Troubleshooting the Reach Stacker Medium Level

1. Troubleshooting the Reach StackerMedium Level Presented by Port Machinery Business Unit

2. Table of Contents Chapter 1: Mechanical System Chapter 2: Electrical System Chapter 3: Hydraulic System Chapter 4: Power System Presented by Port Machinery Business Unit

3. Mechanical Hydraulic Power Electrical Troubleshooting the Mechanical System 1. The open end thimble of front axle is worn Failure: the fixing bolts of front axle tyres are ruptured; the tyre bolts are bent and deformed; the air valve of tyre is ruptured; the protective block of air valve is worn;the open end thimble in wheel rim is worn and deformed; pressure plate of tyre is worn; outer shell of front axle hub reducer is worn.

4. Mechanical Hydraulic Power Electrical Cause: 1. The open end thimble engages with the air valve stopper; 2. The tightening torque of bolts are not enough; 3. The bolt is not tightened symmetrically in accordance with the diagnol; 4. The bolt is not tightened for the second and third time. Methods: 1. Check the engagement between the open end thimble and the air valve stopper; 2. Tighten the bolt symmetrically in accordance with the diagnol; 3. Tighten the bolt with the specific torque (450Nm); 4. Check the tightness of bolt respectively after working 5 hours and 50 hours.

5. Mechanical Hydraulic Power Electrical 2. Malfunction of spreader reducer Failure: 1. Oil leakage of spreader reducer; 2. Ruptured bolt; 3. The gear of spreader reducer is fallen; 4. Broken shaft of reducer. Causes: 1. The spring design of reducer is not reasonable; 2. The rigidness of bolt is not strong enough; 3. The locating bolt of gear shaft is designed unreasonably. Only one bolt is used; 4. The bolt is not tightened for the second and third time.

6. Mechanical Hydraulic Power Electrical • Methods: • Replace the seal and clip. Add the retainer rings; • Replace with the bolt of 10.9 rigidness.

7. Mechanical Hydraulic Power Electrical 3. Apply three locating bolts of gear shaft on the spreader reducer; 4. Replace the reducer.

8. Mechanical Hydraulic Power Electrical 3. The rolling bearing of drive axle is damaged • Failure: • One side of the wheel hub makes some noise when the reach stacker is travelling. • Causes: • The brake sheet is damaged; • The rolling bearing is damaged; • The gear of hub reducer is damaged. • Methods: • Remove the hub mechanism of drive axle. It is found that the rolling bearing is damaged and the brake sheet is normal.

9. Mechanical Hydraulic Power Electrical Troubleshooting the Electrical System 1. Malfunction of CAN resistor Failure： 1. The reach stacker cannot speed up. No alarm message on the display; 2. No display of all the engine information. The accelerator pedal is ineffective; 3. No length and angle signal. Causes: 1. Failure of engine controller program; 2. The main controller is damaged; 3. The interference of other signals, resulting in the wrong signal of engine; 4. CAN BUS malfunction Methods: Check the CAN BUS of engine to confirm if the circuit is normal. Test the resistor between CANH and CANL with the universal meter. The resistance is not 60 ohm. Find out the damaged resistor and replace it with a new one.

10. Mechanical Hydraulic Power Electrical 2. Malfunction of 5V circuit board • Failure: • There is alarm of high gearbox temperature. Check the alarm message on the display and the gearbox temperature is found to be 136-147°; • The idle speed of engine is not stable. The rotate speed is 700-1250. Step on the accelerator pedal, but the foot-Throttle value and engine speed on display have no changes; • Boom lifts and extends automatically; • Check the analogy output value of joystick on the display. The Analn-joy-FB and Analn-joy-LR values alter between 100 and 147.

11. Mechanical Hydraulic Power Electrical • Causes: • It is judged by the phenomenon that numerous related failures occurred at the same time. By analyzing the electrical diagrams, it is found that gearbox temperature sensor, accelerator pedal and joystick commonly used the switching plate assembly SYTB-1G 5V circuit board. • Test the circuit board with the universal meter. Its output voltage is measured to be only 0.25V.

12. Mechanical Hydraulic Power Electrical Methods: Replace the switching board assemblySYTB-1G (part No.: A810299000548 ), and the failure of high gearbox temperature alarm as well as the joystick failure are eliminated. But the throttle is still in malfunction. There is no response of engine when stepping on the accelerator pedal. It is maybe the problem of wiring. But the wire connection is rechecked to be normal. Retest the output voltage of 5V circuit board (loaded) with the universal meter, and the voltage is turned out to be only 0.25V. The 5V circuit board is very hot. Pull out the power supply line of accelerator pedal, and the output voltage is tested to be 4.99V. It means that the 5V circuit board is normal and there is failure of the accelerator pedal. The machine and heat emission of 5V circuit board become normal after replacing the accelerator pedal.

