Chapter Ⅶ

APPENDIX
 Table of Contents
□1A Operation Manual for ROBWAY Load Moment Limiter RCI1550..................................................................6

1.1 Instruction for Main Interface.......................................................................................................................6

1.2 Operation Instructions ..................................................................................................................................8
1.2.1 Startup & Operating Condition Modifying........................................................................................8
1.2.2 Calculating of Empty Hook ...............................................................................................................8
1.2.3 Time & Date Setting ..........................................................................................................................9
1.3 Set Additional Counterweight Operating Condition through Password .....................................................10
1.4 Others .........................................................................................................................................................11

□1B Operation Manual for Robway Load Moment Limiter RCI8200 ...................................................................12

1.1 Instructions for Keys and Operating Interfaces ..........................................................................................12

1.2 Operating Instruction..................................................................................................................................16
1.2.1 Modifying Operating Condition ......................................................................................................16
1.2.2 Empty Hook Calibration..................................................................................................................20
1.2.3 Date & Time Setting ........................................................................................................................24
1.3 Set Additional Counterweight Operating Condition through Password .....................................................24
1.4 Others .........................................................................................................................................................25

□1C Operation Manual for UNIQUE Load Moment Limiter MLS2000................................................................26

1.1 Instruction for Operating Interface .............................................................................................................26

1）Pre-warning Signal Lamp ...................................................................................................................26
2）Overload Signal Lamp........................................................................................................................26
3）Bar Code (Percentage of Moment) .....................................................................................................27
4) Pushbuttons ..........................................................................................................................................27
5）LCD (Liquid Crystal Display) ............................................................................................................27
6）Overload Release Switch....................................................................................................................28
7）Buzzer.................................................................................................................................................28
8）Flip Switch for Operating Condition Selection ..................................................................................29
9）Flip Switch for Boom Length Selection .............................................................................................29
1.2 Operation & Commissioning......................................................................................................................31
1）System Setting ....................................................................................................................................31
2) Empty Hook Calibration ......................................................................................................................31
3) Time Modifying....................................................................................................................................32
1.3 Instruction for Setting Additional Counterweight ......................................................................................32

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 1.4 Others .........................................................................................................................................................32

□2A Operation Instructions for Display of HL-LCD064(C) ..................................................................................33

2.1 Startup Interface .........................................................................................................................................33

2.2 Main Interface Introduction........................................................................................................................33
2.2.1 Interface Logo..................................................................................................................................34
2.2.2 Oil Content Indicating .....................................................................................................................34
2.2.3 Voltage Indicating............................................................................................................................34
2.2.4 Working Hours of Engine ................................................................................................................35
2.2.5 Engine Rotating Speed Indicating ...................................................................................................35
2.2.6 Machine Oil Pressure Indicating .....................................................................................................35
2.2.7 Water Temperature Indicating..........................................................................................................35
2.2.8 Servo Pressure of Hydraulic System ...............................................................................................35
2.2.9 Hydraulic Oil Temperature Indicating .............................................................................................35
2.2.10 Relative Position of Superstructure & Chassis ..............................................................................36
2.2.11 Level Indicating .............................................................................................................................36
2.2.12 Air speed Indicating.......................................................................................................................36
2.2.13 Lockup Indicating..........................................................................................................................36
2.2.14 Lockup & Unlock of Slewing........................................................................................................36
2.2.15 Lockup & Unlock of Main Boom..................................................................................................36
2.2.16 Lockup of Free Fall .......................................................................................................................37
2.2.17 Mode Indicating.............................................................................................................................37
2.2.18 Instructions on Handle Pushbuttons ..............................................................................................37
2.2.19 Total Unload State Indicating ........................................................................................................37
2.2.20 Emergency Stop.............................................................................................................................38
2.2.21 Electric-control Engine Fault Alarm Indicating.............................................................................38
2.2.22 System Fault Alarm Indicating ......................................................................................................38
2.3 Interface Setting..........................................................................................................................................38
2.4 System Information Inquire........................................................................................................................38
2.5 Auxiliary Functions Interface .....................................................................................................................39
2.6 Inquire Interface of Controller & Electric Signal .......................................................................................42
2.6.1 Main Controller U2 I/O Status Inquire ............................................................................................42
2.6.2 Controller U1（HL-MC-A）I/O Status Inquire .............................................................................44
2.6.3 Controller U3（HL-MC-B）I/O Status Inquire..............................................................................44
2.7 Fault Inquire Interface ................................................................................................................................45

