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世联翻译公司完成机械中英翻译

发布时间：2020-04-15 08:09　　点击：

世联翻译公司完成机械中英翻译

前言Preface

欢迎使用由管道人机械设备有限公司制造的PMG40吊管机。我们将为您提供优质的产品和及时可靠的售后服务。

Welcome to use PMG40 pipe layer manufactured by Pipeline Man Mechanical Equipment Co., Ltd. We are dedicated to provide the good quality product and reliable service.

PMG40型吊管机是我公司在消化吸收国内外吊管机先进技术基础上研发的一种集工程机械专用微控制器控制于一体的先进、可靠的管道施工设备。该型吊管机主要用于长输管道建设中管道的布管、对口、管线下沟等作业。该型吊管机采用了吊管机专用底盘，主要由发动机、分动箱、液力变矩器、行星动力换档变速箱、终传动及履带行走装置组成。起吊系统采用静液压开式系统传动，主要由左右支架、吊臂、组合绞车、滑轮组、液压泵、插装阀组及力矩限制器等部分组成。

PMG40 pipelayer is developed and reliable pipe work machinery with microcontroller after absorbing oversea pipelayer developed technology. It is mainly for pipe laying, fit-up and trench lowering etc. Chassis (specially used for pipe layer) is adopted for pipe layer and the pipe layer consists of engine, transfer box, hydraulic torque converter, planet power gear shift box, final transmission and track travel device. Hydrostatic open transmission is adopted for the hoist system. It consists of left and right frame, boom, combined winch, pulley, hydraulic pump, plug-in valves and torque limitor etc.

为使广大用户对PMG40吊管机的使用、维护、保养等方面有更好的了解，特编制了本使用维护说明书。本说明书作为随机技术文件供使用单位的操作人员、维修人员以及设备管理人员使用。操作本设备前请认真阅读，严格按照本说明书要求使用维护该设备，这对于安全使用该设备，延长设备使用寿命是非常关键的。该设备属于专用起重设备，必须持证上岗，定机定人，严禁未经过培训的无证人员操作该设备。

This manual is made for your better understanding of PMG40 pipelayer use and maintenance. As the technical document with the equipment, this manual is to be used by operators, maintenance personnel and equipment managing personnel. Please read this manual carefully before use and use the pipelayer according to this manual. It is very important for safely use and equipment life extension. The pipelayer is the special hoist equipment, thus the operator shall be with the qualification cerficate. The operator shall be dedicated for pipelayer and the unauthorized personnel is not allowed to operate the pipelayer.

本说明书是该设备系列说明书的总纲。其各个功能部件均有自己专门的说明书。在使用各功能部件时除本说明书提到的以外请参阅各部件的说明书使用维护。

This manual is the general instruction of the pipelayer. There are particular manuals for all functional parts. During use, please read other manuals as well apart from this manual for all parts.

该手册应存放在驾驶室的文件夹中或驾驶员座椅后方的文件存放处，以保证取用及读取的方便。

The manual should be kept in the file in the operation cabin or behind operator’s seat to get and read it easier.

由于产品的升级和用户要求的变化，产品的结构和性能还会不断改进，因此不可避免地出现说明书内容与产品稍有差异而未能及时更改，望用户谅解。

Due to product upgradation and customer requirement variation, we will continuously improve product characteristics and performance, thus please understand that we may not renew the content of the manual timely accordingly.

该产品将在使用中不断地改进发展，恳请广大用户在使用中提出宝贵意见和建议，以便在以后的制造中进一步改进。

The product is under improvement and development; therefore you are requested to give your valuable suggestions and advice so that we can further improve our product according to your suggestion.

第一章安全 Chapter I Safety

1.1安全标牌 Safety sign board

下列警告标志和安全标牌适用于本车。

The following caution marks and safety sign boards are applicable to PMG40 pipelayer:

 一定要完全理解标牌的正确位置及内容。

 Please fully and correctly understand the position and content of the safety sign board.

 确保标牌的内容可以正常阅读，确保标牌在正确的位置并始终保持其清洁。当清洁标牌时，不要使用有机溶剂及汽油，以免造成其脱落。

 The safety sign board shall be provided in the correct position and maintained its cleaness to ensure it can be read. The organic solvent and petrol is not allowed to clean the board to prevent drop-off.

 除警告标志和安全标牌外，还有一些其他的标牌。对这些标牌采用同样方法处理。

 Clean other boards in the same way of above safety sign boards.

 如果标牌破损、丢失或不可正常阅读，请更换新的标牌。标牌的详细零件号，请查看本手册或标牌实物，并向管道人经销商定购。

 If the boards are damaged, missing or unavailable, be sure have it replaced. Please refer to this manual or the board for the detailed parts number and place the order to dealer of Pipeline Man Mechanical Equipment Co., Ltd to purchase it.

1.1.1安全标牌位置图 Safety Sign Board Position Figure

1.1.2安全标牌Safety Sign Board

(1)超负载警示 TYBP.14 Overload warning board TYBP.14

超负载警示（TYBP.14）安全标志位于驾驶台的右手控制台的上部突台上。

Overload warning (TYBP.14) is on the projected area of right hand operation console.

警告：Warning

如果超过最大负载容量，机器可能倾翻，从而造成人身伤亡。载荷能力是假设机器静止在水平的混凝土地面上，配重完全伸出时给出的。在斜坡、崎岖地面或软地上提升能力会降低。

If the load exceeds the maximum load capacity, pipe layer roll-over may occur which may cause body injury. The rated load capacity is calculated presuming that the pipelayer is parked on the leveling concreting floor with the counterweight fully extension. In case pipelayer parks on the slope, loose soil or unlevelled ground, the capacity will be lower than rated capacity.

(2)防碾压标识 TYBP.08 Anti-rolling board TYBP.08

防碾压标识（TYBP.08）位于车身尾部油箱两侧。

Anti rolling board TYBP.08 is in both sides of oil tanks.

警告：Warning:

碾压危险。该区域不许站人，机器运转时应远离此区域。

Danger! Stay away from the pipelayer when it is working to avoid body injury.

(3)防火标牌TYBP.06 Fire proof board TYBP.06

防火标牌（TYBP.06）位于吊管机的油箱加注口的上部左侧。

Fire proof board TYBP.06 is in the left side above oil tank inlet.

警告：Warning:

给机器加注燃油时要小心谨慎。不要在给机器加注燃油时吸烟，也不要在靠近明火或火花的地方给机器加注燃油，切记加注燃油前将发动机熄火。

Be cautious when filling oil into oil tank, smoking is not allowed. Do not fill oil in the place close to the flame or spark. Ensure engine shutoff before oil filling.

燃油加注口标牌TYBP.11 Fuel inlet board TYBP.11

燃油加注口标牌（TYBP.11）位于吊管机的油箱加注口的上部左侧。

Fuel oil inlet board TYBP.11 is above left side of oil inlet top.

Caution: 1. Select the diesel oil label number according to the environment temperature; 2. Screw down the cap tightly to prevent oil leakage or unwanted material entering fuel tank.

(4)吊臂警示标识 TYBP.07 Boom warning board TYBP.07

吊臂警示标识（TYBP.07）位于吊臂两侧 Boom warning board TYBP.07 is placed in both sides of booms.

警告：Warning:

在使用该设备进行起吊作业或设备暂时搁置期间，起重臂下严禁站人，另外，包括起重物上、起重物下的地面严禁站人，否则可能会导致人员伤亡！

During operation of the pipelayer or the material suspending, do not stand under the boom. In addition, do not stand on the lifting material or on the ground under the lifting material. Otherwise body injury may occur.

(5)吊点标牌TYBP.03 Hook board TYBP.03

吊点标牌（TYBP.03）位于吊管机的两侧履带前后部。

The hook board is in the both sides of track chain.

警告：Warning:

吊装设备时需按照本说明书规定的起吊点进行起吊，使用具有足够安全系数的起吊设备进行起吊。

Use the lifting points specified in this manual and select the lifting device which is safe enough to lift the material.

(6) 避开电线标牌TYBP.02 Anti-collision with electric wire board TYBP.02

避开电线标牌（TYBP.02）位于吊管机的机头左侧。

Anti-collision with wire borad TYBP.02 is in the left side of pipelayer head.

警告：Warning

触电死亡危险！机器和选装部件应和电源保持一个安全的距离。请阅读和了解该说明书中的相关说明。

Electrocaution! The pipelayer and its parts shall be kept certain safety distance with the power supply wire. Please read the related content in this manual.

(7) 防挤压标牌TYBP.04 Anti-Extrusion board TYBP.04

防挤压标牌（TYBP.04）位于吊管机的配重支臂上侧。Anti-Extrusion board TYBP.04 is in the counterweight holder upside.

警告：Warning

挤压危险。此区域不许站人，机器运转时或配重在展开位置时严禁靠近此区域。

Danger! Do not stand near the area where pipelayer is under operation or counterweight is in extension.

维修机器时，在伸出的配重下方安装适当的支座来支撑配重。

During pipelayer repair, provide the proper support under the extended counterweight.

不按规定操作可能会造成人身伤亡。

Body injury may occur if the pipelayer is not operated as per this manual.

(8) 阅读说明书标牌(驾驶室) TYBP.16

Read manual reminder board (operation cabin) TYBP.16

阅读说明书标牌（TYBP.16）位于驾驶台的右手控制台的上部突台上部。

Read manual reminder board (TYBP.16) is in the right hand side of the projected area in the operation console.

警告：Warning

在通读和理解该说明书的指示和警告之前，请勿操作机器。不遵守这些说明或不注意这些警告，可能会导致人身伤亡。

Do not operate the pipelayer before reading this manual and fully understanding the instruction and warning. Body injury or death may occur in case of non-compliance of the instruction or warning.

避开电线标牌TYBP.02 Anti-collision with electric wire board TYBP.02

避开电线标牌（TYBP.02）位于驾驶台的右手控制台的上部突台上部。Anti-collision with electric wire board TYBP.02 is on the projected area of right hand operation console.

警告：Warning

操作机器时应始终与电源保持安全距离！请阅读该说明书中的相关内容。

During operation, the pipelayer shall be kept certain safety distance with the power supply. Please read the related content in this manual.

安全带警示TYBP.15 Seat belt board TYBP.15

安全带警示（TYBP.15）位于驾驶台的右手控制台的上部突台上部。

Seat belt board (TYBP.15) is on the top of right hand of operaion console.

警告：Warning

在机器运行过程中，要时刻系好座椅上的安全带，以免在事故中或机器倾翻时造成严重受伤或死亡。

During pipelayer moving, fasten selt belt all the times to prevent severe injury or death if the pipelayer collapse.

1.2 安全守则 Safety Rules

1.2.1安全原则 Safety Principle

 在使用该吊管机前，请仔细阅读《PMG40吊管机使用维护说明书》（以下简称说明书），并严格按照使用说明书的内容进行磨合、使用和保养。

 Please read “PMG40 Pipelayer Operation and Maintenance Manual” (hereinafter called Maunal) before use. The running-in, operation and maintenance shall be done as per the manual strictly.

 驾驶员要经过专门培训,合格后方可操作吊管机。吊管机在使用中出现异常，如液压油温过高、机油油压过低、水温过高及各传动部位有异常声音应及时停车检查，故障排除后方可继续使用。行车前应鸣笛后方可行驶。

 Operator can use the pipelayer after training and being qualified only. In case of any problem found during operation such as high temperature of hydraulic oil, low pressure of engine oil, high temperature of water or abnormal noise of transmission parts etc, operator shall stop working and check the pipelayer timely. Restart the pipelayer after problems are resolved. Sound horn before moving.

 操作者必须反应灵敏, 身体健康, 不得吸食影响视力、听力、反应力或判断能力的物品，了解驾驶室内部件的使用方法。

 Operator should be health and should not drink or eat the thing which affects sight, hearing, reaction or judge ability. The operator shall be familiar with the components in the operation cabin.

 尽管采取了预防措施，如果发生意外事故，如吊车碰伤、履带碰伤、燃油渗入皮肤、被柴油机机油烫伤、防冻液溅入眼中等情况发生，请立刻就医。

 Although precaution has been taken, in case any incidents such as hurt by pipelayer or track chain, oil into eyes, burn by hot disel oil or antifreeze entering eyes etc, please see the doctor immediately.

 柴油机喷油泵等有铅封的部位，用户不得随意拆动，出现故障时必须由专业人员进行检修。

 Do not remove the lead sealing area such as disel oil injection pump etc. Any fault found, have the parts to checked and repaired by professional personnel.

 柴油机必须使用CD-4以上级润滑油。严禁新旧润滑油混用、不同牌号润滑油混用。

 CD-4 or above degree lubrication oil shall be used for disel engine. New and used lub oil mixing and different type lub oil mixing is strictly prohibited.

 在操作和保养机器时，应严格按照安全规则、预防措施和说明执行。

 Operation and maintenance shall be done as per safety rules, precaution measures and this manual.

 当和其他操作人员或负责工地指挥任务的人员一起工作时，要确保有关人员都理解所有手语及信号。

 During operation, ensure all personnel understand the gusture and command signal.

 若在机器运行时发现异常现象，应立即停车并进行检修，直到异常现象被排除后方可继续操作。

 If any problem found, stop the operation and check the same. It can be started again only after no any problem is observed.

 该机适应海拔高度3000米以下，随着海拔高度的增加，功率将会下降，若长期在超过规定的海拔高度使用，会造成零部件损坏。超过此高度推荐使用管道人公司高原型吊管机。

 The pipelayer shall be used under 3000m altitude elevation. The capacity will be decreased with increasing of altitude elevation. If it is used in the higher elevation for long time, parts will be damaged. It is advised to use plateau type pipelayer manufactured by our company.

1.2.2 安全装置 Safety Device

 保证所有护罩和盖都在正确位置，并修理好损坏部件。

 All safety guards or covers shall be in correct place. Make sure have the damaged parts repaired.

 正确使用诸如安全操作杆和座椅安全带之类的安全装置。

 Use the safety device such as operation safety lever and seat belt etc correctly.

 禁止拆卸任何安全装置，确保其处于良好的工作状态。

 To keep the pipelayer in a good working condition, dismantle of any part is not allowed.

 不正确的使用安全装置可能造成严重的人身伤亡。

 Severe body injury or death may occur due to wrong use of safety device.

1.2.3 服务和个人防护工具 Service and Personal Protection Equipment (PPE)

 不得穿着宽松的衣服、佩戴首饰及留着松散长发，它们可能被操作杆和运动部件挂住，从而造成严重伤亡。

 Do not wear loose clothes / ornaments or loose long hair due to it may be getting caught by operation lever and movable parts causing severe body injury or even death.

 不得穿有油污的衣服，以防着火。

 Do not wear the greasy clothes to prevent fire.

 操作和保养机器时，务必戴上头盔、防护眼镜、面罩或手套，并穿上安全鞋。如果您的工作会接触到飞溅的金属屑和其它细小颗粒，一定要戴护目镜、硬质安全帽和厚手套，特别是当你用锤子敲打销钉或用压缩空气清理空气滤芯器的滤芯时，必须检查机器附近是否有人。

 During operation and maintenance, the personnel must wear safety helmet, protection glasses, mask, gloves and safety shoes. If there are sweepings and other particle, personnel must wear helmet, hardening safety helmet and thick gloves, particulary when hammer the pin by hammer or use compressed air to clean air filter core, personnel must check the persons around.

1.2.4未经许可的改装 Unapproved Refit

 任何未经许可的改装都可能产生危险，改装前请与管道人公司商议，管道人公司不对任何未经许可的改装所造成的伤害和损坏负责。

 Any unapproved refit may bring risk, so if any please contact with PipelineMan Company. Pipeline Man will not be liable for any damage or body injury due to unapproved refit.

1.2.5离开驾驶室座椅前一定要加锁 Do lock the pipelayer when leave the operation cabin

 当司机离开座位时，要确保安全操作杆和停车制动处于锁定位置。否则有可能触动未锁定的操纵杆，使工作装置突然动作，从而造成严重伤害或损坏

 When the operator leaves the operation cabin, make sure the operation safety lever and brake must be locked, otherwise the pipelayer may start suddenly due to movement of the unlocked operation lever which may cause severe body injury or equipment damage.