13. Mechanical Hydraulic Power Electrical 3. Basic boom cannot be retracted and lowered Failure: The lifting and extension movements of boom are normal, while the boom cannot be lowered and retracted. However, all the movements become normal after the safety bypass is opened. The boom length is displayed as 8.60M and the boom angle is displayed as 0.0 all the time. The reach stacker cannot retract and lower the basic boom. • Causes: • The malfunction of joystick potentiometer; • The lowering / retracting solenoid valve is damaged or clogged; • The malfunction of relay KA13; • The malfunction of length & angle sensor and its related circuits; • The malfunction of CAN-bus.

14. Mechanical Hydraulic Power Electrical • Methods: • Check the resistance and circuit of CAN wire. • Check the length & angle sensor. The sensor is checked to be damaged and it fails to communicate with controller normally. Replace the sensor to recover.

15. Mechanical Hydraulic Power Electrical 4. The boom lowers automatically Failure: The boom lowers automatically after the machine is electrified. • Causes: • Solenoid valve 6 is clogged; • The overflow valve on the pitching valve block is damaged; • The joystick sends the wrong lowering signal when the boom is not operated to lower; • The malfunction of relay KA13.

16. Mechanical Hydraulic Power Electrical • Methods: • The boom is normal when the machine is not electrified. It can be judged that there is failure in the circuit. • Observe the output of simulation amount on the display without operating the joystick. The output is normal. Thus there is no failure in the joystick. • Open the electric control cabinet and find the corresponding relay KA13.Pull out the relay. It is discovered that the armature sheet of relay is closed all the time. • Replace with a new relay. The failure is eliminated.

17. Mechanical Hydraulic Power Electrical 5. Malfunction of gear circuit Failure: The actual travelling speed differs a lot from the displayed speed on screen. Besides, it is hard to start the machine. • Causes: • The joystick signal is abnormal. The controller does not send the switch output value to gear 1 and gear 2 solenoid valves, thus the solenoid valves do not work; • The coils of gear 1 / 2 solenoid valves are damaged or their valve cores are clogged; • The gearbox oil pressure is not big enough. There is failure of the gearbox hydraulic control valve. No oil is pressed into the gear 1 and gear 2 pistons. The friction sheets are seriously worn, thus causing their slippery.

18. Mechanical Hydraulic Power Electrical • Methods: • The gearbox oil pressure is displayed to be normal. It proves that the difficulty to start has nothing to do with oil pressure; • Enter the Digital Input and Output Menus to check the switch situation. The result is normal; • Check the voltage of X1018 / X1019 (gear 1 / 2 solenoid valves) with the universal meter. The voltage is normal. Remove the plug of gear 1 solenoid valve to check the wire between solenoid valve and controller. Normal; • Check the positive and negative poles of gear 2 solenoid valve plug and there is voltage. But the gear 2 valve does not work. The coil is checked to be normal. Test the gear 2 power supply again with the 5W bulb. The bulb does not light on. Check X1019 at the terminal end of electrical control cabinet. The bulb is still not light. There can come to a conclusion that the output of controller is abnormal. • Replace the controller, and the gears become normal.

19. Mechanical Hydraulic Power Electrical Troubleshooting the Hydraulic System 1. Low brake pressure alarm Failure : The system alarms for low brake pressure. Parking brake is not functioning. Brake oil flows into hydraulic oil tank. Causes: The oil seal of gear pump is damaged. The broken pieces of oil seal pass through the brake valve and thus damage the brake valve core. Then the brake oil flows through plunger pump into hydraulic oil tank.

20. Mechanical Hydraulic Power Electrical • Methods: • Open the ball valve. There is no pressure in accumulator; Remove the oil inlet pipe and start the engine. The oil volume of outlet pipe is very small; Remove the oil pipe from brake valve to radiator and start the engine. The oil volume of this pipe is very small; Therefore, it is judged that the gear pump is damaged. • Replace the gear pump and brake oil. The brake oil stops flowing into hydraulic oil tank. However, the system still alarms for low brake pressure. Remove the oil inlet pipe and start the engine. The oil volume of outlet pipe is very small; Remove the oil pipe from brake valve to radiator and start the engine. The oil volume of this pipe is very large; Therefore, it is judged that there is malfunction of brake valve. • Dismount the brake valve and clean it. There are broken pieces of gear pump. Dismount the prefill valve core. It is found that the valve core is damaged. • Replace the gear pump and brake valve. Clean the brake oil tank.