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□2B Instruction on Displayer..................................................................................................................................51

2.1 Start-up interface ........................................................................................................................................51

2.2 Engine rotation speed .................................................................................................................................51
2.3 Warning message check-up ........................................................................................................................52
2.4 Warning message and description...............................................................................................................53
2.5 History ........................................................................................................................................................54
2.6 Track Using Information ............................................................................................................................54
2.7 Air speed.....................................................................................................................................................54
2.8 Switch in/out setup .....................................................................................................................................55

3 Use, Maintenance and Keeping of Air Conditioner...............................................................................................56

3.1 Overview ....................................................................................................................................................56

3.2 Technical Parameters..................................................................................................................................56
3.3 System Composition...................................................................................................................................56
3.4 Working Principle ......................................................................................................................................58
3.4.1 Refrigeration System .......................................................................................................................58
3.4.2 Heating System (Optional) ..............................................................................................................59
3.4.3 Electric Schematic Diagram ............................................................................................................60
3.4.4 System Auto-control ........................................................................................................................62
3.5. Operation Instruction of Digital Air Conditioner Controller.....................................................................62
3.5.1 Panel Instruction ..............................................................................................................................62
3.5.2 Operation Instruction.......................................................................................................................63
3.6. Assembly ...................................................................................................................................................64
3.6.1. Assembly of Compressor................................................................................................................64
3.6.2. Assembly of Evaporator .................................................................................................................64
3.6.3. Assembly of Condenser ..................................................................................................................65
3.6.4. Assembly of Liquid Vessel .............................................................................................................65
3.6.5. Assembly of Refrigerating Pipeline................................................................................................65
3.6.6.Assembly of Apparatus Cables........................................................................................................67
3.7. Commissioning..........................................................................................................................................68
3.7.1. Vacuum ...........................................................................................................................................68
3.7.2. Leakage check ................................................................................................................................68
3.7.3. Refilling refrigerating medium .......................................................................................................68
3.7.4. Table of pressure parameters of the system at different ambient temperatures ..............................70
3.8. Maintenance and Keeping .........................................................................................................................70

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 3.8.1. Routine Maintenance of the Air Conditioner..................................................................................70
3.8.2. Regular Keeping of Air Conditioner...............................................................................................72
3.9. Removal of Common Faults......................................................................................................................73

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

□1A Operation Manual for ROBWAY Load Moment Limiter RCI1550

This manual is applicable only for SCC series cranes equipped with ROBWAY load moment limiter,
following is the Operating Interface:

1 2 3 4 5 6

10

14 11

12
13

1.1 Instruction for Main Interface

1) Instruction of Indicators and Buttons

1、“KEY” indicates limiting release; 13、“×”indicates canceling;
2、“HORN” indicates sound alarm; 14、“▲”indicates ACK Key;
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;
7、“HOOK” indicates the switching buttons of main & auxiliary hook;
8、“T” indicates tare weight of hook
9、“R, F1, F2, F3” are keys of special functions;
10、“▲”indicates menu key;
11、“√”indicates confirming;

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

12、digit key；
2) Descriptions of Operating Interface

1 2

4
7

6 5

1、“Green-Yellow-Red Rectangular Bar” indicates percentage of rated load.