 当离开机器时，一定要把吊载重物完全降至地面、安全操纵杆置于锁定位置，然后关闭引擎，并用钥匙锁住所有装置，应随身携带钥匙。

 When leave the pipelayer, operator shall lower the lifting material on the ground, lock the operation safety lever and shutoff the engine. Lock all devices and take the keys with him.

1.2.6 上下车辆 Operator getting on/off

 上下车辆时，切勿跳上跳下。

 When getting on and getting off the pipelayer, do not jump.

 上下车辆时，应面对车辆，身体与扶手和梯子之间始终保持三点接触（双脚与单手，或双手与单脚），以确保安全。

 When getting on/off, stand towards the pipelayer; contact the pipelayer at least 3 points (i.e. both hands and single foot or both feet and single hand) to ensure safety.

 上下车辆时，切勿抓握任何操纵杆。

 Do not hold any operation lever during getting on/off.

 上下车辆时，应检查扶手和梯子，如果扶手和梯子上有任何油污或油泥，要立即擦掉。必须及时修理所损坏的零件并拧紧松动的螺栓。

 Check handrail and ladders when getting on/off. If any oil stain or greasy filth found, remove it immediately. Check and repair the damaged parts and tighten the loose bolts timely.

 在上下设备时, 不要将控制机构、软管当成扶手。控制装置和软管不能提供刚性支持，且控制装置的活动会造成设备或机构突然运动。

 When getting on/off the pipelayer, do not take the operation lever and hose as the armrest. The operation lever and hose bear the force and the operation device movement will cause the equipment or machinery suddenly move.

1.2.7 油料的防火 Oil fire proof

 燃油、机油和防冻液都是易燃品，容易引起火灾。

 Feul oil, engine oil and antifreeze are flammable material that is easy to cause fire.

 要使液体远离火焰。

 The oil shall be kept away from flame.

 加油时，一定要熄灭发动机，并严禁吸烟。

 During oil filling, engine shall be shutoff and smoking is not allowed.

 可靠地拧紧燃油箱和工作油箱的盖子.

 Tighten the cap of feul oil tank and engine oil tank.

 应在通风良好的地方进行加燃油或润滑油。

 Fuel oil or lubrication oil filling should be done in the well ventilated place.

 把燃油和机油保存在指定的地方，禁止未经许可的人员进入。

 Keep the fuel oil and lubrication oil in the designated place. Unauthorized entry is not allowed.

1.2.8 高温时操作的安全措施 Operation safety measures in the high temperature condition

 刚刚停止工作时，发动机冷却水、发动机油和液压油都处于高温、高压状态。此时，若取下盖子排放油、水或更换滤油器，都有可能导致严重烫伤，一定要等温度降下来后，按照操作规程进行。

 The engine cooling water, engine oil and hydraulic oil are in the high temperature and high pressure condition when just stopping operation. At this time, if remove the cover to discharge oil and water or replace the filter, the severe burn injury will be occurred. The above work shall be done as per operation rules when the temporary is getting lower.

 为防止热水及热油飞溅，在取下盖之前，一定要关闭发动机，并让水及油温冷却下来，缓慢拧松盖子，释放内部高压气体，然后才能取下盖子。

 To prevent spilling of hot water or hot oil, ensure the engine already shutoff before removing the cap. When water and oil cooled, screw the cap up slowly to release the high pressure air and then the cap can be removed.

1.2.9 防止被挤伤或切伤

To avoid crushing injury or cut injury

 不要把手、臂或身体的其它部分伸入或放在活动部件之间（比如工作装置与油缸、身体和工作装置之间等），当机器工作时，间隙会发生变化，从而导致零件严重损坏或人身伤害。

 Do not put your hands, arms or other parts of your body into the moving parts (such as operating parts and oil tank or body and moving parts etc.). When pipelayer working, the clearance will be changed which may cause severe injury.

1.2.10 使用防翻架的注意事项 Notes of using anti-tipping over frame

 如果安装了防翻架，在工作时切不可将其拆除。

 If anti-tipping over frame has been installed, do not move it when the pipelayer is working.

 防翻架是用来在车辆翻倒时保护驾驶员的，它不仅承受车辆翻倒时产生的载荷，而且能吸收冲击能量。

 The purpose to set the anti-tipping over frame is to protect the operator if tipping over happens. It can not only bear the load when pipelayer falls, but also absorb the impaction produced by tipping over.

 管道人公司的防翻架符合ISO标准，未经许可的改装或翻滚时的损坏可能导致强度下降从而不再满足设计要求，只有以规定的方式进行修理或改装后才能再次发挥作用。

 The product of Pipeline Man Company is in compliance with ISO standard; unapproved refit or damage after tipping over may decline the strength, so it will not meet the design requirement. The anti tipping over frame can be used after repair or refit in the proper way only.

 即使安装防翻架，如果司机没有正确地使用安全带，防翻架也不能很好地起保护作用，所以，在操作时一定要系好安全带。

 Althrough the anti tipping over frame installed, it can not protect operator if operator was not use seat belt properly. Thus, please ensure to fasten seat belt.

1.2.11关于选装件的注意事项 Notes of optional parts

 当安装和使用选装件时，先阅读选装件的使用指导手册和本手册的有关内容。

Read the optainal manual and this manual before install and use the optional parts.

 不要使用未经管道人公司或您的经销商许可的选装件，使用未经许可的选装件会引起安全问题，并且会影响机器的正常运行和使用寿命。

 Do not use the optional parts which were not approved by Pipeline Man Company or our dealer. Unapproved parts will cause risk or affect the pipelayer running and decrease equipment life.

 管道人公司不对任何使用未经许可的选装件所引起的伤害、事故和机械故障负责。

 Our company will not assume the responsibility of injury, incident and machine fault due to erection of unapproved optional parts.

1.3安全规程 Safety rules

1.3.1 启动发动机之前 Before start engine

现场安全 Site safety

 开机之前，检查周围有没有可能引起危险的异常情况。

 Check site and observe the abnormal situation which will bring the risk before engine start.

 检查地形和土质，选择最好的工作方法，不要在容易发生落物的区域施工。

 Survy the terrain and soil and choose the best work methodology. Do not work in the place where loose material may fall from heigh.

 当在公路上工作时，要有专人负责指挥交通，并设置路障，以保证交通和行人的安全。

 When working on the road, a dedicated person for traffic command shall be engaged and hard barrication shall be provided to ensure the safety traffic and passengers.

 当在水管、煤气管道、高压电缆等地下暗埋设施的场所施工时，应与有关部门联系，以确定管线的位置，注意在施工过程中，不要损坏它们。

 When working in the place where under ground facilities such as water pipe, petrol gas line or HV cable etc. is there, pls contact concern agency to confirm the exact location of the pipeline. Do not damage the pipeline during work.

 完全清除发动机箱体上的木屑、树叶、纸等易燃物，以免起火。

 Remove all flammable material such as excelsior, leaves or paper on the engine cover to prevent fire.

 检查燃油、润滑油和液压系统有无泄漏。

 Check leakage of fuel oil, lub oil and hydraulic oil.

 保证有一个可靠地灭火器。

 Ensure one set of extinguisher with good quality.

 不得在明火附近操作机器。

 Operating is not allowed near flame.

在驾驶室里 Operation cabin interior

 保证驾驶室地面、操纵杆、踏板和扶手上无油料、润滑脂、雪或其它污物。

 Keep operation cabin clean and ensure there is no oil, grease, snow etc on the floor, operation lever, pedal and handrail.

 检查安全带、扣环和零件有无损坏或磨损，更换所损部件。驾驶时务必系好安全带。

 Check damage or abrasion of seat belt, anchor and other small part. If any damage, have it replaced. Fasten seat belt during working.

 不要将易燃或易爆危险品带入驾驶室。

 Do not bring flammable and explosive articals into operation cabin.

 驾驶室内严禁吸烟。

 No smoking in operation cabin.

密闭空间的通风 Ventilation in the confine space

 如果必须在密闭空间内开动发动机，一定要保持足够的通风，过量的发动机废气可以致人死亡。

 If running engine in the confined space, sufficient ventilation shall be ensured to prevent death due to emission produced by engine.

关于后视镜、窗和车灯的注意事项

Notes of back mirror, windows and lights

 擦净所有的窗户和车灯，以确保您有清晰的视野。

 Clean all windows and lights to ensure the clear eyesight.

 调整后视镜，以便您能在驾驶座上清晰地看见，若有破裂应立即更换。

 Adjust the back mirror, so that you can see the road clearly. In case of crack on the mirror, replace it immediately.

 保证顶灯和工作灯正常工作。

 Ensure the top light and work light is working.

1.3.2 操作机器 Pipelayer operation

当启动引擎时 When engine start

 开车或操作之前，检查确保操纵杆可靠地置于空位。

 Be sure the operation lever in neutral position before starting or operation.

 上车前再一次绕车检查，确保周围没有人或其它障碍物。

 Before getting on the pipelayer, check around and ensure there is no any person or obstacle.

 只有在坐好以后，才能开动发动机。

 Work can be started after operator is seated well in operation cabin only.

 不要让司机以外的任何人进入驾驶室或车辆的其它地方。

 Unauthorized person is not allowed to enter operation cabin or get on the pipelayer.

 确保倒车喇叭能正常工作。

 Ensure the reversing horn is in proper functional.

 发动机起动时，当钥匙拧到启动位置后，启动时间不得超过20秒，二次启动间隔时间，不少于2分钟。

 While starting engine, start-up time should be no more than 20 seconds when keys turn to “START”; secondary start up shall be at least 2 minutes later after first start-up.

 发动机启动后，应减小油门，待机油压力升高后使用中低速运转,暖机5分钟以上方可加载工作。停车时不允许在水温过高时聚然停机。应怠速运转3～5分钟后停机。

 After start up, throttle the accelerator and then engine oil pressure will increase. After that the pipelayer can start work in intermediate or low speed. Warm up at least 5 minute before start loading. Engine should be shut off after 3-5 minutes idling, but not shutoff when water is excessive overheated.

 新发动机走合期间，发动机怠速运转或全速全负荷运转严禁超过5分钟。走合后，发动机怠速运转严禁超过10分钟。

 During new engine running-in period, engine ilding or full load operation must be no more than 5 minutes. After running-in period, engine idling time must be less than 10 minutes.

 发动机运转时操作人员不得靠近转动部分，不得在运转情况下拆卸零件，检查时应特别小心，注意安全。一旦发生“飞车”应立即停机，当熄火器失灵时应及时采取切断油路、堵塞气路的方法迫使发动机熄火，操作时应注意人机安全。

 During operation, persons should keep away from rotary parts. Do not remove the parts under running condtion. Extend more attention to safety when checking the parts. Once engine is out of control and extinguisher is out of service, cut off the oil supply and the air supply to force engine shutoff. Ensure body and machine safety during operation.

 避免发动机在冷却液的温度低于60℃或高于100℃的情况下持续运转，如出现此问题应尽快查找原因，以免导致发动机的损坏。

 Do not continuously run the engine if the coolant temperature is lower than 60℃ or higher than 100℃. If happenes, resolve the issues immediately to prevent damage of engine.

倒车时的检查Check pipelayer when reversing

操作机器或工作装置前，先做以下事情：

Before operation of pipelayer or working device, precaution to be taken as follows:

 鸣笛警告周围人员。

 Horn to the persons around pipelayer.

 确定车辆周围没有其他人，尤其注意车后。

 Confirm nobody standing around, particularly standing backside of pipelayer.

 如果需要，可派专人检查安全，特别是车辆倒行时。

 If required, engage dedicted person for safety inspection, particularly during pipelayer reversing.

 当在危险区域或视野很差的情况下，要指派专人指挥现场交通。

 Engage dedicated person for traffic command in case the pipelayer is working in the risky or dark area.

 不得让任何人员进入车辆行驶路线。

 Nobody is allowed to enter the route of pipelayer moving.

行车注意事项 Notes of travelling

 在不平整的路面上行驶时，速度要低，转向要平稳，避免突然转向。

 During travelling on the rough road, travel in the low speed and turn smoothly to avoid steering sharply.

 行驶车辆时，不允许使用移动电话。

 Cell phone is not allowed to use during operation.

 如果行驶时发动机或操纵杆发生异常现象，应立即停车，进行检修。

 Any problem of engine or operation lever found during travalling, stop the pipelayer immediately for maintenance.

在斜坡上行驶 Travalling on the slope

 禁止沿斜坡横向行驶。禁止在坡度大于20度路面上作业。

 Do not travel transverse with slope. Working on the slope more than 20o is not allowed.

 不要在斜坡上转弯。

 Do not make a turn on the slope.

 不要在草地、落叶或湿钢板上穿行，这些地方可能会使车辆打滑，若沿坡边缘行驶时，应保持非常低的速度。

 Do not travel on the grassland, leaves or wet steel plate which may cause slipping of pipelayer.If travel along the edge of slope, keep the speed very slow.

 下坡时，应缓慢行驶，并利用发动机作制动。

 When downward on the slope, travel slowly and use engine to brake.

 发动机在斜坡上熄火时应立即踩刹车，并使用停车制动。

 If engine shut down on the slope, slam the brake immediately.

 长期停车时要加枕木等制动装置。

 If the pipelayer stoped for long time, put the sleeper to block track chain.

 满载时，特别要防止突然启动、突然转向或突然刹车。

 During full load working condition, prevent suddenly start, turn or brake.

保证良好的视野 Keep the good eyesight

 在黑暗处工作时要使用工作灯和顶灯，并需要安装工地照明装置。

 Work light and top light shall be used when working in dark area and the site illumination device shall be provided.

 视野不好时，如雾天、雪天和雨天应停止工作，等天气转好后方可工作。

 When working in foggy, snowy or rainy weather, work should be stopped. Work can start only when the weather become fine.

在松软的地面施工时 Work on the loose earth

 不要过分接近悬崖、峭壁和深沟施工。如果这些部分崩塌您和机器将有坠落或翻倒的危险，从而导致死亡。切记这些地方的土壤在风雨过后承载能力会降低。

 Keep a certain distance with cliff and ditch, otherwise tipping over may happen which will cause death. Be sure to keep in mind that the soil bearing load shall be declined after rain.

 沟壑附近的土壤比较松软，可能会因为您机器的重量和震动而引起崩塌。

 Soil near gully is looser and may collapse due to the load and vibration of pipelayer.

 在危险地域和有掉落沙石的危险的地方施工时一定要安装防落物装置。

 When working in area where stone or gravel may fall, fall prevention device must be provided.

 在有掉落沙石和车辆翻倒危险地方施工时一定要安装防翻滚装置和座椅安全带。

 When working in the area where stone may fall or pipelayer may tipping over, anti-tipping over device and seat belt must be provided.

其他注意事项 Other notes

 吊管机过铁路路口时，应低速行驶，行驶方向要与铁路相垂直，中途不得停车、熄火。

 When pipelayer cross the railway, it should be in low speed and the travelling direction should be perpendicular with railway. At this time, do not shut off the pipelayer.

 在隧道中、桥下、电缆下或仓库中要特别小心，不要撞坏工作装置。

 Place more attention when working in tunnel, under bridge or in the warehouse. Do not damage the operation parts.

警告：Warning:

不要在电缆附近驾驶和操作车辆。因为有发生电击的危险，可能导致严重的人身伤害和财产损失。需要在电缆附近施工时应按照以下操作要求进行：

Do not drive and operate the pipelayer near cable as electric shock may happen causing severe body injury or equipment damage. If work is required to be done around the cable, operate pipelayer according to the following requirement:

施工之前应通知当地电力部门采取必要措施，得到他们的允许后方可施工。

Before working, inform local power management authority to take necessary action. Work can be started after their approval.

靠近高压电缆施工，可能遭受电击，从而导致严重火灾，所以电缆要保持一定的安全距离（见下表）。在操作车辆之前要详细了解当地电力部门的安全操作规程。

Electric shock and further fire disaster may happen if pipelayer is near the HV cable, thus a certain distance shall be kept with the cable. Before operating, please fully aware of the local power authority’s regulation.

电缆电压 Cable voltage 安全距离 Safety distance

100V—200V 大于2m More than 2m

6600V 大于2m More than 2m

22000V 大于3m More than 3m

66000V 大于4m More than 4m

154000V 大于5m More than 5m

187000V 大于6m More than 6m

257000V 大于7m more than 7m

500000V 大于11m more than 11m

1.3.3 起重操作安全 Hoist operation safety

 作业前空载检查起重臂、配重机构、液压系统是否正常及有无机械损伤。

 Check boom, counterweight mechanism and hydraulic system to ensure it is working without any damage before hoist.

