ep ICE301B, Service Manual

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28
REV. 09/2020
29
REV. 09/2020
TROUBLESHOOTING TROUBLESHOOTING
3 3
Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Gear Pump
Fault
1. Gear pump does not
absorb oil or of small
flow
• Insufficient hydraulic oil;
• Pump body defects;
• Poor sealing with leakage;
• Oil filter clogging;
• Oil temperature is too high.
1. Replace the hydraulic oil;
2. Replace the gear pump;
3. Replace the sealing;
4. Clean or replace the oil filter;
5. Cool down the hydraulic oil.
2. Insufficient gear
pump output
pressure
• Pump body defects;
• Pump body with cracks or leaks;
• Impurities in the pump, oil filter
clogging;
• Low viscosity of hydraulic oil;
• Oil temperature is too high.
1. Replace the gear pump;
2. Replace the gear pump;
3. Replace the hydraulic oil and
clean the gear pump;
4. Replace the hydraulic oil with
higher viscosity;
5. Cool down the hydraulic oil
3. Too much vibration
and noise
• Pump body defects;
• Gear pump inlet tubing diameteris
too small;
• Oil filter clogging, or motorspeed
is too high;
• Motor and oil pump shaft
misalignment.
1. Replace the gear pump;
2. Replace the inlet tubing;
3. Clean the oil filter, adjust the
motorspeed to a lower value;
4. Remove and reinstall the
motor.
4. Oil leaks
• Pump body defects;
• Seal skeleton spring off;
• Shaft sealing surface scratche
1. Replace the gear pump;
2. Remove and reinstall the seal
skeleton;
3. Replace the shaft sealing.
5. Pump is not
functioning properly
or blocked
• Pump body defects;
• Poor alignment of pump
andmotor coupling;
• Impurities in the pump.
1. Replace the gear pump;
2. Remove and reinstall the gear
pump;
3. Remove and clean the gear
pump.
Redirector
Fault
1. Oil leaks
• Redirector defects;
• Poor sealing with leakage;
1. Replace the redirector;
2. Remove and reinstall the
redirector, if neccessary
replace the redirector.
2. Redirector is not
functioning properly
or noise
• Redirector defects;
• Insufficient oil;
• There is air in the oil;
• High viscosity of oil.
1. Replace the redirector;
2. Add the hydraulic oil;
3. Discharge the air in the oil;
4. Replace the hydraulic oil with
lower viscosity;
* Carry out trouble shooting in accordance with the order listed in the table, it can help you quickly
identify problems and resolve accordingly.
Table 3.1 Troubleshooting of Common Faults (continued)
Fault Fault Symptom Probable Causes Troubleshooting
Lifting System
Failure
1. Lift roller does not
rotate
• Grease stiffened or dirt
accumulated on lift roller and
mast sliding surfaces.
• Improperly adjusted lift roller.
1. Clean and lubricate lift rollers.
2. Adjust.
2. Excessive mast
noise
• Insufficient lubrication.
• Improperly adjusted lift roller,
side roller and back-up metal.
• Rubber pad on lower of outer
mast is useless for container fork
lift truck.
1. Lubricate.
2. Adjust.
3. By adjusting shims and
rubber pad, piston rod is in
touch with bottom of cylinder
body after inner mast is in
touch with rubber pad.
3. Insufficient lift power
or no lift movement.
• Excessive wear occurs between
the oil pump body and gears,
causing too much clearance.
• The lifting jack piston Yx-ring has
worn, resulting in excessive inner
leaks.
• Springs of the multiple control
valve and its relief valve are
inoperative oil leaks.
• Excessive wear occurs of the
hydraulic control valve, resulting
in excessive oil leaks.
• Oil leaks occur between the
hydraulic control valve sections.
• Leakage occur in the hydraulic
pipe.
• The hydraulic oil temperature is
too high. Oil viscosity is too low
and the rate is insufficient.
1. Replace the worn parts or the
oil pump.
2. Replace Yx-ring.
3. Replace.
4. Replace.
5. Dismantle for regrinding the
joint surfaces and reassemble
the valve.
6. Tighten the joint nuts and
inspect the seal for damage.
7. Change the wrong hydraulic
oil or stop operation for
reducing the oil temperature.
Find out the reasons for high
oil temperature and eliminate
the trouble.
Manual Valve
Fault
1. The vehicle
cannot perform the
hydraulic control
instructions
• Valve failure;
• Valve seat blocked by large
impurities;
• External leakage:
i. sealing damaged;
ii. poor threaded connection;
iii. valve body defects;
• High viscosity of hydraulic oil;
• High frequency of use, service
life has expired already.
1. Replace the manual valve;
2. Remove and clean the valve
seat;
3. Replace the sealing;
4. Replace the screwed joint;
5. Replace the manual valve;
6. Replace the hydraulic oil with
lower viscosity;
7. Replace the manual valve;
2. Slow pace of
actuator
• Overflow valve in the connection
block started;
• Valve seat leakage;
• Valve rod cannot push/pull to
bottom; the channel cannot be
fully opened;
• High viscosity of hydraulic oil;
• High frequency of use, service
life has expired already.
1. Restart the truck;
2. Replace the valve seat;
3. Clean the valve rod, if necc-
essary replace the valve;
4. Replace the hydraulic oil with
lower viscosity;
5. Replace the manual valve;