2、Current operating condition displaying area：“B.len” is length of main boom; “J.len” is length of fly jib，
“Duty” is operating condition ，“Winch 1”is main hook，“Winch 2” is auxiliary hook.
3、“main load” is current workload;
4、“SWL” is rated load;
5、Information displayed in this area (if any) indicates the limiting release key on the load moment limiter is
open;
6、radius3.1 indicates operating scope;
7、angle45.6 indicates angle of main boom；

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

1.2 Operation Instructions

1.2.1 Startup & Operating Condition Modifying

1. After machine startup, the scream displays “Communication connecting, please wait”, which may last a few
seconds.
2. The information interface with certain items of Edition NO., chip NO. etc. will be displayed automatically. Note
down the chip no. #, find “press ok” in the last line (press the “√”key).
3. When entering the interface of Operating Condition Modifying, the items of Duty, WINCH, BOOM LENGTH,
JIB LENGTH, JIB-ANGLE etc. will be displayed. If any modification is needed, press the canceling key of
“×”, and enter the required Operating Condition no. # via digit key or “UP” and “Down” keys. Then press
the confirming button of “√” to finish the modification.
4. After finishing Operating Condition modification, the “Main Falls” interface for modifying the number of main
hook ropes comes out. Press the button of“×” to implement modification. Enter the required number of main
falls; and press the “√” key to finish the operation.
5. After modifying the number of the main falls, the interface of “Aux Falls” comes out for modifying the number
of auxiliary hook wire ropes. Press the “×” key to implement modification. Enter the required number of
main falls; and press the “√” to finish the operation.

1.2.2 Calculating of Empty Hook

1. After changing the Operating Condition, three letters “ACK” will show up above the “▲” key, pressing which
will back to the main Operating Interface.
2. Press the “▲” key with the word “MENU” above at the right bottom to enter a new interface. Press the
“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 digits 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

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Press the “PAGEDOWN” and select the “02Cal.active winch”, press the “√” key.
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 current hook weight at the flashing frame of “Edit” and press the button of “√”, which can increase main
boom angle from 30°to 65°, or decrease from 65°to 30°. After reaching the required angle, press the
confirming button to finish the calculating of empty hook.
5. Press the “canceling” key continuously to back to the working interface, and trail lifting a heavy block to
validate its accuracy.
6. If the accuracy is off required, find 37 with the “DOWNPAGE” key in item 3 and press the button of “√” to
enter, then select “08 Amplified (Amplifier 1)” and press “√”, the following interface will show up:
RAW LO (initial signal value of sensor without load)
RAW HI 980 （signal limit value）
CAL LO 0 （Unload value）
CAL HI （maximum tonnage value of sensor）
Press the “DOWNPAGE” to find the line of “cal hi” and modify the latter figures; if the value displayed is bigger
than the actual tonnage, minish the value; and 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 format (HH:MM:SS); improper input will lead 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.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

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 format (YYYY-MM-DD); improper input will lead to the display of “Error”

1.3 Set Additional Counterweight Operating Condition through Password

a) Setting password
Use F2 on the instrument panel to set password.
If it is required to set a new password, press down key F2 in normal operating interface until “Setting
password…” appears on the screen.
If the time of pressing F2 is less than 5 seconds, password cannot be set and “Operation Aborted!” is shown on the
screen, then it will go back to normal operating interface.
If the time of pressing F2 is more than 5 seconds, password can be set. “Input ID: (8 digits)” will appear on the
screen, cluing to input 8 digits ID numbers. The ID number for all the system is “31315470”. Following
information will appear on the screen after inputting correct ID number:
Input Password: 输入密码
(6 digits). （6 位）

Old: xxxxxx 旧的：xxxxxx

New: 新的：
A new 6 digits password then can be input.
If the password input is non 6 digits or “CANCEL” is pressed to exit halfway, the old password is kept.
Meanwhile “Password not valid!” appears on the screen and it will return to normal operating interface.
If 6 digits valid password is input and key <Ok> is pressed to confirm, then the old password is replaced by the
new one. Meanwhile “Password Setting Ok” is shown on the screen and it will return to normal displaying
interface.