 起吊作业时必须遵守起重机械通用安全规则。

 Hoist operation shall be done as per crane general safety regulation.

 不允许随意调整液压系统安全阀的开启压力。必要时应由专业人员调整，调整后的开启压力必须与说明书要求压力一致。

 Unauthorized reset of start pressure of hydraulic system safety valve is strictly prohibited. If necessary, pressure shall be reset by professional personnel; the reset pressure shall be compliance with this manual.

 吊重时要按照说明书指示的额定起重量以下作业，严禁超载。

 Load capacity shall be less than the rated capacity. Overload is strictly prohibited.

 作业时，应保证吊臂、吊钩、吊具和起吊物对正、平衡。

 During operation, ensure boom, hook, wire rope and lifting material shall be under balance condition.

 有起重工指挥方能进行作业。作业时要随时注意吊臂端部的运动及负荷情况。

 Signal man is a must for hoist. Observe boom end moving and load during working.

 操作前应鸣笛示警。

 Horn before operaton.

 吊重时，吊臂下严禁站人。

 Do not stand under the boom during work.

 起重物上,起重物下的地面严禁站人。

 Do not stand on the lifting material or on the ground under the lifting material.

 吊载作业前必须检查钢丝绳，确保安全后方可作业。绞车滚筒上最少保持3圈钢丝绳；

 Wire rope must be checked before hoist and work can start after confirming wirerope is safe. At least 3 circles wirerope should be wound on the hoisting barral.

 吊钩上升过程中，注意吊钩上升高度，以防钢丝绳过卷、发生危险。

 Observe the hook during hoist to avoid overwinding and risk.

 吊载行驶时必须在1档行驶。吊载行走时的起吊载荷不得大于额定起重量的70％。行走时起重量达到接近额定起重量的60%时，行驶坡度不得大于10度。

 When travelling with load, pipelayer shall be in first gear and the load shall be no more than 70% of rated load. If the load is around 60% of the rated load, the slope shall not more than 10o.

 作业中司机不得离开操作台，如必须离开需先将所吊物体放至地面。

 During work, operator shall not leave operation cabin. If he has to leave, release the lifting material on the ground.

 作业完成后须将所有机构回到非工作位置，方可熄灭发动机。严禁吊载停机。

 After operation, all working mechanism shall be kept in non-working condition and then engine can be shutoff. Shutoff with load is not allowed.

 必须把所吊物体升到一定高度才允许进行变幅或行驶操作。

 Luffing and driving is allowed when hoisting to a certain height.

 起重作业中不得进行调整、清扫、和与作业无关的事情。

 During operation, thing which has nothing to do with operation such as adjustment and cleaning is not allowed.

1.3.4运输 Transportation

1.3.4.1装卸 Loading & Unloading

 装卸吊管机总有潜在的危险，要特别小心，装卸时发动机应低速运转、低速行驶。

 During loading and unloading, there is potential hazard, so the personnel shall pay more attention. The transportation and running of pipelayer shall be in low speed.

 装卸前一定要用垫块垫住拖车的车轮和斜板。

 Have the wheel and inclined plate blocked by wood before loading & unloading.

 使用有足够强度的斜板，保证斜板有足够的长度和宽度，以构成具有安全斜度的斜坡。

 Use the inclinded plates with the sufficient strength and length & width to make the safe ramp.

 确保斜板稳固地放置和固定，两板要保证在同一平面。

 Ensure firm fixed plates and both plates shall be on the same level.

 确保斜板表面清洁，无油污、冰或其他松散物，清除吊管机履带上的污物。

 Ensure the plate surface clean without greasy dirt, ice or other loose material. Remove the dirt from pipelayer track chain.

 不要在斜板上操作转向操纵杆。如有必要须退下斜板并校正方向后再次爬上。

 Do not operate steering rod on the slope. If necessary, withdraw from plates to correct the direction and then go forward to the plate.

 装卸完毕用木块垫住履带并使车辆可靠停住。

 After unloading, put the wood block under track chain to keep the pipelayer stable.

1.3.4.2装运Transportation

 当用拖车装运设备时，应遵守各国家、地区有关货物长、宽、高的规定，并遵守所有适用法律。

 When transporting the equipment by trailer, regulations and applicable laws of all contries and regions regarding length, width and height shall be followed.

 确定装运路线时，应当考虑货物的长、宽、高以防超限。

 Material length, width and height shall be considered before transportation to avoid the size exceeds the limit one.

1.3.5 蓄电池 Battery

 蓄电池电解质中含有硫酸，一旦溅上，会很快烧坏皮肤和衣服。如果您身上溅上硫酸，立即用水冲洗干净。

 The sulfuric acid in battery electrolyte will burn your skin or clothes in case of spilling on it. Flush the sulfuric acid from your skin with flowing water immediately.

 如果溅入眼睛，蓄电池的硫酸能够致盲。若不慎进入，要立即用大量的清水冲洗，并赶快去看医生。

 You may be blinding if the sulfuric acid enter your eyes; in case acid spills into eyes, flush your eyes with plenty of water and see the doctor immediately.

 如果偶然喝入酸液，应立即喝大量的水或牛奶，鸡蛋或菜油，赶快请医生。

 If carelessly drink some acid, please drink plenty of water, milk, eggs or rape oil. See the doctor immediately.

 处理蓄电池时要佩戴安全眼睛或护目镜。

 Wear protection glasses when handling the battery.

 蓄电池会产生氢气，氢气非常易爆，很容易被一点小火星或火苗点燃。

 Hydrogen produced by battery is explosive and easy to burn by a few sparks or flame.

 处理蓄电池前，应停止发动机并把点火开关置于OFF（断开）的位置。

 Before handling battery, shut off the engine and put the switch “OFF”.

 当拆卸或安装时应检查正负极。

 During removal or installation of battery, cathode/anode pole to be identified.

 可靠地紧固蓄电池盖。

 Fasten battery cover tightly.

 可靠地紧固好电极，松动的电极可能引起火花，从而引起爆炸。

 Fasten the loose electrode to avoid spark and further explosion.

 不要用金属物放在电瓶两极之间检测电瓶的充电状况，这将产生火花可能引起爆炸. 只能用电压表来检测。

 Do not put metal between two poles of battery cell for checking charging. It will produce spark and then cause explosion. Voltmeter is allowed to use only.

 保养直流低压电器系统之前，将电源开关断开，以免烧坏线束发生危险。

 Before maintenance of LV DC electrical equipment, switch off power supply to prevent wire burn and danger.

1.3.6 用充电电缆启动 Startup with charging cable

 用充电电缆启动时，要佩戴安全眼睛或护目镜。

 Wear protection glasses before startup by changing cable.

 当用其它机器的电池启动时，不要让两机器接触。

 Machine can not contact each other if startup by other machine’s battery.

 当使用充电电缆时，一定要先联接正极电缆；拆除时，一定要先拆卸负极地线。

 When using charging cable, connect anode pole first; when removal, remove the cathode pole first.

 如果有任何工具同时接触正极和底盘，会产生火花，这是非常危险的。所以，一定要小心操作。

 Spark will be produced when any tool contact anode pole and chassis at same time. As it is very dangerous, be caution to operate.

 并联电池，正极联负极，负极联正极。

 For the parallel battery, anode pole shall connect to cathode pole, vice versa.

 当把地线联结到将被启动的车辆的车架上时，应确保可靠联结。

 Ensure the reliable connection of ground wire and the started pipelayer.

1.3.7 拖拽 Traction

 当拖拽时，用缆绳系住拖拽销。

Tie the rope with traction pin when traction.

 错误的拖拽方式会造成人身伤害或机器损坏。

Wrong traction way may cause body injury or equipment damage.

 用其它车辆牵引此车时，一定要使用具有足够强度的缆绳。

If dragged by other vehicle, use the rope which has sufficient strength.

 禁止在斜坡上牵引车辆。

 Do not drag vehicle on the slope.

 不得使用卷曲、绞结的牵引绳。

 Curly and kinky traction rope is not allowed.

 不要横跨或靠近牵引缆绳。

 Do not stride over or stand near the traction rope.

 当联接被牵引的车辆时，不要让任何人进入牵引车和被牵引车之间。

 Nobody is allowed to stand between the vehicles when traction.

 使牵引车的轴线和被牵引部分处于同一轴线上，保证其处于正确位置。

 The center line of two vehicles shall be same and correct.

 吊管机进行牵引作业时须有刚性连接器，应采取措施避免碰撞事故发生。

 Rigid connector must be provided when traction by pipelayer. Precaution shall be taken to avoid incident.

1.3.8 进行保养前 Work to be done before maintenance

适当的工具 Proper tools

 只能使用质量可靠的工具。如果使用坏的、低劣质量的、有缺陷的或临时代用的工具可能对您造成伤害。

 Good quality tools must be used; any damaged, inferior or defective tools may bring injury.

定期更换关键安全部件 Replace the essential safety parts regularly

 定期更换以下易老化的部件。燃油系统：进油软管，回油软管。液压系统：泵输出软管和油泵前后支管。

 Replace the aging parts regularly such as oil inlet hose, oil return hose and hydraulic system pump distribution hose and branch hose.

 无论以上元件看起来有没有损坏，都要定期更换它们，因其会随时间而老化。

 No matter the above parts seems damaged or not, replace the same regularly as it is aging gradually.

 即使没到更换期，只要看起来有任何缺陷，都要更换它们。

 Any defective found, replace it immediately even it does not reach the replacing time.

检查和保养前先停止发动机 Shut off engine before checking and maintenance

 进行检查和保养前，务必要先把车辆停放在坚硬平整的地面上，关闭发动机并取下钥匙后方可进行。否则，其他人在您进行保养或润滑是有可能开动发动机或操作操纵杆，将会对您造成伤害。

 Park the vehicle on the level and firm ground, shut off engine and remove the key before checking and maintenance. Otherwise, other personnel may start engine or move operation lever during checking and maintenance. It may hurt you.

 如果需要在发动机运转的状态下进行保养，如清洁散热器内部时，一定要把安全操纵杆置于锁定位置，并有两人进行操作，其中一人应坐在司机位置，以便能够在需要时能立即关闭发动机，他必须特别小心，以避免错误触动操纵杆对进行保养者造成伤害。

 During maintenance of parts in the operation condition such as clearance of radiator interior, operation safety lever must be locked. Two personnel must be engaged and one of them should sit in operation cabin so that he can shut off the engine immediately when shutoff is required. He must be very carefull to avoid touching the operation lever.

 进行保养的人必须特别小心，不要触动运动部件或被其挂住。

 Maintenace personnel shall pay more attention to aviod touching rotary parts. He should be caution that he is caught by rotary parts.

1.3.9 进行保养期间 During maintenance

人员 Personnel

 只有经过许可的人员才可进行保养和维修。在磨削、焊接和使用大锤时，应采取一些安全措施。

 Maintenance can be done by authorized person. If hammer must be used during grinding or welding, safety precaution shall be taken.

配件 Fittings

 从机器上拆下的零件应置于安全处，确保不会掉落和倒下，否则会对人造成严重伤害。

 Fitting removed from pipelayer shall be put in safety place so that it will not drop and fall, otherwise it will cause injury.

在机器下面工作时 Working under the pipelayer

 保养机器或在机器下面维修前，应把工作装置放至地面或最低位置。

 When maintain pipelayer or repair under the pipelayer, working mechanism shall be put in the lowest place.

 禁止在没有安全支撑的车辆下工作。

 Working under the pipelayer without safety support is not allowed.

保持车辆清洁 Keep the pipelayer clean

 任何时候都应保持车辆干净整洁。溢出的油料、润滑脂、满地散落的工具或损坏的零件可能使人摔倒，受到伤害。

 Keep the pipelayer clean at all the times. The oil, grease or loose tools and damaged parts will make persons falling down.

 不要用水或蒸汽清洗传感器、插头或驾驶室内部。如果水进入电气系统，可能导致机器不能运动或突然运动的危险。

 Do not clean sensors, plugs or operation cabin inside with water or steam. If water enters electrical system, pipelayer will be not able to move or it will move suddenly.

加燃油和机油的原则 Principle of fuel oil and engine oil filling

 一定要及时清除泄露的燃油和机油，以免使人滑倒。

 Remove the leaked fuel oil and engine oil timely to prevent slipping.

 一定要拧紧加油口的盖子。

 Fasten the cap of oil inlet.

 切勿用燃油清洗部件。

 Do not clean pipelayer parts by fuel oil.

 一定要在通风良好的地方加油。

 Oil filling shall be done in well-ventilation place.

 机车使用的油、水的型号和品种，取决于工作环境和气温，请按《燃油、冷却水和润滑油种类和用量》表使用。

 The selection of specification and type of oil and water shall be based on work circumstance and temperauter. Please refer to “Sheet of fuel oil, cooling water and lubrication oil type and quantity”.

 防冻液切勿用甲醇或乙醇配制，以免引起发动机故障。防冻液是易燃品，要隔绝火源。

 Do not mix the antifreeze with methyl alcohol or ethyl alcohol to prevent fault of engine. Antifreeze is the flammable liquid; therefore it should be isolated with fire.

 冷却水尽可能用“软水”，绝不可用污水做冷却水。冷却水中不可添加任何防漏剂。

 Use soft water as cooling water. Do no use dirty water. No any leakage preventive agent is allowed to add in cooling water.

 一定要按时清理或更换各种滤清器。

 Replace or clean all filters regularly.

 对冷却水、燃油、润滑油、工作油等，要随时检查，按要求进行补充，以保证车辆的正常使用。

 Check the cooling water, fuel oil, lubrication oil and working oil etc time to time and fill the above oil as per requirement to ensure the smooth operation of the pipelayer.

散热器水量 Water quantity of radiator

 检查水量时，应停止发动机并等待发动机和散热器冷却，然后检查水量。

 Shut off engine and cool the engine and radiator before water quantity checking.

 在取下盖子前，要先慢慢拧松盖子，释放内部压力。

 Screw up the cap slowly and release the pressure before remove the cover.

使用照明 Illumination

 检查燃油、机油、冷却液或蓄电池电解液时，一定要使用防爆灯，否则会有爆炸的危险。

 Explosion proof lamp shall be used when checking fuel oil, engine oil, cooling fluid or battery electrolity. Otherwise there will be risk of explosion.

 保养蓄电池的注意事项

 Note of battery maintenance

 修理电气系统或使用电焊时，应断开蓄电池负极以切断电源。

 Disconnect the cathode pole of battery when repairing electrical system or welding.

处理高压软管 Handling high pressure hose

 不得弯曲或用硬物敲打高压软管，不得使用弯曲或有裂缝的软、硬管，否则在使用时会有爆裂的危险。

 Do not bend or hit the high pressure hose; do not use curly and crackle hose and pipes, otherwise explosion will happen.

 一定要修好松掉或破裂的油管，如果有油料泄漏，可能引起火灾。

 Have the the loose or broken oil pipe repaired. In case of oil leakage, fire disaster will occur.

处理高压油的注意事项 Notes of high pressure oil handling

 切勿忘记工作装置油路中始终有压力。

 Be fully aware that pressure is always in working mechanism oil pipe.

 在放掉内部压力前，不要加油、放油或进行保养检查工作。

 Do not fill oil, discharge oil or maintain the pipelayer before releasing inside pressure.

 如果高压油从小孔中泄漏，高压油流打在皮肤上或溅入您的眼睛是非常危险的，一定要戴安全眼罩和厚手套，并用厚纸板或小木块去阻挡泄露。

 In case HP oil leakage happens, it is very dangerous if the oil contact with your skin or eyes. Before handling, wear the protection eyeguard or thick gloves and block the leakage by presspaper or wood plate.

 如果您被高压油流击伤，应立刻与医生联系以取得治疗。

 If you are hurt by HP oil, pls see the doctor immediately.

在高温或高压时进行保养的注意事项

Notes of maintenance in the high temperature and high pressure condition

 刚刚停止工作时发动机冷却水和各处的油都处于高温高压下。在这种情况下，如果卸掉盖子、放出油或水或者更换过滤器，都可能会导致烫伤或其它伤害。应该等温度降低后才按照本手册给出的步骤进行检查和保养。

 After just stopping work, the cooling water of engine and oil is in high temperature and high pressure. In this case, if remove the cap, discharge water/oil or replace the filter, burn or other injury may occur. Check and maintain according to procedure given by this manual after cooling down.