21. Mechanical Hydraulic Power Electrical • 2. The telescopic movements of boom are ineffective sometimes • Failure: The telescopic movements of boom are ineffective sometimes. • Causes: The impurities in hydraulic system damage the main valve core. • Methods: • Check the circuit: check whether the output of joystick is normal, if the electrification of electric proportional valve is normal, if the electrification of solenoid valve on telescopic valve block is normal, and if there is electrical protection. • Check the hydraulic system: check if the pilot pressure is normal, if the filter screen of electric proportional valve is clogged, if the output of oil pump is normal, if the valve core on telescopic valve block is clogged, if the main valve core is clogged, and if the oil seal of telescopic cylinder is damaged. • Dismount the valve core and grind it with sand paper until the valve core can slide freely in the valve body. Valve core is worn. There is groove. Clogged main valve core

22. Mechanical Hydraulic Power Electrical 3. When operating the retraction movement, the boom inversely extends itself Failure: When the boom is placed horizontally, operating the joystick to retract boom without stepping on the accelerator pedal cannot move the boom. If the accelerator pedal is stepped again, the boom would be extended instead of being retracted. Causes: 1. The malfunction of joystick; 2. The malfunction of controller; 3. The differential solenoid valve 4 is not locked completely, resulting in the oil leakage; 4. The hydraulic valve cores related to telescopic movements are clogged; 5. The telescopic cylinder is leaking.

23. Mechanical Hydraulic Power Electrical • Methods: • Start from checking the electrical and hydraulic systems. Then check if it is the malfunction of telescopic cylinder itself. • Check the input and output simulation value on display. There are statistic directives about boom retraction and extension shown on the display. Therefore, the joystick is not damaged. • Check the balance valve 6, differential solenoid valve 4, 5 on telescopic valve block and proportional solenoid valve on main valve. Check if the main valve is clogged. No failures discovered. • After extending the boom completely, pull out the plug of differential solenoid valve 4, 5 and remove the oil pipe B1. Operate the extension movement of boom again. The mouth B1 is leaking oil seriously then. So dismount the telescopic cylinder to check. • It is discovered that the telescopic cylinder rod head is cracked. Reinstall it after welding its head.

24. Mechanical Hydraulic Power Electrical 4. The boom movements are slow. It is hard to turn the steering wheel. Failure:The boom movements are slow. It is hard to turn the steering wheel. • Causes: • The malfunction of oil pump; • The oil suction flange is cracked, causing the air into the oil circuit; • The damping hole of flow amplifier is clogged; • Inner leakage of steering cylinder; • The malfunction of pilot reducing valve and overflow valve.

25. Mechanical Hydraulic Power Electrical • Methods: • Measure the pressure of oil pump. Normal pressure. • Remove the oil suction flange. No crack is found. • Remove the oil pipe of flow amplifier. Take the damping hole out and check it. No blockage. • The idle pressure displayed on the screen is less than 3.0MPa. Abnormal pressure. Test the max. pressure of steering cylinder and the value is about18Mpa. Normal pressure. Besides, the pilot pressure is tested to be under 2.0MPa, which is 2.5MPalower than the normal pressure. • Adjust the overflow valve, pressure-reducing valve and one-way throttle valve on the pilot valve block. No obvious effects. Remove the overflow valve and the valve core is found to be clogged. • Clean the valve core. The machine becomes normal. Clogged overflow valve Cracked inlet pipe of pump

26. Mechanical Hydraulic Power Electrical • 5. The spreader movements are slow • Failure: Abnormal movements of spreader. The speed of rotation and side-shifting are slow. • Causes: • The malfunction of piston pump, causing insufficient output flow; • The malfunction of pressure-reducing valve on the spreader multi-channel block , causing insufficient oil-supply pressure; • The malfunction of shuttle valve on the pilot valve block , causing abnormal feedback oil pressure; • Oil leakage of spreader feedback overflow valve on the pilot valve block; • The spreader oil supply valve is in malfunction or not electrified. The malfunction of shuttle valve on the spreader oil supply valve group.