b) Choosing Increase or Cancel Additional Counterweight Operating Condition:

After the password is set, user may choose to set or cancel additional counterweight. Method: Enter main menu by
pressing “menu” key, and choose “F-00 crane configuration change”. Then choose “Extra 17.5+1.5T
Counterweight Charts” and input 6 digits password that has already been set. Then the additional counterweight
operating condition is set.
For cancelling additional counterweight operating condition, just input 6 digits password in the same place again.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

1.4 Others

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

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

□2A 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 the main interface.

Shanghai SANY Science & Technology

Personality decides success

Quality perfects world

Welcome to use crawler crane of SCC series

2.2 Main Interface Introduction

The main interface displays as：

（Main InterfaceⅠ）

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

（Main Interface Ⅱ）
Specifications on information in main interface:

2.2.1 Interface Logo

Main Interface logo shown as:

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

Time Display Area：Displaying 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 percentage is smaller than 10%, the process bar shows in red; when ranging between 10%
and 20%, it shows in yellow; when bigger than 20%, it shows in green.

2.2.3 Voltage Indicating

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

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

123456.5
12.3V h

System Voltage Machine Working Hours

2.2.4 Working Hours of Engine

The machine working hours is the accumulated engine working hour;

2.2.5 Engine Rotating Speed Indicating

2.2.6 Machine Oil Pressure Indicating

20kPa 12.3℃

Machine Oil Pressure Engine Water Temperature

2.2.7 Water Temperature Indicating

2.2.8 Servo Pressure of Hydraulic System

56.6℃

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.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

2.2.10 Relative Position of Superstructure & Chassis

Positive Position Inverse Position

2.2.11 Level Indicating

The level will be indicated by coordinate and rings. When out of the danger angle, the color of
side angle point is orange; the valid inclining angle of alarm signal is -5.0°——+5.0°.

Gradienter Air speed

2.2.12 Air speed Indicating

2.2.13 Lockup Indicating

Indications of lockup and unlock of main & auxiliary winch.

M M

（Main winch unlock） （Main winch lockup）

Aux Aux

（Auxiliary winch unlock） （Auxiliary winch lockup）

2.2.14 Lockup & Unlock of Slewing

Slewing lockup Slewing unlock

2.2.15 Lockup & Unlock of Main Boom

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

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 there is alarming, the logo
will be yellow and glittering.

Free Fall Unlock Free Fall Lockup

2.2.17 Mode Indicating

The installation mode and operating mode are shown at one position with different indications.
The high position of 0X10 B1.1 is the assembly mode and low position indicates working mode.

Assembly Mode Working Mode

2.2.18 Instructions on Handle Pushbuttons

Left Handle

Left Right
pushbutton pushbutton

Down
pushbutton

Left pushbutton： concourses （REXROTH configuration） ，

free slipping（KAWASAKI configuration）
Right pushbutton：Slewing braking
Down pushbutton：Horn

2.2.19 Total Unload State Indicating

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

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

Total Unloading Indicating Emergency Stop

2.2.20 Emergency Stop

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

2.2.21 Electric-control Engine Fault Alarm Indicating

.
Indication of Electric-Engine Fault Indication of System Fault

2.2.22 System Fault Alarm Indicating

It can indicate alarm in case of electric-control system fault.

2.3 Interface Setting

Interface of System Setting (System Setting):

Press F1 at the Main Interface to the password validating interface before entering System Setting
Interface; the password has been set during machine manufacturing and unchangeable.