旋转的风扇和皮带 Rotating fans and belts

 不要接近选装部件，小心被挂住。

 Do not stand close to the optional parts as you may be caught by the rotating parts.

 如果身体或工具碰上风扇叶片，有被切掉或击飞的危险，所以不要接触任何旋转中的零件。

 If your body or tools touch the fan blades, your body wil be cut or the tools are knocked off.

废弃物 Waste

 不要把废油倒入下水道或河里。

 Do not dump the waste oil into sewer or river.

 一定要把从机器中放出的油装入容器中，不得直接倒在地面上。

 Discharge the oil from machine into vessel. Do not dump the oil directly on the ground.

 在处理诸如机油、燃油、冷却液、溶剂、过滤器、蓄电池和其它有毒（害）物质时，要遵守有关法律和规定。

 Please follow the related laws and regulations when handling engine oil, fuel oil, cooling agent, solution, filter, battery or other hazardous or poison material.

1.3.10 其他安全规则 Other safety rules

本设备使用中除应严格执行工程机械、起重机械和交流发电及低压电器的通用安全规则外还应注意下列事项：

Besides the safety rules of engineering mechinery, crane and AC power supply & LV electrical device, the following safety rules also to be followed during using the pipelayer:

 设备不允许“带病”工作，特别是在无油压或油压过低、水温过高或出现异响时,有此现象应及时停车检查并排除故障。

 Pipelayer shall be operated in good condtion without any fault; particulary it is found when no oil pressure or lower pressure, higher water temperature or any other abnormal found, shut off the pipelayer immediately and solve the faults.

 设备上配备灭火器，操作者应会使用灭火器; 使用灭火器以后, 应立即填充灭火器。

 Extinguisher should be provided and the operator must be fully aware how to use the same; refill the extinguisher immediately after use.

 除了操作者以外, 任何人都不得进入驾驶室工作. 不允许未经授权的人员驾驶、保养或修理本设备。

 Nobody is allowed to enter into the operation cabin other than the operator; unauthorized person is strictly prohibited to operate, maintain or repair the pipelayer.

 请不要在库房内长时间启动本设备。启动发动机后, 发动机的废气, 能造成人员的昏迷和死亡，应尽快将设备开出库房。

 Do not use the pipelayer in warehouse for long time as too much emission gas will cause unconsciousness and death. Leave the warehouse ASAP.

 在装有电子控制装置的机器和发动机上焊接时，焊接程序必须正确，以防损害电子控制装置及轴承。要在装有电子控制装置的机器或发动机上焊接，应遵循下列步骤：

 When welding on the machine with electronic control device or engine, welding procedure must be correct to prevent damage of electronic control device or bearing. The following procedure should be complied during welding on the machine with electronic control device or the engine:

1. 关掉发动机。

Shut off the engine

2.将蓄电池的负极电缆拆下。

Remove the cable which is connected with cathode pole of battery.

3.用电焊机的地线夹子夹住要焊接的组件。夹子离焊点尽量近些。确保地线到部件的电流不通过任何轴承和密封件。使用此程序可以降低损坏下列部件的可能性：传动系轴承、液压部件、电气部件等。

To clip the welding parts, use the ground wire clamp of welding machine closely. Ensure the currency from ground wire to parts will not through any bearing or sealing parts. The procedure can reduce the possibility to damage the parts such as transmission bearing, hydraulic parts or electrical parts etc.

4. 防止焊接时产生的飞溅物及碎屑损伤线束或其它零部件。

Take precaution to protect wire or other parts from damage by spatter or scrap.

5.使用标准的焊接程序将物料焊接在一起。

Welding must be done in accordance with the standard procedure.

1.4 新车试运转规则 New pipelayer trial running rules

 吊管机出厂前，虽经精心调试，然而新车在最初100小时使用期间，仍要求仔细操作，以使各零件磨合。

 Before dispatch, commissioning of pipelayer has been completed; however, operate the pipelayer carefully at the first 100 hours for running-in.

 如果在初始阶段，新车就处于不合理的满负荷状态下使用，则吊管机的结构和功能就会过早损伤，使其寿命缩短，所以新车必须按下列要求细心操作：

 If the new pipelayer is operated in full load condition in the initial period, the mechanism and function will be declined and the life of pipelayer will be decreased. Thus the new pipelayer shall be operated gentally as per requirements as follows:

1. 做好吊管机起动前的检查工作；

Check the pipelayer to ensure it is in good condition.

2. 发动机起动后，怠速运转时不少于5分钟，使其正常升温，逐渐进入工作状态；

After start up, idling operation shall be no less than 5 minites; temperature will be increased and it will become to working condition gradually.

3. 不要匆忙起步或急促加速及不必要的紧急制动或急转弯；

Do not start hastily, accelerate sharply, use unnecessary emergency brake or swerve suddenly.

4. 避免重载或高速作业；

Avoid overload or high speed work;

5. 随时观察，调整，使机车保持正常状态；

Observe and adjust the pipelayer time to time and keep it in norm working condition.

6. 吊管机经过250小时使用后，应按照最初250小时保养表和下列内容进行保养：

After 250 hours, maintenance shall be conducted as per the first 250 hours maintenance sheet and the following requirement:

a. 最初250小时保养表；The first 250 hours maintenance sheet;

b.作业时间由计时表显示；

Working time shall be based on the chronograph.

c.更换油滤芯时，要检查其内部是否有脏物，如果积聚严重，要尽量在更换前弄清原因，排除隐患。

Check the filter core and its dirt accumulation; if there is much dirt accumulation, find the reason before replacing to eliminate the potential risk.

7. 如在冬季寒冷季节进行新车磨合，还要考虑冬季冷启动的要求。

Start up requirement in winter season shall be considered if new pipelayer running in happens in winter season.

第二章技术规格及性能参数

Chapter II Technical Specification and Performance Parameter

2.1 设备结构简介 Brief introduction of pipelayer components

PMG40吊管机采用了吊管机专用底盘，主要由发动机、分动箱、液力变矩器、行星动力换档变速箱、终传动及履带行走装置组成。起吊系统采用静液压开式系统传动，主要由左右支架、吊臂、组合绞车、滑轮组、液压泵、液压阀组及力矩限制器等部分组成。

PMG40 pipelayer has the chassis dedicated for pipelayer and it consists of engine, transfer case, hydraulic torque converter, planet power shift gear box, final transmission and track chain travelling device. The hoist system adopts transmission by static hydraulic open system and mainly consists of left & right bracket, boom, combined winch, pulley, hydraulic pump, hydraulic valve sets and torque limiter etc.

1. 发动机：采用重庆康明斯发动机（型号NT855-C280 ），该发动机采用独特的PT燃油系统，涡轮增压进气。发动机重量轻、功率高、扭矩大、油耗低、维修保养简便。大修时间≥10000小时。

The engine (NT855-C280) is manufactured by Chongqing Cummins Co.,Ltd. The specialized PT fuel oil system and turbocharged intake was adopted for the engine. The feature of the engine is lighter weight, higher output, greater torque, lower oil consumption and easier maintenance etc. the overhaul interval is no less than 10000 hours after use.

2. 液力变矩器：采用3元件1级1相，变矩系数大，传动平稳。

Hydraulic torque convertor is three elements, single stage and one phase which has the greater torque and more stable transmission.

3. 行星动力换档变速箱：行星齿轮动力换挡操作轻便、灵活。前进三档，后退三档。终传动为承载能力很高的行星齿轮传动，可靠性高。单边7个支重轮，承载能力大，耐低温，适合吊管机工况。

Planet power shift gear box - the planet power shift operation is light and nimble; there are 3 shifts for forward and reverse respectively. Final transmission is the planet gear transmission with high load capacity. There are 7 track wheels in each side with high load capacity. The box can bear low temperature and is suitable for pipelayer work condition.

4. 整机液压助力转向，转向离合器：采用湿式多片常闭结合式结构。转向操纵手柄在驾驶座椅侧面，具有很好的操纵舒适性。

Hydraulic power assisted steering and steering clutch- wet multichip normal closed feature is adopted. The steering lever is in seat side which is very convenient to operate.

5. 吊臂：采用低合金高强度结构钢焊接的箱式A型臂，且外型美观，标配吊臂长度7.5m。

Boom: box type A boom is made of welded steel structure of low alloy metal, high strength and it has nice appearance. The standard length is 7.5m.

6. 吊臂变幅与吊钩升降系统：均采用行星齿轮传动，内藏在卷筒内，并带有常闭式制动器。两绞车均用液压马达驱动，实现无级调速。该机可达到操纵一次手柄，吊钩只升降1mm的微动性能，适合管对口作业。通过常闭式离合器，起升绞车具有紧急抛载功能，确保人机安全。

Both boom luffing and hook hoist system has the planet gear transmission which is placed inside of wire rope reel with the normal closed brake. Both winches are driven by hydraulic motor to achieve govern speed stepless. The device can do the micro action such as operate lever once and the hook can be up/down 1mm only. It is suitable for pipe line-up. The winch has function of emergency load dump to ensure the safety of equipment and personnel.

7. 配重机构：采用改进的四连杆结构，结构合理，外伸距离远。

Counterweight mechanism has improved four bar linkage structure. It is reasonable structured and has further extension distance.

8. 安全装置：发动机、传动系统装有各种仪表，操作人员能够随时掌握各部件运行情况。若有异常，立即关机停车，排除故障。

Safety device: there are various instruments provided for engine and transmission system, so operator can be aware of all parts’ running. If any problem found, operator can shut off the engine and eliminate the fault.

9. 吊臂限位装置：达到限定角度时，自动切断手柄油源，防止吊臂被拉弯。 Boom limit switch can cut off the lever oil supply automatically when the angle is upto the limit value to avoid the boom exceed the limit angle.

10. 吊钩限位装置：在吊钩达到最大高度时自行切断液压油路，防止过卷。Hook limit switch will cut off the hydraulic oil supply when hook is up to the maximum height to avoid over winding.

11. 吊重作业：将该角度下的额定起重力矩及当前起重量显示出来，使用户一目了然，当达到规定值时，自行切断液压油路，防止倾翻，保证了吊管机的安全运行。

Hoist load: it can show the rated hoist torque and the actual hoist torque in each angle to make the user clear the same. When the load is upto the rated value, the hydraulic oil supply will be cut off to prevent tipping over.

2.2 外形尺寸 Dimensions

工作状态是安装了吊臂和配重后的状态，在此状态下该车可以完成行走和起重作业。下图给出了配重收回并且吊臂（7.5m）处于最小幅度时的设备尺寸。图中尺寸：（9292）表示吊管机装配8.5m吊臂时的整机高度。

Working condition is such a condition when boom and counterweight installed of which the pipelayer can travel and hoist. The dimension in the condition of counterweight retraction and boom (7.5m) in the minimum angle is shown in the following figure. The value (9292) shows the overall height of pipelayer when install 8.5m boom.

普通运输状态外形尺寸：Dimensions during normal transportation

运输状态是指按照说明书第五章的相关规定进行了拆除及固定后的主机状态，下图给出了该状态下的主机外形尺寸。

Transportation condition means the condition of essential parts of the pipelayer after dismantle and fixing according to Chapter V. The essential parts dimensions is shown in the following figure:

2.3 起重性能 Hoist Performance

PMG40吊管机主钩额定起重量38.25t（吊钩中心距离同侧支重轮外缘的1.22m处），其起重性能曲线和起重性能表见下图。

Rated lifting capacity of main hook of PMG40 pipelayer is 38.25t (1.22m from hook center to same side track wheel outer edge). Refer to the following tables for lifting performance chart and lifting performance:

注意：Notes:

 起重能力是设备静止在水平的混凝土地上，配重伸出状态下测定的。因此在配重收回或斜坡、软地上起重其起重能力会降低。

 Lifting capacity is calculated in the condition that the pipelayer counterweight is fully extended and it stays in the level concrete ground. Therefore, the capacity will be deducted in case of retraction of counterweight or working on the loose soil.

 表中重量包括吊钩滑轮组的重量0.46t.

 The weight in the table is including the weight of hook and pulley i.e. 0.46t.

 如果超过了最大起重量进行吊载作业，设备可能会侧翻并造成人员伤亡。

 Pipelayer may be tipping over and injury may happen if the lifting load excesses the maximum capacity.

 吊载行走时的起吊载荷不得大于额定起重量的70％。

 Lifting capacity during travlling shall be no more than 70% of rated lifting capacity.

 请牢记：起吊载荷的实际值可能比估计值重。因此即便起重性能曲线中显示起吊载荷允许的值比估计的起吊载荷大（即在设备的能力范围内），也应小心尝试起吊。

 Caution: the lifting load may be greater than what you estimated, therefore althrough the lifting capacity in performance chart is more than estimated capacity (i.e. in the capacity scope of pipelayer), please try to lift slowly and carefully.

2.4 主机性能参数 Performance Parameter

最大起重量(t) Maximum lifting capacity 46

吊臂最小幅度最大起重力矩（t.m）

Max lifting torque when minimum boom luffing 56.12（46t×1.22m）

吊臂最大幅度最大起重力矩（t.m）

Max lifting torque of max boom luffing 50.4(7.2t×7m) 【7.5m吊臂】【7.5m boom】

48.8（6.1t×8m）【8.5m吊臂】【8.5m boom】

吊钩最大起升高度（m）

Max hook lifting height 6.4 【7.5m吊臂】【7.5m boom】

7.4 【8.5m吊臂】【8.5m boom】

起升速度（8倍率）（m/min）

Lifting speed (8 times) (m/min) 6.2

变幅时间（s） Luffing time 20

底盘型号 Chassis type SD23

发动机型号 Engine type 康明斯NT855-C280 Cummins NT855-C280

发动机额定功率（KW/rpm）

Engine rated output（KW/rpm） 169/2000

履带中心距（mm）T

Tack chain centre distance 2250

履带接地长度（mm）

Track chain ground connection length（mm） 3050

履带板宽（mm）Track chain width（mm） 660

液压泵型号Hydraulic pump type CBY4080-4080-K1008-169L -A【常温】

【Room temperature】

CBY4080-4080-K1008-169L -B【低温】

【Low temperature】

系统额定工作压力（Mpa）

System rated operating pressure（Mpa） 20

组合绞车 Combined winch 起升机构

Hoist mechanism 液压驱动、行星传动、自由落钩功能

hydraulic drive, planet transmission, free hook-down function

最大单绳拉力（N）(第四层)

Max. single wirerope force (N)(4th layer) 58,000

钢丝绳直径（mm）Wire rope diameter Φ18

变幅机构 Luffing mechanism 液压驱动、行星传动，Hydraulic drive, planet transmission

最大单绳拉力（N）(第一层)Max. single wirerope force (N)(1st layer) 58,000

适用环境温度（度）

Applicable environment temperature (degree) -20℃～+50℃【常温配置】【room temperature configuration】

-50℃～-40℃【低温配置】【low temperature configuration】

外型尺寸（长×宽×高）Dimensions (length×width×height) 带吊臂时（m）

With boom (m) 4.75×4.63×8.3 【7.5m吊臂】【7.5m boom】

4.75×4.63×9.3 【8.5m吊臂】【8.5m boom】

运输时（m）

Under transportation 4.75×3.35×3.27

空载平均接地比压（kPa）

No load average ground pressure 85.8

整体总质量（kg） Total weight 35,000

2.5 发动机参数 Engine Parameter

发动机型号

Engine Type NT855-C280

缸数-缸径×行程

Cylinder number-cylinder bore × journey 6-139.7×152.4

总排气量（t）

Total air displacement 14.01

点火顺序

Ignition sequence 1-5-3-6-2-4

最低燃油消耗率（g/kw·h）

Lowest fuel oil consumable rate <217

蓄电池

Battery 24V195Ah×2

发电机

Power generator 硅整流发电机24V35A

Silica rectifier generator 24V35A

润滑油容量（L）

Lubrication oil capacity 45

冷却水容量（L）

Cooling water capacity 79

额定功率KW

Rated output 169

额定转速

Rpm Rated rotating speed 2000

最大扭矩

Nm Max torque 1036Nm/1400rpm

净重kg

Net weight 1404

第三章使用和操作说明

Chapter III Use and Operation Instruction

3.1 操作装置及仪表 Operation device and instrument

操纵装置位置图 Operation device position figure

变速杆Gear shift lever (2) 右转向杆Right steering lever (3) 燃油控制杆 Fuel control lever (4) 左转向杆Left steering lever

(5) 左制动踏板 Left brake padel (6) 右制动踏板Right brake padel

(7) 减速踏板Deaccelarator padel (8) 起重手柄Lifting handle

(9)配重手柄 Counterweight handle (10) 变速安全杆 Gear shift safety lever

3.1.1 变速杆 Gear shift lever

吊管机前进、后退各有三档行驶速度，都由此变速杆操纵。发动机起动时，必须将变速杆处于空档“N”的位置，待发动机起动后，再操纵变速杆置于所要求速度档的位置。

Pipelayer has three forward gears and three reverse gears and all gears are controlled by gear shift lever. When starting, put gear shift lever in “N”; after starting, move the gear shift lever into the gear required.

