair
5. The relay contacts badly Check and repair
1. Belt is too loose Adjust or replace
2. Support frame of the compressor is Adjust
Noise increased

The system loosened

produces abnormal 3. Wind wheel of the evaporator’s fan Adjust
sound. get loosened
4. The clutch slips Repair or replace
5. Wear inside the compressor Repair or replace
1. Valve is not opened Open the valve
insufficiently

2. The pipeline is blocked. Repair

Heating

The hot wind is not

3. Temperature of the heating medium is Open after the
hot.
not high temperature rises
4. Leakage in the pipeline Repair or replace
Replace
1. The compressor’s clutch
Repair or replace
a) The coil circuit is broken or short
Check and connect
b) The clutch slips
Replace
The evaporator’s 2. The cable is disconnected
Check the leakage and
fan is normal but 3. The belt is broken
refill
the compressor does 4. Action of the pressure switch
Properly release
not work a) Too much refrigerating medium leaks
Replace the part
b) Refill too much refrigerating medium
damaged
c) The switch is damaged
Not refrigerate

Replace the part

5. Temperature controller is damaged
damaged
Check leakage &
The evaporator’s refill
1. Too much refrigerating medium leaks
fan is normal and
2. Refill too much refrigerating medium
the compressor Properly release
3. The compressor is broken
works
Repair or replace

The evaporator’s 1. Fault with incoming power supply

Check and repair
fan does not rotate a) Grounding cable contacts badly
Check and replace
and the compressor b) The fuse is broken
Check and replace
does not work c) The power supply switch is damaged

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The evaporator’s 1. The fan is damaged Replace

fan does not rotate 2. The fuse is broken Replace
but the compressor 3. Wind shift switch is broken Replace
works 4. Speed adjusting resistance is broken Replace

Adjust
1. The belt is loose
Check leakage &
2. There is leakage, and the refrigerating
refill
medium is not enough
3. High pressure value is high and low
pressure value is high
a) Radiating fins of the condenser is
Clean
dirty and blocked
Repair or replace
b) Fan of the condenser stops
Properly release
c) Refill too much refrigerating medium
Check leakage,
d) Air in the system, the pressure meter
release & refill
vibrates
Adjust or replace
e) The expansion valve is opened too
largely
4. High pressure value is high and low
pressure value is low
Refrigerating effect is not good

The evaporator’s a) The expansion valve is dirty and

Clean or replace
fan is normal blocked
Replace
b) The liquid vessel is dirty and blocked
Repair or replace
c) High pressure pipeline is blocked
5. High pressure value is low and low
pressure value is low
a) There is leakage, and the refrigerating
Check leakage &
medium is not enough
refill
b) The expansion valve is opened too
Adjust or replace
small
Repair or replace
c) Low pressure pipeline is blocked
Repair or replace
d) The evaporator is blocked
6. High pressure value is low and low
pressure value is high
a) Fault with the compressor
7. Valve of the refrigerating system is
Repair or replace
opened
Repair or turn off
Remove the
Wind of the 1. The inlet and outlet are blocked obstruction
evaporator is not 2. The wind exhaust is blocked Remove the
enough 3. The evaporator is frosted. obstruction
Repair

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