2.4 System Information Inquire

Press F6 at the Main Interface to enter the System Information Inquire Interface (as shown). Displays
of updated cranes are over SCC-LCD064C V5.0. Information on Controller version and type can also
be found here.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

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

2.5 Auxiliary Functions Interface

1. Press F5 in the Main Interface to enter the Auxiliary Functions Interface (as shown):

? ? ? ? 2008-3-18 8:31:18

? ? ? ? ? ? ? ? :

F1 ? ? ? ?
F2 ? ? ? ?
F3 ? ? ? ? ? ? ? ?
F4
F5
F6 ? ? ? ? ?

? ? ? ? ? ?
? ? ? ? ? ? ? ? ?

F1 F2 F3 F4 F5 F6

2. In Auxiliary Functions Interface, press F1 to enter Oil-fan Controlling Interface (as shown):

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

? ? ? ? 2008-3-18 8:31:18

? ? ? ? ? ? ? ? ? ? ? ? ? ? :

? ? ? ? : ? ?

? ? ? ?
? ?

F1 F2 F3 F4 F5 F6

Oil-fan can be started and shutoff by pressing F6.

3. In Auxiliary Functions Interface, press F2 to enter Time Setting Interface (as shown):

Time Setting 2006-8-18 8:31:1 8

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 decrease the value. After setting the digits, press F6 to confirm,
and then press F1 to back to System Setting Interface.
4. Time Setting
In Auxiliary Functions Interface, press F2 to enter the following interface (as shown):

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

? ? ? ? 2008-3-28 8:31:18

时间设置

-03-28 10：42

调整后必须确认

? ? ? ?

F1 F2 F3 F4 F5 F6

Modification method: press F2, F3 to move the cursor, the digit at where the cursor stops will turn into red,
then press F4, F5 to increase or decrease the value. Following setting the digits, press F6 to confirm and then
press F1 to return to System Setting Interface.
5. Unit Conversion
In Auxiliary Functions Interface, press F4 can achieve converting between the metric system and the
imperial system. When selecting the imperial system, the units in Main Interface show as follows:

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

2.6 Inquire Interface of Controller & Electric Signal

The inquire interface of electric input & output signal of controller & I/O module:
Press F2 at main interface to enter (details refer to Section 2: U1—>>A Module, U2—>>RC6-9
Module, and U3—>>B Module.

2.6.1 Main Controller U2 I/O Status Inquire

The current electric status of input & output of main controller (RC6-9) and the signal definition
is shown in the attached sheet.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Press F6 forward to the next page. Press the function button F1 return to the Main Interface,
press F2 to enter the status inquire of U1 controller, press F6 to enter next page for U2 I/O Status
Inquire。

Press the function button F1 to back to the main interface, press F2 to enter Controller U1 I/O
Status Inquire, press F3 to enter Controller U3 I/O Status Inquire, press F6 to enter previous page of

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Controller U1 I/O Status Inquire。

2.6.2 Controller U1（HL-MC-A）I/O Status Inquire

Controller U1 I/O Status Inquire.

Requirements on interface logo and time display same as previously describe.

F1 button is for return to the Main Interface, F2 button is for entering I/O Status Inquire Interface of RC6-9
Module, and F3 button for entering I/O State Inquire Interface of HL-MC-B Module.

2.6.3 Controller U3（HL-MC-B）I/O Status Inquire

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

I/O status of output module（HL-MC-B）and communicating definition of signals seen shown in the attached
sheet:

Requirements on interface logo and time display same as previously describe.

F1 button is for return to the Main Interface; F2 button is for entering I/O Status Inquire Interface of RC6-9
Module, and F3 button for entering I/O Status Inquire Interface of HL-MC-A Module.

2.7 Fault Inquire Interface

There are four sub-interfaces for fault inquire. Press “Fault Inquire” button and enter the “System Current

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Fault Inquire” interface (as shown); at the Fault Inquire Interface, the horn alarm is mute.