3.1.2 变速安全杆 Gear shift safety lever

此杆是变速杆的闭锁装置。当吊管机停放时，必须将变速杆处于空档“N”的位置，并用此杆锁紧。

This lever is the lock deivce of gear shift lever. When pipelayer stops the work, put the gear shift lever in “N” and then lock safety lever.

3.1.3 左转向操纵杆 Left steering lever

把左面的转向操纵杆向后拉，左面的转向离合器就分离，车辆就向左边转弯；将左转向杆继续向后拉，拉到底，左面制动器即制动，车辆即在原地向左边转弯。Pull up the left steering lever and left steering clutch will separate, so that the pipelayer will turn to left; further pull the steering lever fully back, the left brake will be functional and the pipelayer will turn left on spot.

3.1.4 右转向操纵杆 Right steering lever

右面转向操纵杆控制吊管机向右转弯，其操作过程同左转向操纵杆一样。Pipelayer will turn to right direction when right steering lever is operated. The method is same as above left one.

3.1.5 减速踏板 Decelerator pedal

减速踏板用于降低发动机转速。该踏板能控制发动机二档转速，常用于第一档，即为800-850转/分；若再进一步踏下该踏板，为第二档，即处于怠速运转。

Decelerator pedal is used to decrease the running speed of engine. The pedal is normally control the first gear (800-850 r/min) and it can control the secondary gear. If further stamp the pedal, it will became to second gear and it will be idling.

警告：当吊管机开到斜坡或开到悬崖边施工时，由于负荷减轻，会使车速加快时，应踏上减速踏板控制车速，并适当降低。

Warning: when drive on slope or cliff edge, due to the reduction of load, the speed will be accelelated. At this time, stamp on the decelerator pedal to better control speed and reduce it properly.

3.1.6 左制动踏板 Left brake pedal

为便于驾驶员操纵，吊管机在转向时，除用转向操纵杆外，还可同时用踏板制动，先将转向杆向后拉，行程约70毫米，然后踏下与转向杆同一侧的制动踏板，吊管机就在原地转弯；吊管机在平地作业时，碰到特殊情况，须紧急刹车，此时立即踏下制动踏板的中部位置，使左右制动器同时制动。

For easier operation, besides steering lever, pedal can be used during steering. Pull up steering lever approximately 70mm and then stamp on the brake pedal which is in the same side of steering lever, so the pipelayer will turn on spot. During working on level ground, in case of particular condition and an emergency brake is required, stamp on the middle of brake pedal immediately so that both left and right brake will be functional at the same time.

3.1.7 右制动踏板：Right brake pedal

右面制动踏板控制吊管机向右转弯，其操作过程同左制动踏板一样。

The right brake pedal makes pipelayer turn right and the method is same as the above left one.

警告：在不需要操纵制动踏板时，不要把脚踏在制动踏板上。

Warning: Do not put your foot on brake pedal when the brake is not required.

3.1.8 右侧仪表及上车操纵 Instrument in right side and on board part operation

座椅右侧 Right side of seat

1. 双轴手柄 Biaxial lever 2. 快速落钩按钮Rapid hook down button

3. 启动开关Start switch 4. 翘板开关 Rocker switch

5. 单轴手柄 Single axle lever 6. 仪表 Instrument

3.1.9 仪表 Instrument

下图依次为机油压力表、充电指示表、水温表、油温表及计时表。

The following instruments are engine oil pressure indicator, power charging indicator, water temperature indicator, oil temperature indicator and chronograph (from left to right side).

a) 发动机油压表 Engine oil indicator

油压表的量程为 0 bar～10bar（约 0MPa～1 MPa），1 bar～10bar 为发动机的正常工作范围，冷起动时压力有时偏低，应先进行预热，使指针指在正常工作范围之内，方可进行作业。

The measuring range of oil indicator is 0～10 bar (about 0MPa～1MPa). 1 bar～10 bar is the normal working range. However, the value is lower when cold starting, so warm up is required and after the needle putting in the normal working range, the operation can be started.

b) 电压表 Voltmeter

正常运转之前，若电压表指针指向绿区，即高于 24V，说明蓄电池电压正常，若低于24V，说明蓄电池电压偏低，可能造成起车困难，如果不能起动发动机，需对蓄电池进行补充充电。机器正常运转时，电压表指针应指在绿区，28V 左右，若电压偏低或偏高，应查明原因，故障排除后再操作。

Before operation, if the voltmeter needle is in the green area (higher than 24v), it means the voltage of battery is in good condition; if the voltage is lower, the pipelayer may be difficult to start. In case the pipelayer engine can not start, charge the battery immediately. During operation, the indicator needle should be in green area (about 28V). If the voltage is higher or lower, stop operation and find out the reason.

c) 水温表 Water temparature indicator

指示发动机水温，机器正常运转时，水温表指针在 40℃～100℃范围内，如果温度过高，应降低发动机转速，使指针回到正常范围之内；必要时要停车检查水位。

The indicator shows the water temperature. During the operation of pipelayer, the indicator shall be in the range of 40℃～100℃. If the value is greater, engine running speed shall be reduced, so the the indicator shall be return to the normal range; if necessary, shut off the engine and check the oil level.

d) 油温表 Oil temperature indicator

指示液力变矩器油温，正常工作范围为 50℃～120℃。在作业中，若温度过高，应减少作业负荷，使指针回到正常范围之内。

The oil temperature indicator shows the hydraulic torque oil temperature and the normal range i.e 50℃～120℃. During working, if the temperature value is much more than normal value, the operation load shall be deducted so that the needle can return to the normal range.

e) 计时表 Chronograph

记录发动机的运转时间，作为定期保养及检测故障发生时间的依据。

The maintenance interval and fault test interval shall be according to the time shown on the chronograph.

3.1.10 启动点火开关 Start ignitor switch

启动开关有三个位置，如下说明：

There are 3 positions on the start switch as follows:

“关OFF” 位置是钥匙插入位置，此时，所有的电路系统为关闭状态；“运转ON”位置是蓄电池继电器（电源开关）接通；“启动START”位置为发动机起动。起后，当手离开钥匙时，钥匙便自动回复到“运转ON”位置上。

“OFF” is the position where keys should be inserted and all electric system is in the off condition; “ON”is the position where battery relay (power supply switch) to be connected. “START” position is for engine start. After start, the key will be back to “ON” automatically.

3.1.11 翘板开关 Rocker switch

下图依次为前灯开关、后灯开关、工作灯开关、仪表灯开关、驻车制动开关、空调开关。后面2个为备用按钮。

The following switches are headlight switch, Taillight switch, working light switch , indicator switch and Brake switch. (From left to right side) The last 2 switches are backup switches.

3.1.12 双轴手柄 Biaxial lever

用于控制变幅、吊钩升降，须按住该手柄握键。

Press the button on the lever to control luffing, hook up & down.

左侧按键为喇叭按钮，当按下该按钮时，喇叭将发出响声。

The left button is for horn and if press it, the horn works.

3.1.13 快速落钩 Rapid hook-down

按下快放开关后（持续操作）重物可自由快速落地，确保人机安全。松开按钮后，终止该操作。

When press the rapid hook down switch (continuously press), the load can be freely and rapidly down to ground to ensure the safety of persons and machine. When releasing the button, this action will be stopped.

3.1.14 单轴手柄 Single axial lever

控制配重机构，须按住左侧的油源开关或双轴手柄握键。

Press the oil supply switch in the left side or the button on the biaxial lever to control the counterweight mechanism.

3.1.15 制动器闭锁杆 Brake lock lever

此杆是制动踏板闭锁装置。闭锁后，脚即使离开踏板制动器仍处于制动状态。 This lever is the lock device of brake pedal. After locking, even your foot left the brake pedal, the pipelayer brake is still working.

操作过程中，首先须同时踏下左右制动踏板（即只要踏下制动踏板的中部位置），然后把此杆置于“锁紧”位置，这样制动踏板即闭锁住了；若要解除闭锁状态，仍需首先踏下制动踏板的中部位置，然后把此杆置于”自由”位置即可。During operation, stamp both left pedal and right brake pedal (i.e. middle of brake pedal) and then move the lever to “Lock”position, so the brake pedal is locked. If it is to be unlocked, stamp the pedal in the same way and move the lever in the position of “Free”.

警告：利用制动器闭锁杆锁紧制动踏板使吊管机停止行驶，必须在发动机运转状态下进行，因发动机停止运转时，液压制动助力器处于非工作状态，这样使制动力减小。特别注意在坡道上停车，危险性很大，所以，必须在发动机运转状态下操纵此闭锁机构。

Warning: pipelayer stopped by means of locking the brake pedal by brake lock lever should be in the condition of engine running as the hydraulic brake booster is not working when engine shutoff. Particulary if shut off on the slope, it is very dangerous. Thus the lock mechanism must be operated during engine running.

3.1.16 其他部件 Other parts

3.1.16.1左侧仪表及上车操纵 Left instrument and on board part operation

座椅左侧 Seat left side

1.力矩显示器接头 Torque monitor joint 2. 紧急抛载 Emergency free fall

3. 限制解除 Limit release 4. 先导油源 Pilot oil source

5. 油滤堵塞报警 Oil filter blocking alarm

1) 力矩限制器使用、保养及维修请参阅《力矩限制器使用手册》

Please refer to “Torque Limitor User’s Manual” for use, maintenance and repair.

2) 油滤堵塞报警，详见如下说明

Oil filter clogging alert. Details are as follows:

吸油滤清器堵塞报警高压油滤堵塞报警回油滤清器堵塞报警

Oil suction filter clogging alert HP oil filter clogging Alert return oil filter clogging alert

3) 先导油源按钮，操作卷扬及配重时需按下此按钮或双轴手柄握键

Pilot oil source button- when operate winch or counterweight, press pilot oil source button or the biaxial lever

力矩解除按钮 Torque release button 手柄有效按钮 Lever effectiveness button

4) 紧急抛载开关:用户在吊重作业时，遇到地基下沉，吊管机具有倾翻趋势时，按下快放按，重物可一甩到地，确保人机安全；

Emergency free fall switch: during lifting, the pipelayer may tip over when working in the settled soil base. At this time, push this switch and the material will be fall on the ground directly to ensure the safety of pipelayer and person.

5) 限制解除按钮：可解除力矩及吊钩限制；

Limit release button can release the limit of torque and hook.

3.1.16.2 保险丝盒 Fuse box

保险丝防止电气元件或导线烧坏，如果保险丝生锈或覆盖一层白色粉末，应更换。

Replace the fuse in case fuse rusted or be covered by white powder to prevent from damage of electric element or wire.

★ 更换保险丝时，应用相同容量的保险丝。

★ New replaced fuse should have the same capacity of the old one.

★ 更换保险丝时，务必关闭起动开关。

★ Start switch must be off when replacing fuse.

保险丝的排列及电器电流容量:

Fuse range and electrical currency capacity:

序号 SL.No 保险丝容量 Fuse capacity 电路 Electric circuit

01 10A 备用 Backup

02 10A 喇叭电源

Horn power supply

03 10A 司机室

Operation cabin

04 20A 前灯、后灯

Headlight and tail light

05 40A 发电机电源

Power generator power supply

06 30A 监控室电源

Power supply for monitoring room

3.1.16.3 司机座的调整

Adjustment of seat

说明：Note:

前后调整：提起控制杆“1”，调整前后所需位置。调完后，放回控制杆。 Forward and rearward adjustment: to adjust the seat toward the front or rear, pull up lever“1”. After adjustment to the desired position, release the lever in the orginal place.

升降调整：用双手提起手柄“2”可使座位升降，手柄 2 左右对称各一个。 Seat raise and lower adjusting: pull up both levers “2” by both hands to raise and lower the seat.

靠背倾斜调整：提起手柄“4”，倾斜度调整适当后，松开手柄。

Adjusting seatback angle: pull up the lever “4” and release the lever until the seat is adusted to the desired angle.

座的硬软调整：顺时针旋转手柄“3”，使座位强硬。逆时针旋转手柄，使座变软。可据体重，调至最佳舒适状态。

Seat hardness and softness adjustment: turn handle “3” clockwise, then the seat became hard. Turn handle counterclockwise, the seat will be softer. Adjust the seat according to operator’s weight.

3.1.16.4 集中测压装置

为便于用户在设备使用过程中监测及排除工作装置液压系统故障，PMG40吊管机专门设置了集中测压装置，该装置位于设备液压油箱前方、座舱右侧的平台上，各测压接头的作用如下图所示。

主阀压力：该测压点检测压力为工作装置主阀压力，即任一工作装置（包括起升绞车、变幅绞车、配重油缸）在工作时的工作压力。

先导压力：该测压点检测压力为先导操纵装置的压力，即先导操纵装置（包括起重手柄及配重手柄油路）在工作时的工作压力。

离合压力：该测压点检测压力为起升绞车离合器在释放时的工作压力。

3.2 发动机起动及停止 Engine start and shutoff

3.2.1发动机起动前的检查 Before starting your engine

1.按日常检查项目进行（检查项目参看“定期保养” ）。

Check pipelayer according to routine inspection (for the checking items, please refer to “Periodical Maintenance”)

2. 制动踏板要处于制动锁紧状态。

Brake pedal should be locked.

3. 变速杆要置于空档“N”位置，且用闭锁杆锁紧。

Gear shift lever should be in “N” (neutral) position and locked by lock lever.

4. 油门操纵杆置于怠速位置。

Accelerator lever shall be in idling position.

5. 双轴及单轴手柄处于中位。

Biaxial and single axial lever shall be in middle position.

6. 快放控制开关、快放按钮处于断开位置。

Rapid free fall control switch and rapid free fall button shall be in shut off position.

3.2.2发动机起动 Engine start

1.钥匙插入起动开关，转向通的位置，蓄电池继电器（电源开关）接通后再转向起动位置，发动机开始工作。

Insert key into start switch and turn the key “ON”. After connection of battery relay (battery switch) and then turn to “Start” position, the engine can start.

2.起动时要注意观察发动机油压表的指针位置是否正常。

Observe the engine oil indicator needle in the normal condition.

3.钥匙在起动位置，不得超过20秒钟。

Do not hold the key in the “START” position more than 20 seconds.

4.若起动不成功时，应立即将钥匙置于通的位置，然后等待2分钟后再起动。 Turn the key to “ON” position if failed to start. After 2 minites, start it once again.

5.若发动机再次起动仍有困难，可能是由于断油阀未打开，此时可用手动操作旋钮来打开断油阀，待起动后，将旋钮返回。

If again the start failed, it may be because the oil cut off valve is not open. Thus, open the oil cut off valve manually and after start, turn it back.

6.起动后须将钥匙回至通位置（能自动返回）。

After start, turn the key to “ON” position (can return automatically).

7.档位必须置于空档状态，发动机方能启动。

Pipelayer can start only when it is neutral position.

3.2.3发动机停止 Engine shutoff

1.在发动机停车之前，须进行5分钟的怠速运转，使其慢漫冷却后方可停止运转；

Before shutoff, 5 minites idle running is required to cool down the system.

2.停止时将起动开关上的钥匙拧到“关”的位置，然后将钥匙拔出。

Turn the key to “OFF”position and remove the key.

3.3 行走操作Travel operation

3.3.1吊管机起步 Pipelayer start-up

发动机正常运转后，方可实现吊管机行驶起步操作，操作步骤如一下：Pipelayer can start travelling after engine running normally, the operation is as follows:

1.将油门控制杆向后拉，提高发动机转速；

Pull back the accelerator lever to increase the running speed.