27. Mechanical Hydraulic Power Electrical • Methods: • Operate the spreader and find out that all its movements are slow. Observe the system pressure on the display. When the spreader is operating, system pressure is only approx. 4.8MPa. Therefore, it can be concluded that the spreader movement solenoid valves are normal. • Operate the spreader and boom at the same time. It is found that the spreader speed and system pressure are increased. It is judged that there is no failure of pump, pressure-reducing valve and overflow valve on the spreader multi-channel block. • It is unable to move the cab and counterweight. And the system pressure cannot raise up. The steering movement is normal. Thus it proves that there is malfunction of feedback oil supply system. • Feedback pressurized oils from the general oil supply valve and the multi-channel valve control both piston pump, while the steering mechanism only controls the piston pump on double pump. So there is no failure of the shuttle valve on the pilot valve block; • Check the general oil supply valve. Its electrification situation is normal. The spreader feedback overflow valve is checked to be clogged by dirt. It still cannot be used after being cleaned. • For the temporary solution, move the pilot overflow valve to this position. Readjust the spreader feedback overflow pressure to 16MPa, and the Failure is eliminated. After the spare part is arrived, replace it with the new pilot overflow valve.

28. Mechanical Hydraulic Power Electrical • 6. The pitching cylinder cannot hold the pressure. • Failure: the pitching cylinder cannot hold the pressure. The basic boom would automatically lower. • Causes: • Inner leakage of lowering solenoid valve; • Failure of differential solenoid valve or other valves; • Inner leakage due to cylinder piston seal; • Signal wiring failure or joystick malfunction. The lowering signal is wrongly sent. The contact is burnt. Methods: Replace the lowering solenoid valve.

29. Mechanical Hydraulic Power Electrical • 7. The brake is not sensitive • Failure:The brake is not sensitive • Causes: • Brake valve group failure • Brake valve failure • Accumulator failure • Brake mechanism failure • Methods： • Check if the brake valve is normal; • Adjust the travel of brake valve; • There is no pressure gauge for measurement of nitrogen pressure on site. There is no brake pressure when stepping on the brake pedal for the second time. It can be primarily judged that the accumulator nitrogen is not enough. Fill some nitrogen, and the machine becomes normal.

30. Mechanical Hydraulic Power Electrical Troubleshooting the Power System 1. VOLVO pump nozzle malfunction Failure： 1. Engine malfunction of reach stacker with the alarm of SPN651 code; 2. Abnormal noise of engine; instable idle speed between 500 and 700 rpm; 3. When the machine is operating, engine emits black smoke and is powerless. Besides, engine cannot supply oil automatically and drastically lowers the rotate speed even stops when the machine is doing loaded movement such as boom pitching. Cause： Search for the meaning of SPN651code——The failure of nozzle cylinder 1

31. Mechanical Hydraulic Power Electrical • Methods: • Check if the oil nozzle is electrified and works normally. The result is that cylinders 4/5/6 work normally while cylinders 1/2/3 stop working. So respectively remove the cylinder 1/2/3 pump nozzle coil connecting wire to test their control wire. When removing the cylinder 3 pump nozzle coil connecting wire, cylinder 1/2 pump nozzles recover electrified. Thus it can be concluded that the cylinder 3 pump nozzle inner coil gets short circuit. • Remove the rocker arm. • Replace the oil nozzle.

32. Mechanical Hydraulic Power Electrical 一、机械 1、2、3缸共用一根信号线 4、5、6缸共用一根信号线 Cause analysis： When the cylinder 3 pump nozzle coil is short circuit, cylinders 1/2/3 will not be electrified because they use the same wire. Engine controller starts the protection program, and cylinders 1/2/3 stop working.

33. Mechanical Hydraulic Power Electrical • 1. Reversing gear and gear 4 are ineffective • Failure: • When turning the gear selector to gear 4, the reach stacker cannot move anymore (or cannot start up). • The reversing gear and forward gear 2 are ineffective. • Causes: • Lack of transmission oil; • Circuit failure; • The solenoid valve core on the gear valve block is clogged; • The failure of controller program; • Gear 4 or reversing gear clutches are burnt, or other abnormalities; • Oil-supply pipeline of gearbox has leakage, damaged clutch seal, pressure leakage; • The reversing gear shaft is broken.

34. Mechanical Hydraulic Power Electrical • Methods: • Check the electrical components and circuits; • Test related gear clutch pressure. It is found out that all the gear pressure are insufficient; • Drain out the oil to check the gearbox pre-filter. Lots of metal scraps are discovered in the gearbox with ineffective gear 4. Similarly, a few metal scraps are left in the gearbox with ineffective gear 2.

35. Mechanical Hydraulic Power Electrical Methods: 4. Remove the gearbox. It is discovered that the clutch of gearbox with ineffective gear 4 is burnt; 5. The gearbox with ineffective reversing gear and gear 2 has a broken reversing gear shaft; 6. Replace the related damaged parts. Test and run the machine again. The mobile balance of transmission shaft in the reach stacker with broken shaft is found to be abnormal, resulting in vibration and resonance which cause the damaged reversing shaft.

36. Quality Changes the World! Thank you! Presented by Port Machinery Business Unit