If the crane is equipped with electric-controlling engine, F3 and F4 buttons are visible and functioning;
otherwise they are invisible and void.
System History Fault Inquire
Press “System History Fault Inquire” button in “System Current Fault Inquire” interface or “Engine Current
Fault Inquire” interface or “Engine History Fault Inquire” interface for entering the following interface:

This interface displays the information on history faults, time of fault happening, and time of fault eliminated
or disappearing, in time sequence with the latest listed at the top.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Engine Current Fault Inquire:

Press “Engine Current Fault Inquire” button in “System Current Fault Inquire” interface, or “System History
Fault Inquire” interface or “Engine History Fault Inquire” to enter the following interface:

If the number of engine current fault is 0, the interface displays “No Engine Current Fault”, meanwhile the
Up Shift button and Down Shift button are void.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Engine History Fault Inquire:

Press “Engine History Fault Inquire” button in “System Current Fault Inquire” interface, or “System History
Fault Inquire” interface, or “Engine Current Fault Inquire” to enter the following interface:

Number of engine history fault, serial number, SPN, FMI, OC.

If the number of engine history fault is 0, the interface displays “No Engine History Fault”, meanwhile the
Up Shift button and Down Shift button are void.

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Attached Table：Fault Information Inquire Table

Serial Serial
Code Code
No. Details No. Details
1 0 27 26
Main Winch Over-hoist Air Filter Block
2 1 28 27
Main Winch Over Run-out Main Boom Anemometer Fault
3 2 29 28
Auxiliary Winch Over-hoist Fly Jib Anemometer Fault
4 3 30 29
Auxiliary Winch Over Run-out Engine Water Temperature Sensor Fault
5 4 31 30
Main Boom Upper Limit Engine Oil Pressure Sensor Fault
6 5 32 31
Fly Jib Upper Limit Engine Accelerator Position Sensor Fault
7 6 33 32
Overload Alarming Engine Rotating Speed Sensor Fault
8 7 34 33
Moment Limiter Main Luffing Upper Limit Hydraulic Oil Temperature Sensor Fault
9 8 35 34
Moment Limiter Main Luffing Lower Limit Servo Pressure Sensor Fault
10 9 36 35
Moment Limiter Jib Luffing Upper Limit Fuel Line Sensor Fault
11 10 37 36
Moment Limiter Jib Luffing Lower Limit Speed Regulator Potentiometer Fault
12 11 38 37
Crane Incline Accelerator Pedal Potentiometer Fault
13 12 39 38
Engine Oil Pressure Low Accelerator Handle Potentiometer Fault
14 13 40 39
Engine Water Temperature High Main Winch Lift Safety Valve Fault
15 14 41 40
Generator Fault Main Winch Lower Safety Valve Fault
16 15 42 41
Fuel Volume Low Auxiliary Winch Lift Safety Valve Fault
17 16 43 42
Hydraulic Oil Temperature High Auxiliary Winch Lower Safety Valve Fault
18 17 44 43
Servo Pressure Low Main Luffing Lift Safety Valve Fault
19 18 45 44
System Voltage Low Main Luffing Lower Safety Valve Fault
20 19
Air Speed High 46 45
Jib Luffing Lift Safety Valve Fault
21 20 47 46
Suck Oil Filter Tip 1 Block Jib Luffing Lower Safety Valve Fault
22 21 48 47
Suck Oil Filter Tip 2 Block Unload Valve Fault
23 22
Back Oil Filter 1 Block 49 48
Concourse Valve Fault
24 23
Back Oil Filter 2 Block 50 49
Engine Start Relay Fault
25 24
Servo Oil Filter Block 51 50
Engine Fuel Relay Fault
26 25 52 51
Slewing Oil Filter Block Engine Warm-up Relay Fault

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 Chapter Ⅶ APPENDIX SCC Series Crawler Crane