2.踏住制动踏板的中部位置，操纵制动闭锁杆，解除对制动踏板的锁紧作用，使制动踏板复原至常态位置；

Stamp on the middle of brake pedal to operate the brake lock lever and unlock the brake pedal so that brake pedal can return to its original place.

3.操纵变速闭锁杆，解除对变速杆的锁紧作用，然后将变速杆置于一档速度位置,即吊管机起步向前行驶；

Operate the gear shift lock lever, unlock the gear shift lever and then move the gear shift lever into first gear speed position. After that, pipelayer will move.

4.起步时，踏下减速踏板，再将变速杆置于前进一档位置，然后再慢慢减少踏下的力，缓缓复回减速踏板，使发动机转速逐渐增加，这样能防止急剧起步；

When start up, stamp on the decelerator pedal and move the gear shift lever into forward shift, then decrease the stamp force slowly to make the decelerator pedal back gradually. The running speed of engine will be increased progressively to prevent sharp start up.

5.起步后，可将变速杆置于所需要的速度档位。

After start, put the gear shift lever into the position of which the speed is required.

3.3.2吊管机前进、后退、变速 Pipelayer forward, reverse and gear shift

把变速杆置于所要求的速度位置。吊管机在行驶中也可以进行变速，不必停车变速。在变速前进、后退行驶档时，须踏下减速踏板，待发动机有所减速后，再操纵变速杆，改变吊管机行驶方向。

Put the gear shfit lever in the required speed gear. Pipelayer gear shift can be done during travelling and it is not required to stop the pipelayer. If gear shift for drive and reverse, stamp the decelerator pedal first to reduce the engine speed and then operate gear shift lever to change the direction of pipelayer driving.

3.3.3转弯 Steering

在行驶中，要向左（右）转向时，应将右的转向杆拉至中途，转向离合器就分离，即能作缓慢转向（大转弯），若将该侧转向杆拉到到底，并踏下同一侧的制动踏板，即能做原地转向（小转弯）。

During driving, to turn left (right), pull up the right steering lever in the middle place, so the steering clutch will be working. In this case pipelayer will make turn gradually (wide turn); if pull up the steering lever fully and stamp on the brake pedal at the same time, pipelayer can turn on a spot (tight turn).

警告：在坡道上若要进行左侧大转弯时，则要把右侧转向杆拉至中途，即能往左缓慢转向；若要进行向左侧原地转弯时，则要把左侧转向杆拉到底。

Warning: if pipelayer wil make left wide turn on the ramp, pull the right steering lever in the half way and the pipelayer will turn to left side slowly; to make left turn on a spot, pull the left lever back fully.

3.3.4吊管机暂时停车 Pipelayer stop for a while

吊管机暂时停车时，不必使发动机停止运转。其步骤如下：

If pipelayer stops for a while, it is not required to shut off running. The procedure is as follows:

1.将油门控制杆（1）向前推，使发动机处于低速运转；

Push the accelerator lever (1) onward to make the engine running in low speed.

2.将变速操纵杆(2)置于空档“N”，的位置，并操纵其闭锁杆(3)使变速操纵杆锁紧；Put the gear shift lever (2) into “N”position and move its lock lever (3) to lock the gear shift lever.

3.踏下制动踏板(4)的中间部位，并操纵制动闭锁杆（5），使制动踏板锁紧；

Stamp on the middle of brake pedal (4) and move brake lock lever (5) to lock the brake pedal.

4.吊臂收回到最小幅度，配重收起。

The boom shall be in minimum overhang and counterweight shall be retracted as well.

3.3.5当吊管机在坡道上停车时 When stopping on ramp

当吊管机在坡道上停车时，一定要使用吊管机改进的驻车制动系统。步骤如下（步骤1、步骤2和步骤4同上）：

When stopping on the ramp, the developed brake system of pipelayer shall be used. The procedure is as follows (procedures 1, 2 and 4 are same as above):

1.将油门控制杆（1）向前推，使发动机处于低速运转；

Push the accelerator lever (1) onward and make the engine running in low speed.

2.将变速操纵杆(2)置于空档“N”，的位置，并操纵其闭锁杆(3)使变速操纵杆锁紧；

Put the gear shift lever (2) in “N” position and move its lock lever (3) to lock the gear shift lever.

3.踏下制动踏板(4)的中间部位，将驻车制动按钮按到“OFF”位置，再松开制动踏板；

Stamp on the middle of brake pedal (4), move the brake button to “OFF” position, and then release the brake pedal.

4.吊臂收回到最小幅度，配重收起。

The boom shall be in minimum overhang and counterweight shall be retracted as well.

3.4 起重操作 Lifting operation

3.4.1 变幅机构操作 Luffing mechanism operation

1）变幅操纵杆平常处于中间位置，此时吊臂停止不动。当变幅操纵杆向右推时，吊臂向上抬起，吊臂变幅的速度和程度与变幅操纵杆推过的速度和行程成正比。当变幅操纵杆向左推时，吊臂下摆。变幅操纵杆不受力时能自动回归中间位置，变幅停止动作。（为了避免误操作带来的危险，操作变幅操纵杆时，需同时将手柄握键按下方可动作）

When luffing lever is normally in the middle position, the boom is static. When pushing the luffing lever to right side, the boom will raise. The luffing speed and range will be directly related to the luffing lever moving speed and range. Push luffing lever to left side, boom will be down. If no force is acted on the luffing lever, it can return to the middle position automatically and luffing action will be stopped. (Press the button on lever at the same time during luffing to prevent the risk raising from wrong operation)

2）吊臂变幅限位装置的操作：为提高整机安全性能，避免重物摆动撞击吊臂的发生，本机在吊臂收到接近1.22m幅度（指吊钩下垂中心距支重轮外缘，下同）时会发出预警。

Limit switch for boom luffing: to improve the safe performance, if boom become overhang near 1.22m (hook center to same side track wheel outer edge)， pipelayer will sound the alarm.

警告:即使安装了预警装置，但由于环境影响，也可导致预警装置失灵，所以司机在吊臂将要收到最小幅度时，务必谨慎小心，降低收臂速度，注意观察预警装置是否失灵。

Warning: although alarm system has been provided, but due to environment issues, it may be not working. Thus during operation, operator shall be careful to make the boom to the minimum luffing range by means of decreasing speed and observing the alarm system.

3.4.2 起升机构操作 Lifting mechanism operation

起升操纵杆和变幅操纵杆一样，平时处于中间位置，此时吊钩静止不动。当起升操纵杆向后拉起时，重物提升;当起升操纵杆向前推时，重物下降。如果想停止重物上升和下降，则把作用在起升操纵手柄上的力减为零，此时起升操纵手柄自动回归中间位置，重物停止不动。重物起升的速度和程度与起升操纵后拉的速度和行程成正比，但吊钩上载有重物时，起升和下降速度不宜太快，以免产生安全隐患。执行此操作时，请确认“紧急抛载”按钮处于旋出状态（为了避免误操作带来的危险，操作起升操纵杆时，需同时将手柄握键按下方可执行该动作）

Lifting lever, same as luffing lever, is in the middle position normally. At this time the hook is static. When pull back the lifting lever, it will lift the material. When push the lever onward, the material will be down. To stop moving of the hook, reduce the force on lifting lever to zero and the lifting lever will return to the middle position. The lifting speed and height will be related to the lever pulling back speed and distance. If there is heavy load on the hook, do not lift and lower too fast to avoid the potiential risk. During this operation, please confirm the “Emergency Free Fall Switch” has screwed out (when operate hoist lever, the button on lever shall be pressed down at the same time to prevent the risk due to wrong operation).

高度限位开关安装在吊臂顶部，在吊钩达到最大高度时，自动切断油路，使吊钩上升停止，防止过卷。当所吊重物接近地面时，速度一定要降低，轻放重物。

The height limit switch is installed on the boom top. If the hook is on the highest place, the limit switch will cut off the oil automatically and the hook will stop lifting, so that over winding can be avoided. If the lifting material is nearly down on land, lower speed and put the material on the land gently.

3.4.3 配重控制操作 Counterweight operation

配重伸缩操纵杆平时处于中间位置，此时配重静止不动。配重操纵杆向前推则配重展开，摆到最大位置后，可以进行正常的吊重作业。向后拉则配重收回。中间位为停止。配重操纵杆要缓慢操作，防止配重产生过大冲击。（为了避免误操作带来的危险，操作配重操纵杆时，需同时按下左侧面板的“手柄有效”按钮或者手柄握键，方可执行该动作）

Counterweight lever is normally in the middle place and at this time the counterweight is static. Push the counterweight lever onward and the counterweight will extend fully, so lifting work can start. Pull back the lever, the counterweight will retract. The middle position means work stopping. Operate the counterweight gently to prevent the great impact produced by counterweight (When counterweight lever, the button on lever or “lever effectiveness” button in left side of penal shall be pressed down at the same time to prevent the risk due to wrong operation)

警告:在配重行程的两端，一定要减慢配重的速度，即减小配重操纵手柄的行程，以减少配重惯性对机器的冲击。

Warning: in the both ends of counterweight travelling, lower the speed of counterweigt i.e. reduce the stroke of lever to decrease the impaction on pipelayer produced by counterweight inertia.

3.4.4 快速落钩 Rapid hook down

快速落钩功能是为了应付紧急情况的，一般情况下不得频繁使用。当司机发现吊管机将要倾翻时，为保证人机安全，才可使用快速落钩，而且只能一落到地，中间不得停止，否则，吊管机倾翻更快。

Rapid hook down function can be used when emergency happens only. Do not use it frequently. If tipping over found, operator can start rapid hook down to ensure the safety and pipelayer and persons. The hook should be down on the land at once and it cannot stop till it is completely on the land, otherwise the pipelayer will be tipping over faster.

快速落钩功能可在熄火状态下完成，前提是设备处于通电状态，蓄能器处于饱压状态。

The rapid hook down founction can be done when engine shutoff. The precondition is equipment is power on and battery is in saturation pressure condition.

当操作快速落钩阀至快落位置时，蓄能器中的储存能量，将打开起升机构离合器，实现快速落钩。操作时一定要小心，载荷下面不得有人或其它物品。下落过程不得停止，否则会将吊管机拉翻。空钩时因重量太轻，下落也不快，请勿频繁使用。

When put the rapid hook down valve to the rapid down place, the force from accumulator shall open the clutch, so it will be down rapidly. Operator must be carefull and ensure no any person or objects should be under the boom. Do not stop the hook down funcation till it is on the ground, otherwise the impaction will make the pipelayer tipping over. Due to light weight of the hook without lifting material, the down speed will not as fast as with load. This function cannot be used frequently.

吊管机具有倾翻趋势时，按下快放开关后（持续操作）重物可自由快速落地，确保人机安全。松开按钮后，终止该操作。左侧面板有紧急抛载按钮，拍下后，吊钩自由快速落地，需要手动旋出，方可终止该操作。

If tipping over is to happen, push the rapid down switch (continuous operation), the lifting material can be down to land rapidly to ensure the safety of pipelayer and person. After releasing the button, the action will be stopped. When push the emergency dump button in the left side of control console, the hook will be drop on the land freely. The button shall be manually screwe out and then the action can be stopped.

3.5 作业技术 Operation technology

吊管机在施工时，要掌握安全施工技术；特别是在联合作业时，要有步骤、有条理的操作，切不可轻率盲目施工，以防发生重大事故。

During working, safety work technology shall be fully awared, particularly for the joint operation, the work shall be planned and done orderly. The hasty operation may cause major incident.

3.5.1下沟作业 Pipe lowing-in

下沟作业 Pipe lowing-in

A.在利用吊管机进行下沟作业时，应事先根据重物的重量和地面情况确定联合作业的台数，保证有足够的安全储备。

Numbers of pipelayer shall be confirmed according to the weight of lifting material and the ground condition. Sufficient safety measures shall be taken in advance.

B.作业前要检查钢丝绳是否有缠绕、压绳等现象，若有应进行理顺；理好后方可进行吊管作业。否则，容易因钢丝绳突然抖动而增加吊重的冲击载荷，造成倾翻事故。

Before operation, wire rope should be checked to avoid the problems such as wire rope twist or rubbing. If any problem found, straighten out the wirerope, then work can start, otherwise tipping over will happen due to impaction arising from additional load produced by wirerope shock.

C.起吊作业时，吊管机停放位置要与管沟有足够的距离，以防作业时造成塌陷事故。

During lifting, pipelayer must be kept in sufficient distance with trench to avoid the trench collapse.

D.操作人员要根据地面指挥人员的指令进行作业，所有动作要在均匀低速下进行。

Operator shall follow the command given by signal man. All actions shall be done slowly and evenly.

E.起重臂下和配重摆幅范围内严禁站人。

Do not stand under the boom and swing area of counterweight.

3.5.2对口作业 Pipe line-up

对口作业 Pipe line-up

在对口作业时，需要对吊管机进行微动操作，其要领如下：

When doing pipe line-up, micro operation to be done as follows:

A.发动机要在低速下运转。

Engine runs in low speed.

B.先导手柄要控制在较小摆角范围内。

Feedunit lever shall be in the smaller swing angle.

3.5.3摆管作业 Pipe laying

A.吊管行进时要保持低匀速，不得进行急转弯。

When carrying pipe, the pipelayer shall be move slowly and evenly. No tight turn is allowed.

B.管子距离车体应有一定的距离，避免相互间的碰撞。

Keep the adequate distance with the pipelayer to avoid the collision of each other.

C.必要时应在吊杆适当位置增加橡胶等缓冲物，保护管子不被碰坏。

If necessary, provide the protection material such as rubber sheet etc to protect the pipe.

D.当吊重较轻时，不必将吊管机配重打开。这需要根据地况、吊重等因素并依照管道人公司的吊管机性能曲线进行安全确认后方可进行吊重作业。

If the load is quite light, the counterweight is not necessary to extend. However, this should be done as per ground condition or lifting material. Lifting work can start after confirmation according to performance chart provided by Pipeline Man Mechanical Co., Ltd.

摆管作业 Pipe laying

3.5.4坡道作业 Works on the ramp

配重展开状态下在斜坡上进行吊重作业，能够保证整机稳定性的最大坡度限定为：

If counterweight exends during working on the ramp, the max degree to ensure the pipelayer stability shall be as follows:

A.纵向斜坡即车体顺着斜坡方向进行吊重作业，允许斜坡最大坡度为12°。Longituational slope (pipelayer body is along slope)-max allowable slope is 12o.

B.横向斜坡即车体与斜坡方向垂直进行吊重作业：

Crosswise slope (pipelayer body direction is vertical with slope)

1）配重侧在上坡时，允许斜坡最大坡度为10度。

The allowable max slope is 10o when counterweight is in upslope.

2）配重侧在下坡时，允许斜坡最大坡度为"0"，即不允许此工况下作业。The allowable max slope is “0”i.e it is not allowed to working in this condition.

警告：吊管机起重性能曲线表中所示重量是吊管机在硬质水平地面条件下所获得的起重量。在坡道上，起重性能会急剧下降。

Warning: the weight shown in capacity performance table is the value getting when pipelayer working on the hard level ground. If working on the slope, the lifting performance shall be reduced dramatically.

3.5.5 牵引操作 Traction

1.一定要检查用于牵引的钢丝绳对于被牵引机器的重量具有足够的强度。

Wire rope strength must match the dragged machine’s weight.

2.不要使用断股的、直径缩小的、扭折的钢丝绳，在牵引过程中，这种钢丝绳有断开的危险。

Do not use the wirerope with broken strand, shrinked diameter and kink. During traction, the wirerope has the possibility of rupture.

3.牵引作业时应在低速Ⅰ档下进行。

Traction work shall be done under first gear.

4.不要在斜坡上牵引机器。

Do not drag the machine on the ramp.

5.牵引过程中，不要站在牵引机器与被牵引机器之间。

During traction, person is not allowed to stand between pipelayer and dragged machine.

6.要缓慢的操作机器并注意不要突然给钢丝绳施加负荷。

Operate the pipelayer gently. Do not give force to wirerope suddenly.

7.牵引较重的物品时应用后牵引装置进行。

When traction heavy machine, rear traction device shall be used.

8.严禁使用吊钩拖拉物品。

No traction by means of hook is allowed.

3.6 低温环境使用注意事项 Note for using in low temperature circumstance

当气温降低，发动机起动就较困难，根据说明书添加防冻液（0℃以下）。

When working in lower temperature, it is difficult to start the engine. Antifreeze shall be added according to the manual.

防冻液使用时，先将冷却水全部放空，清洗内部，除去水垢等，检查散热器、水泵、送水软管等是否有渗漏，然后加入防冻液。

Before using antifreeze, discharge the water and clean interior to remove the scale. Check whether there is leakage in radiator, water pump or hose pipe etc. After confirm everything is ok, add the antifreeze.

在没有防冻液时，因恒温器开启温度是77℃ （即水温低于77℃，水不流进散热器），所以为了防止散热器水结冻，可取下恒温器；或者为了防止发动机过冷，可装上帽状侧罩和散热器百叶罩等，要充分注意发动机体内的保温。

If there is no antifreeze, as the start temperature of thermostat is 77oC (i.e if water temperature is lower than 77 oC, water will not be able to come to radiator), thermostat can be removed to prevent water freeze of radiator. Capped side casing or radiator shutter cover shall be installed to avoid cold temperature of engine. Be caution of engine inside temperature.

在运转中要经常注意水温表的指针是否在正常范围内。

During operation, observe the water temperature indicator frequently.

蓄电池随着气温下降，其功能要下降，充电量要减少，为此，先要把充电率提高到75%以上，并注意保温。

The capacity of battery will be decrease with the temperature lowering. Thus charging rate shall be increased to more than 75%. Keep the battery warm.

充电率根据温度变化（见表），按测出电解液的比重来换算。

Charging rate (refer to following table) calculated by gravity of electrolyte with the temperature changing:

20℃ 0℃ -10℃ -20℃

100% 1.28 1.29 1.3 1.31

70% 1.26 1.27 1.28 1.29

80% 1.24 1.25 1.26 1.27

75% 1.23 1.24 12.25 1.26

另外，当蓄电池需要补给蒸馏水时，为了防冻，不要在作业完了后补加，应该在次日作业前进行补给。

In addition, if distilled water to be added for battery, do not add it after work for antifreeze. It should be added before work in the next day.

本机可选装电动燃油加热器，在极寒冷（-20℃以下）环境下，可以利用电源，通过燃油加热器对发动机机体内冷却液加热。燃油尾气对发动机油底壳进行加热，待温度上升后再进行发动机的启动。

Optional electric fuel heater can be selected during working in the extreme cold climate (below -20oC). It can heat the coolant in engine when connecting the power supply. Fuel exhaust gas can heat engine oil sump tank. Start engine when temperature rising.

第四章拆卸、组装与调试

Chapter IV Dismantle, Assembly and Commissioning

为方便吊管机的运输，需根据不同的交通运输工具，把吊管机按拆卸流程分拆，并按部件包装、运输（包装及运输事项见说明书第五章），以满足运输的高度、宽度和载重要求。待吊管机运输到指定的地点后，再按照组装流程及要求进行组装。

To facilitate transportating of pipelayer, according to the transportation vehicle, pipelayer can be dismantled as per dismantle procedure and it shall be packed and transported part-wise (refer to Chapter V for detailed packing and transportation items) to meet the requirement of transportation length, width and height. After reaching destination, reinstall the pipelayer as per procedure.

4.1 拆卸 Dismantle

PMG40吊管机运输前，为满足高度、宽度和载重要求，可按照以下步骤进行拆卸(根据不同法规和运输形式，进行选择性拆卸)：

PMG40 pipelayer shall be dismantled as per the following procedure to meet the requirement of length, width and height (dismantle shall be optional according to various regulations and transportation forms):

警告：拆卸该吊管机前，应将该吊管机停放在平坦的场地上（场地面积不小于15m×6m），并通读本节，了解相关事宜及关键点后，将所需工具、设备及人员准备妥当，在拆卸过程中时刻注意人身安全！

Warning: park the pipelayer on the level ground (no less than 15m×6m) before dismantle. Read this manual and be fully aware the related essiential contents. Prepare tools & equipment and arrange manpower in advance. Pay attention to personal safety during dismantling

1. 拆卸起升滑轮组 Dismantle the hoist pulley

① 拆起升动滑轮：按操作要求将吊臂摆动到图4-1-1所示的位置，拆除防过卷开关及其线束插头，拆除固定在定滑轮上的楔铁，缓慢的操作起升手柄至“吊钩起”的位置，使起升钢丝绳收回至卷筒上；

Remove the hoist pulley: operate the boom in the position shown in the following 4-1-1 figure. Remove the anti-over winding switch and unplug the wire; remove the adjusting wedge on the fixed pulley; operate the lifting lever to “Hook up” position to make the wire rope winding on the reel.

注意：一定要将吊钩完全放至地面后再拆除楔铁！

Caution: adjusting wedge can be removed when hook is totally on the gound.

图4-1-1 Figure 4-1-1

② 拆起升定滑轮：操作手柄至“吊臂降”的位置，将定滑轮完全放至地面，拆除称重传感器线束插头，拆除上销轴。将起升定滑轮移走后，再将上销轴穿回至原位置并用锁板固定（以下所有销轴同），如图4-1-2所示。

Remove the fixed pulley: operate lever to “Boom down” position and lower the pulley on the ground. Unplug the weighing sensor and its upper pin. After removal of fixed pulley, reinsert the upper pin and lock it with locking plate (be applicable to all pins hereinafter) as shown by figure 4-1-2.

注意：一定要将定滑轮完全放至地面后再拆除上销轴，拆卸上销轴时注意保护其上的注油杯！（以下所有销轴同）

Caution: Personnel must lower the fixed pulley on the ground and then remove the pin. Take care of the oil cup during removal. (Be applicable to all pins hereinafter)

图4-1-2 Figure 4－1-2

2. 拆卸吊臂 Dismantle the boom

① 收变幅钢丝绳：按操作要求将吊臂活动到图4-1-3所示的位置，拆除固定在变幅动滑轮上的楔铁，缓慢的操作手柄至“变幅起”的位置，使变幅钢丝绳收回至卷筒上；

Wind luffing Wirerope: move the boom to the position shown in figure 4-1-3 according to this manual and remove the wedge on the fixed pulley. Pull the lever to “Luffing”position and the luffing wirerope will wind on the reel.

图4-1-3 Figure 4-1-3

② 拆吊臂：Dismantle boom

a) 拆除吊臂弹簧线；Remove the boom spring wire.

b) 采取安全措施，用吊带吊住吊臂尾部，拆除吊臂下销轴；

Take safety meaure by means of hanging the boom tail by slings and remove the lower pin of boom.

c) 将吊臂移走，置于合适位置。

Remove the boom and place it in the suitable place.

图4-1-4 Figure 4-1-4

3. 拆卸配重总成 Dismantle the counterweight

① 拆配重片：按操作规程操作配重总成至便于拆除配重片的位置，拆除配重锁紧垫及配重锁紧杆，用吊带将配重片逐个吊出；

Dismantle the counterweight stack: put the counterweight in the place where is easier to remove the counterweight stack and then lift the stack out one by one by sling.

② 拆配重支架：用吊带吊住配重支架上的吊环，拆除长销轴、下摇臂下销轴，将下摇臂与配重支架整体吊走，如图4-1-5所示；

Dismantle the counterweight frame: use sling to hang the lifting ring on the counterweight frame, remove the long pin and lower pin of rocker and then lift the lower rocker and counterweight frame out like shown in figure 4-1-5.

图4-1-5 Figure 4-1-5

③ 拆下摇臂：拆除下摇臂上销轴，断开下摇臂与配重支架，如图4-1-6所示；

Dismantle lower rocker arm: remove the upper pin on lower rocker arm and disconnect rocker arm and counterweight frame as shown in figure 4-1-6.

图4-1-6 figure 4-1-6

4. 拆除排气尾管 Remove the emission tail pipe

拆除排气尾管上的卡箍，取走排气尾管，如图4-1-7。

Remove the clamp of the emission tail pipe and dismantle the emission tail pipe as shown in figure 4-1-7.

注意：取走排气尾管后，必须将排气尾管安装座覆盖严实，如需着车时须暂时移开覆盖物！

Caution: after removing tail pipe, cover the tail pipe emission securely; when igniting pipelayer, remove the cover temporarily.

图4-1-7 Figure 4-1-7

5. 拆除驾驶室（按需选择拆装）

Dismantle operation cabin (optional dismantle as desired)

① 拆除左侧面板后端的航空插头及右侧座舱的驾驶室电源线，如图4-1-8； Unplug the aviation plugs in the left penel end and cable power supply wire in the right side of operation cabin as shown in figure 4-1-8

图4-1-8 Figure 4-1-8

② 拆除驾驶室固定螺栓，用吊车吊走驾驶室，置于专用铁架上。

Remove the fixed bolts in the operation cabin and lift out the operation cabin by crane on the dedicated steel frame.

4.2 组装 Assembly

吊管机组装时可按照与4.1（拆卸流程）相反的步骤进行。

During assembly, the procedure is reversed with 4.1 (dismantle procedure)

组装前的准备工作如下：Preparation before reinstallation

1. 组装前应将主机停放在一平坦的场地上，场地面积不小于15m×6m；

Before assembly, park the pipelayer in the level ground no less than 15m×6m.

2. 准备起吊设备，起吊能力不低于8吨；

Arrange the crane with the capacity no less than 8 Tons.

3. 准备安装工具、安装人员和辅助材料，如润滑脂、胶皮等；

Provide the tools, manpower and auxiliary material such as lubrication grease and rubber etc.

4. 清点各部件，部件清单参见表5-1-1；Check the parts as per part list 5-1-1.

5. 在组装前必须进行各部件的检验，如各结构件有无影响使用的变形、各焊缝是否有开裂等；

Check deformation which affects using or crack in the welding joints of all parts before assembly.

组装过程： Assembly Process

1. 安装排气尾管，按扭矩要求紧固螺栓（下表为螺栓推荐拧紧力矩表，以下所有螺栓同）；

Install the tail pipe and the bolts should be tightened as per the requirement of torque (the following table is the list of advised bolts tightening torque, it is applicable to all bolts hereinafter):

螺纹规格Screw thread type Tension拉伸力 Fv(N) 拧紧力矩MA(N·M) Tightening torque

8.8级

Class 8.8 10.9级

Class 10.9 12.9级

Class 12.9 8.8级

Class 8.8 10.9级

Class 10.9 12.9级

Class 12.9

M4 3900 5750 6700 3 4.4 5.1

M5 6400 9400 11000 5.9 8.7 10

M6 9000 13200 15500 10 16 18

M8 16500 24300 28400 25 36 43

M10 26300 38700 45200 49 72 84

M12 38400 56500 66000 86 126 145

M14 62500 77500 90500 135 200 236

M16 72500 10700 12500 210 310 365

M18 91000 129000 152000 300 430 600

M20 117000 166000 195000 425 610 710

M22 146000 208000 244000 580 820 960

M24 168000 240000 281000 730 1050 1220

M27 222000 316000 369000 1100 1550 1800

M30 269000 384000 449000 1450 2100 2450

2. 将下摇臂安装到配重支架上；

Install the lower rocker on the counterweight frame.

3. 将下摇臂安装到右活支架上；

Install the lower rocker on the right bracket.

4. 安装油缸下销轴，安装长销轴；

Install the oil tank lower pin and then install long pin.

注意：在此过程中，须用调整垫调整油缸上下绞点的轴向间隙，保证其窜动量在A＜5mm。

Caution: during this process, clearance between oil tank and winch shall be adjusted time to time to eusure the moving value A＜5mm.

5. 安装吊臂，连接吊臂弹簧线；

Install the boom and connect the spring wire.

6. 操作手柄至“变幅降”的位置，将变幅钢丝绳缠入变幅滑轮组，尾端用楔铁固定在楔套里，并安装钢丝绳夹，要求如图4-2-1所示；

Push the lever into “Luffing down”position and wind the luffing wirerope on the luffing pulley; fix the wire rope end by wedge and then install the wirerope clamp as shown in figure 4-2-1.

图4-2-1 Figure 4-2-1

7. 安装起升定滑轮，安装时应使销轴传感器出线端口朝向图4-2-2的右侧。

Install the fixed lifting pulley and the direction of pin sensor outgoing line end shall toward to the right side of figure 4-2-2.

8. 将吊臂置于如图4-2-2所示的位置，用吊车吊起起升动滑轮，操作手柄至“吊钩降”位置，将起升钢丝绳缠入起升滑轮组，上过卷限位开关，尾端固定方式同第6）步；

Operate the boom in the position shown in 4-2-2 and lift the movable pulley. Put the lever into “Hook down” position and wind the wirerope in the lifting pulley; install overwinding limit switch and the fixed type is as the same way of fixing the boom end (procedure 6)

注意：安装起升动滑轮时要注意方向，过卷限位托板的位置应与起升定滑轮的卸套方向一致，如图4-2-2所示！

Caution: pay attention to the direction of the lifting movable pulley! The overwinding limit switch splint direction shall be same as fixed pulley withdrawal sleeves as shown in figure 4-2-2.

9. 连接过卷限位开关及销轴传感器线束；

Wires connecting with over winding limit switch and pin sensor.

10. 发动设备并收起吊臂，操作配重手柄，将配重摆动到便于安装配重片的位置，安装配重片，并上配重锁紧垫及锁紧杆。

Start engine and retract the boom. Operate counterweight lever to swing the counterweight into the place where is easy to install the counterweight stacks and provide counterweight lock washer and lock lever.

图4-2-2 figure 4-2-2

警告：组装完毕的吊管机不可马上投入使用，需按调试流程进行调试、验证合格后方可进行相关作业！

Warning: pipelayer newly installed shall not be used immediately; commissioning and test shall be done and after qualified only, it can start work.

4.3 调试 Commissioning

每次吊管机组装完毕后，须按以下步骤进行调试，未经调试的吊管机禁止投入使用：

Commissioning shall be conducted after each assembly as per the following procedure. Do not use the untested pipelayer.

4.3.1装配完成后的检查 Checking after assembly

装配完成后须立即进行以下检查，确保机器完整性：

Check the pipelayer immediately afte assembly as per the following procedures to ensure the pipelayer is complete:

① 检查各运转机构是否落入杂物，各部位紧固螺栓是否牢固；

Check whether unwanted material drops in the rotary parts and whether the bolts tightening securely.

② 将各绞点加足润滑脂，检查燃油、液压油、机油及防冻液等是否满足用量要求；

Add sufficient lubrication grease for the joints and check quantity of fuel, hydraulic oil, engine oil and antifreeze etc.

③ 活动装配过程中涉及到的所有电气插头，确保插接可靠；

Check all electrical plugs and sockets during assembly should be reliable.

④ 着车进行试运行检查、调试，使液压系统及电气系统工作正常，各活动部位无卡滞现象；

Getting on the pipelayer and conduct the test and commissioning to make sure the hydraulic system and electrical system is working and all movable parts moves smoothly.

4.3.2施工前的整机试验 Overall test for pipelayer before start work

吊管机在施工前还需完成以下试验过程，以确保装配及调试过程中没有影响到吊管机的施工能力。

Complete the tests before pipelayer working to ensure the normal running after assembly and commissioning as follows:

整机试验前需具备以下条件：Fronts to be available for overall test:

 整机符合完整性要求，不得有漏装、错装；

 Pipelayer shall be reinstalled completely without any pending and wrong erection.

 进行试验的场地应平整、坚实，地面倾斜度不大于1°；

 The place for test should be level and firm less than 1°.

 试验用砝码的误差小于1%；

 Deviation of test weight shall be less than 1%.

 试验用测距装置（如卷尺等）的误差小于1%；

 The deviation of measurement device such as tape measure shall be less than 1%.

 检查起升及变幅钢丝绳，不允许有挤压变形、严重腐蚀、断股（3根或以上）等的缺陷。

 Check the lifting and luffing wire rope. Crushed, corroded and broken strands (3 strands or above) are not allowed.

4.3.2.1空载试验 No load test

吊钩上不加载荷，使配重、起升及变幅机构分别以低速及高速在最大工作范围内各动作五次，以检查各机构安装的正确性及操作灵活性，并随时观察有无异常状况，发现问题及时排除。

Operate the counterweight without load, lifting and luffing mechanism acts 5 times in the max working radius and in the min speed respectively to confirm all the mechanism erection correctly and operation smoothly. Observe closely and if any problem found, solve the problem timely.