Serial Serial
Code Code
No. Details No. Details
53 52 74 73
Main Pump Flow Regulator PWM1 Fault Slewing Brake Valve Fault
54 53 75 74
Power Limit Controller PWM2 Fault Slewing Lockup Valve Fault
55 54 76 75
Engine Communication Fault Slewing Pressure Valve Fault
56 55 77 76
Gradienter Sensor Communication Fault Free Slipping Mode Valve
57 56 78 77
Controlling Module A Communication Fault Slewing Jiggle Valve Fault
58 57 79 78
Controlling Module B Communication Fault Main Pump Inch Valve Fault
59 58 80 79
Moment Limiter Communication Fault Oil-Fan Motor Valve 1 Fault
60 59 81 80
Engine Start Fault, try again 10 seconds later Oil-Fan Motor Valve 2 Fault
61 60
Engine Start Fault, try again 30 seconds later 82 81
Free Fall Valve 1 Fault

62 61 83 82
Engine Start Fault, try again 120 seconds Free Fall Valve 2 Fault
later
84 83
Horn Fault
63 62
A Frame Not Erected
85 84
Slewing Alarming Lamp Fault
64 63
Track Not Opened
86 85
Sensor Power Fault
65 64
Slewing Lock Bolt Not Opened
87 86
Green Lamp Signal Fault
66 65
Display Controller Bus Fault
88 87
Yellow Lamp Signal Fault
67 66
Main Winch Pawl Valve Fault
89 88
Red Lamp Signal Fault
68 67
Main Winch Pawl Valve Fault
90 89
Dynamic Power Fault
69 68
Main Luffing Pawl Valve Fault
91 90
Cab Tilting Down Control Valve Fault
70 69
Auxiliary Luffing Pawl Valve Fault
92 91
Cab Tilting Up Control Valve Fault
71 70
Speed Travel Valve Fault
93 92
Auxiliary Mode Switching Solenoid Fault
72 71
Travel Direction Valve 1 Fault
94 93
Slewing Sound Alarm Fault
73 72
Travel Direction Valve 2 Fault

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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
pipelines. The compressor is auxiliary driven by the vehicle’s engine through belt, 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（6.17hp） Wind volume: 550m³/h (132 miles³/h)

Working voltage: 12V or 24V Overall power consumption: 500W(0.67hp)
Refrigerating medium: R134a Refrigerating oil: PAG100
Compressor: SE5H14 Shaft power: 2000W(0.27hp)
Refilling volume: 1Kg(2.2lb) Heating volume: 5000W (optional)(10.5hp)

3.3 System Composition

Air conditioning system of CD series engineering vehicles is composed of compressor, evaporator, condenser,
liquid vessel and pipelines. 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.
This process consumes mechanical power.

B． The process of condensing

After being sent into the condenser, the refrigerating medium gas with high temperature and high pressure is force
d to dissipate heat to become refrigerating liquid with 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 liquid with low temperature and low pressure through throttling expansion. This process features
dramatic decrease of pressure and temperature.

D． The process of evaporation

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The refrigerating liquid enters the evaporator after its temperature and pressure are lowered by the expansion
valve. The evaporated liquid absorbing the heat to become gas with low temperature and low pressure is sent into
the compressor. Heat of air inside the vehicle shall be absorbed by the evaporator through the fan, and the
temperature is lowered, achieving the aim of refrigeration.

3.4.2 Heating System (Optional)

Heating is achieved through cycling 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.(24.5psi~455.7psi) The system pressure can disconnect the compressor when there is a little
medium or no medium; the compressor can also 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 (420.9psi) 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 Instruction of Digital Air Conditioner Controller

3.5.1 Panel Instruction Working indicators

Power-off Button

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

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: 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.
: 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 Instruction

A． Refrigerating
l Start the engine.

l Press to switch on power supply with the power indicator on.

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

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

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

l After the temperature is set properly, adjust the wind speed as required.
B． Heating
l Start the engine.

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l Press to switch on power supply with the power indicator on.

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

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

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

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

3.6. Assembly

Notice:
The assembling personnel shall possess knowledge of vehicle air conditioning system.
This manual is required to be read through before assembly.
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.

3.6.1. Assembly 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(3/8”~1/2”).
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 feet and the fixing feet of the supporting frame shall be smaller than
0.1mm(1/250”).

3.6.2. Assembly of Evaporator

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a) The evaporator shall be moved slightly to prevent damaging the paint on the surface.
b) It is required to consider preventing condensed water, wind leakage and the evaporator shall be well sealed.
c) It should be installed securely with a tightening moment of 20Nm(1.37lb-ft); 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. Assembly 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 put 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. Assembly 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 assembly to connect the pipeline.
Notice: Identify the inlet and outlet 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. Assembly of Refrigerating Pipeline

a) Connector of the pipeline and the O-ring should be coated with cooling oil before assembly.
b) First screw tight the nut with hand 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 one wrench screwing the nut rotating and the other wrench keeping unmoved.
c) Tightening moment 3/4 thread 16-18Nm(1.1- 1.2ft-lb)
7/8 thread 16-28Nm(1.1-1.9fft-lb)
9/16 thread 15-18Nm(1.0-1.2ft-lb)
d) If necessary, the thread should be added with some thread glue (which cannot enter the pipeline system).

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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.Assembly 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. Commissioning

After the system assembly is completed or system repair is finished, it is required to carry out system
commissioning (commissioning should be implemented by trained personnel).
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 consistent. R12 and R134a cannot be mixed.

3.7.1. Vacuum

The purpose of vacuum is to remove 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 beforehand, making the vacuum degree at -0.1MPa.

3.7.2. Leakage check

Shut down the manual high-low position valve. If the pointer of pressure meter remains stable, the system has no
leakage. Otherwise, it indicates there is leakage, which requires check and repair. If the pointer keeps unmoved,
open the manual valve to vacuum for another 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. If there is no leakage after checked,
connect the middle hose with the refrigerating medium tank. (Notice: the valve of the refrigerating medium
tank should be opened then 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 from sideway: 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
prohibited to start the engine for the risk of liquid strike.

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c) Refilling at low pressure from sideway: when it is unable to refill any more at the high pressure from
sideway 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
reaches regulated volume.
Notice:
l During ordinary repair, refilling method for leakage of refrigerating medium adopts refilling at low
pressure from sideway.
l 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 dismantled 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:
l 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
0.2MPa±0.02MPa 1.4MPa±0.2 MPa
25℃
(29±2.9psi) (203.2±2.9psi)
0.21MPa±0.02 MPa 1.6MPa±0.2 MPa
30℃
(30.5±2.9psi) (232.2±2.9psi)
0.23MPa±0.02 MPa 1.8MPa±0.2 MPa
35℃
(33.4±2.9psi) (261.2±2.9psi)
0.27MPa±0.02 MPa 2.2MPa±0.2 MPa
40℃
(39.2±2.9psi) (319.3±2.9psi)
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 and 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 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:

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l No matter whether the air conditioner is used, the pipelines and other devices should be regularly
checked and maintained.
l If the air conditioner is not used for several months, it is required to run the air conditioner for about
10 minutes continually each month to ensure the system can operate normally.
l During 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. Regular Keeping of Air Conditioner

Items and Period of Regular Maintenance of the Air Conditioning System

Maintenance Frequency
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 assembly 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 assembly ※
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 Details Cause Measures
1. Water inside the system, causing the Replace liquid vessel
Refrigerate at

expansion valve blocked by ice Re-vacuum to refill

intervals

The refrigerating 2. Temperature controller beyond medium and adjust

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

2. Support frame of the compressor is Adjust

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

Repair
Heating

2. The pipeline is blocked.

The heating wind is Open after the
3. Temperature of the heating medium is
not hot as required. temperature rises
not high
4. Leakage in the pipeline Repair or replace

1. The compressor’s clutch Replace

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

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

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

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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
Refrigerating effect is not good

4. High pressure value is high and low

pressure value is low
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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