将吊臂和吊钩在起升、下降到中间位置时各制动一次，观察有无抖动、反转，油压是否正常。

Brake once during boom and hook is up and down to middle position of max working radius respectively. Check whether there is shake or reversing and whether the oil pressure is in the normal value.

按下“紧急抛载”按钮或按住“自由落钩“按钮，观察吊钩能否自由下落，旋出”紧急抛载“按钮或松开”自由落钩“按钮，观察吊钩能否停止下落。

Punch the “Emergency Dump Button” and continuously press“Free Hook-down Button” to check whether the hook drop freely. Screw out the “Emergency Free Fall Button” or release the “Free Hook-down Button”to check the hook dropping stopping.

4.3.2.2额定载荷及密封性试验 Rated load and sealing test

吊重额定载荷时，分别以最低速和最高速起升、降落5次，记录起升、降落油压。检验整机在起吊最大载荷时的稳定性及可靠性，检验起升马达的承载能力，检验制动器开启的灵敏度及制动器关闭的可靠性。

When working in rated capacity, hoist and lower 5 times at the maximum and minimum speed respectively. Record the oil pressure when hoisting and lowering and check the stability and reliability when in the maximum load. Check the motor capacity as well as braker smooth start & secure close.

4.3.2.3液压油清洁度检查 Check hydraulic oil cleanness

吊管机经过试验后应拆检回油滤清器并清洗。吊管机的液压油固体颗粒污染等级不超过ISO 4406 19/16的标准。

After test, oil filter shall be removed and cleaned. The particle class of hydraulic oil shall be no more than standard ISO 4406 19/16.

4.3.2.4安全装置检验 Safety device test

 发动机仪表盘显示及指示正常；

 Engine instrument panel indicating and display is working in good condition.

 报警装置、倒车喇叭及工作灯可正常工作；

 Alarm device, reverse horn and working light can be functioning properly.

 档位及制动锁紧杆可正常工作；

 Shift lever and brake lock lever can work properly.

 灭火器位于伸手可取的地方；

 Extinguisher should be in the place easy to reach.

 安全带可正常使用；

 Seat belt works properly.

 力矩显示器应界面清晰、显示完全；

 Torque monitor has the clear and complete interface.

 摆动吊臂，力矩显示器的幅度有相应变化，取任意两点进行验证，其幅度误差均不得大于±5%；

 Torque monitor interface shall change according to the swing of boom. If take any 2 points for testing, the deviation shall not be more than ±5%.

 吊一定重量的砝码，力矩显示器的重量有变化，重量误差不得大于±5%；

 Hoist a certain weight, the weight shown by torque minitor will be changed and the deviation shall not be more than ±5%.

 操作手柄使吊臂收到与缓冲器接触后，缓慢操作，当幅度收至1.22m时，幅度限位装置起作用（即手柄变幅起失效）；

 Extract the boom to contact with buffer, operate it slowly untill it is to 1.22m, the luffing limit switch will be working (luffing lever is not working).

 展开配重，当配重完全展出或即将完全展出时，力矩显示器显示“配重展“；

 Exend the counterweight fully, the torque monitor will display “Counterweight Extended”

 操作手柄使吊钩收到与过卷限位重锤接触后，高度限位装置起作用（即手柄吊钩起失效）；

 Operate the lever to retract the hook contacting with overwinding limit switch, then the height limit switch is working (lever operation is not working).

 分别在配重展及配重收的状态下，吊一定重量的砝码，然后将吊臂展出或增加砝码重量，力矩限制器的吊重百分比应有变化，当百分数达到90%时，间断报警并限制力矩，即手柄吊钩起及变幅降失效，达到100%时，蜂鸣器持续报警并限制力矩，同时按下“限制解除“按钮后，能够解除限制。

 Hoist weight when counterweight extends and retracts respectively, then extend the boom or increase the weight, the torque limiter’s load percent will be changed; if it is upto 90%, it will alarm intermittently and limit the torque (hoist lever and luffing down function is not working); when it is upto 100%, the buzzer alarms continuously and torque will be limited (lever “Hook up” and “Luffing down” is not working); at the same time, after pushing the “Limit Release Button”, limit will be released.

4.3.3 行走系统试验 Travel system test

① 将吊管机停放在水平地面上，逐个检查支重轮、托链轮及引导轮中油的消耗情况。可缓慢拧松密封螺栓，看油是否从螺纹中渗出，如有油渗出，则油量充足，应立即将螺栓拧紧，如果在密封螺栓完全卸下后，油还不流出，则说明油量不足，需要加油；

Park the pipelayer on the firm and level ground and check the oil consumption in track wheel, carrier roller and idler. Loosen the sealing bolts slowly and observe any oil seepage from screw thread. If any seepage, it means the oil is adequate and you should lock the bolts tightly; if no oil running out as the sealing bolts completely removed, the oil quantity is less and oil should be added.

② 检查履带下垂量，不得大于40mm，否则需加注黄油；

Track chain sag should be less than 40mm, otherwise grease shoule be increased.

③ 检查履带板螺栓无松动;

Check is there any looseness of the track chain

④ 行车检查：着车后分别以I、II、III档及倒档行走1分钟，期间各向左、右转向5次，前进、行走各制动5次，看制动踏板行程是否在标准范围内（150-170mm）；转向操纵杆行程是否在正常范围内（操纵杆行程在0-18.5mm时，转向离合器分离，进一步拉动操纵杆，使行程在18.5-67mm时，制动器开始制动，制动器完全制动的行程为114-134mm之间）。

⑤ Travel checking: after getting on the pipelayer, travel in gear I, II and III and reverse gear for 1 mininuts each, and turn to left and right 5 times respectively. Brake 5 times during start-up and driving to ensure the brake pedal is in the range of 150-170mm; the steering lever is working properly (when steering lever is in the 0-18.5mm, steering clutch will separate and further pull up the lever to 18.5-67mm, the brake works; the fully limited range of braker is 114-134mm.)

第五章运输 Chapter V Transportation

按PMG40吊管机拆卸流程进行拆卸后，需对其各部件进行包装，机车运输途中，要熟悉和遵守各种道路规则，路面运输车辆法及车辆限制条例等交通规则，在穿越桥梁和隧道时，要测定桥梁的通过重量和隧道的空间尺寸；在使用铁路及水路运输时，应学习、遵守相关法规，使车辆安全运送到指定地点。

After dismantling PMG40 pipelayer, packing should be provided part-wise. During transportation, be fully aware of various traffic rules, transport vehicle laws and vehicle limitation etc. When cross the bridge or tunnels, measure the bridge load capacity and dimension of tunnel; when transport by railway or waterage, the related regulation shall be learned and applied so that the vehicle can reach the destination safely.

在运输前，除本章要求的内容外，还需了解运输途中的不可抗拒条件，并针对其作出如防水、防盐雾、防碰撞、防盗等措施。

Before transportation, force majeure shall be considered as well and actions against water proof, salt proof, anti collision and theft proof etc. shall be taken.

5.1包装 Packing

包装是保护货物在运输、装卸及仓储过程中安全、完好的必要条件。PMG40吊管机在运输或存储前可拆分成几部分，其最大外形尺寸、重量及包装方式详见表5-1-1，在包装时，各部件上应有注明该件代号、名称、规格及数量等的标签，并与表5-1-1所列清单一致。

Packing is the necessary precondition to ensure safe and complete goods during transportation, loading & unloading and storage. During transportation and storage, PMG40 pipelayer shall be dismantled into some parts and the maximum dimension, weight and packing shall be in accordance with 5-1-1. Numbers, title, description, and quantity of all parts shall be clearly marked on the packing. The above shall be in accordance with 5-1-1 table.

表5-1-1 PMG40包装、运输部件清单

Table 5-1-1 PMG40 packing and transportation part list

序号SL.No 部件名称Component title 最大外形尺寸（长×宽×高）mm

Maximum dimension (length×width×height) mm 重量 t

Weight t 数量

Quantity 包装 Packing

1 主机

Main engine 4748×3348×3265 26 1 裸装 Naked

2 配重支架 Counterweight frame 2222×1060×1200 2.4 1 裸装Naked

3 配重片 Counterweight stack 1269×547×1294 4.1 1 带运输架 With transporation frame

4 附件 Accessory 7745×1504×1233【7.5m吊臂 Boom】 3.4 1 带运输架With transporation frame

8745×1504×1233【8.5m吊臂 Boom】 3.6

说明：表中第3项（配重片），置于配重运输架里，每台设备配备1个配重运输架，每个配重架可以放置2片配重片。表中第4项（附件），全部安装在附件运输架上，包括吊臂、起升定滑轮、起升动滑轮、变幅动滑轮、下摇臂，可叠加为多层，方便多台运输。详见图5-1-1。

Note: counterweight stack in table item 3 is placed in the counterweight transportation frame. For each pipelayer, 1 counterweight transportation frame is provided and this frame can place 2 stacks. All accessory in table itme 4 including boom, hoist fixed pulley, hoist movable pulley, luffing pulley, lower socker etc. are placed in the accessory transportation frame. To facilitate transportation, the accessory can be placed in multilayer. Please refer to figure 5-1-1 for detailed information.

注意：按管道人提供的运输及包装架进行包装，可满足公路、铁路及水路运输和多次装卸而不发生损坏的需要，且重心位置好，便于吊装及叉装，若不使用管道人提供的运输和包装架，可能会造成意外。

Caution: pack the pipelayer parts according to Pipeline Man Mechanical Co., Ltd can meet the transportation requirement of road, rail or waterway. The packing frame can be repeatedly loading & unloading without damage; it has the lower gravity center which is easy to lift and fork lift; if you don’t use the frame supplied by our company, incident may happen during transportation.

图5-1-1 Figure 5-1-1

主机吊装 Main set lifting

当对PMG40主机进行吊装作业时，请按图5-1-2执行。

Lifting of PMG40 main set shall be done as per figure 5-1-2.

吊管机主机起吊位置Pipelayer main set lifting position

图5-1-2 Figure 5-1-2

注意：起吊时，应确保起吊绳具可靠锁定，且采取措施避免承重部位与吊管机棱角部位直接接触，如在履带边角处垫一方木。

Caution: before lifting , ensure the wirerope was locked securely; take precautions such as putting wood block under the track chain to avoid the directly connection of bearing and pipelayer edge.

进行起吊作业时，应确保吊管机已被锁止，驻车制动已打开且制动锁杆处于锁定位置。

Ensure the pipelayer has been locked, stop brake has started and the brake lever is on lock position when lifting.

5.2公路运输 Road transportation

公路运输即为用拖车运输，运输前应确保使用该运输车辆运输时满足途中各种交通规则、路面运输车辆法及车辆限制条例等，如高度、宽度及载重量的限制。Road transportation is transported by means of trailer. During transportation, be fully aware of various traffic rules, transport vehicle laws and vehicle limitation etc such as the limitation towards height and width.

公路运输前推荐将PMG40吊管机拆分为表5-1-1所列的几部分分开运输，如果该方式无法满足运输要求，可视情况再行拆除其他部件。

It is advised to dismantle PMG40 pipelayer as per figure 5-1-1 for transportation. If it still cannot meet the transportation requirement, further dismantle is required.

装卸吊管机主机时，最好使用专用的装卸台，如没有专用的装卸台，可用爬梯向拖车上装卸，但要遵守以下规定：（图5-2-1）

During engine part loading & unloading, it is better to use the specialized platform; if the platform is not available, use the ladders for loading of main set to trailer. However, the requirements shall be complied with as follows:

1. 拖车要处于制动状态，并用方木将轮胎固定好；

Brake the trailer and block it by wood block.

2. 爬梯要有足够的宽度、长度及强度，能承受主机安全装卸，必要时可在下部支撑方木加强；

Ensure the ladder has sufficient width, length and strength which can bear the capacity of main set loading. If necessary, ladder shall be supported by wood under the ladder.

3. 放正放好爬梯，然后慢慢的装卸主机；

Loading & unloading shall be done slowly on the ladder.

注意：装卸过程中，要有专人指挥，指挥人员应时刻保持在操作手视线可及的地方，手势应清晰明了；

在爬梯上行驶或行驶到拖车轮胎上时，不能调整行驶方向，如需调整，需直线退回到地面后方可调整，否则可能导致主机倾翻、拖车损坏，造成人员伤亡！

Caution: during loading, commander should stand in the place where the loading persons can see clearly; his signal should be clear to understand.

If engine has been on ladder or on the tyre, do not adjust the direction; if adjustment is required, return to ground straightly, otherwise adjustment will make main set tipping over or trailer damage which may cause severe injury.

4. 将主机装在拖车的适当位置，然后在履带前后下方垫上木块，再用坚实的链子或绳索固定，以防途中滑脱而造成事故；

Put the main set on the proper place of the trailer, block the track chain with wood and then fix the main set with firm chain or rope to avoid slipping which may cause incident.

5. 确保各手柄放于下列位置：

Put the lever in the following position:

 油门操纵杆放在低速位置，取下起动钥匙；

 put accelerator lever in the low speed position and take off the keys;

 变速杆放在空挡位置；

 put gear shift lever on the neutral position;

 制动闭锁杆放在锁定位置；

 put the brake locking lever in locking position;

 驻车制动开关放在制动位置。

 Put parking brake on the brake position.

图5-2-1 Figure 5-2-1

5.3 铁路运输 Railway transportation

在进行铁路运输前，应根据当地铁路货运的相关法规、安全条例等制定运输方案，办理相关托运手续。

When railway transporting, consign formality should be done according to local regulation and safety rules of railway transportation.

铁路运输的标准尺寸及超限尺寸可参照图5-3-1。

Refer to the figure 5-3-1 for the standard dimension and limited dimension of railway transportation.

图5-3-1 Figure 5-3-1

5.4 海上运输 Marine transportation

长距离水上运输，要采取喷蜡防锈的措施，海上运输前的准备工作可按下述要求进行。

In case of long distance marine transportation, antirust measure (wax injection) shall be taken. The preparation can be done as follows:

 检查主机（包括车底、车舱内部）及拆下部件的油漆情况，有缺漆的地方必须按喷漆工艺进行补漆处理；

 Check painting of main set (including engine bottom and cabin) and the removed parts; if any pending painting is found, paint the same as per the standard.

 从主机上拆卸后暴露的安装面必须涂油；

 Paint the oil for the exposed surface of dismantled parts.

 支重轮、托链轮、引导轮与履带的配合面必须涂油

 Paint oil for surface of track wheel, carrier roller and idler which connecting with track chain.

 所有管接头（包括液压阀箱及车舱内部）必须涂油；

 Paint oil for all pipe joints (including hydraulic valve & tank and cabin interior).

 用浸油的麻布或塑料袋对电气接头及电路板进行包扎；

 Use the oiled cloth or plastic bags to wrap the electrical connector and electrical panel.

 所有外露的销轴、螺栓头部及钢丝绳、配重油缸缸杆必须涂油；

 Paint oil for all exposed pin, bolt head, wire rope and counterweight oil tank rod.

 用塑料袋对倒车喇叭、工作灯及液压滤清器等进行包扎；

 Use plastic bags to wrap the reverse horn, working light and hydraulic filter etc.

 右活支架、下摇臂及吊臂的销轴孔内必须涂油；

 Paint oil for right bracket, lower rocker and boom pin holes.

 整车喷蜡，蜡的厚度不低于0.035mm；

 Wax injection shall be done for whole pipelayer and the thick is no less than 0.035mm.

 当主机及零部件无法进仓而停放在甲板上时，除满足以上要求外，必须对其进行覆盖，避免风浪的侵蚀。

 If main set and its parts should put on the deck other than in the warehouse, cover it to avoid wave corrosion.

第六章存放 Chapter VI Storage

PMG40吊管机长期存放时最好放入车库内，如无条件露天存放时应用防雨布遮盖，其履带下应垫置方木或水泥板。每隔1个月应启动运转半小时，并将车辆运行一段距离。关键部位应作好防锈处理（如配重油缸的活塞杆应涂满黄油）。It is better to park PMG40 pipelayer in the garage in case of long term storage. If it parks outdoor, use tarpaulin to cover it and put wood block or cement slab under the track chain. Start engine for half hours monthly and drive it for a certain distance. Anti rust treatment shall be done for the essential parts such as painting grease for piston rod of counterweight oil tank.

6.1 短期存放 Short term storage

6.1.1存放及储存前的准备 Preparation before storage

吊管机在完成布管作业后，需要停放时，必须做好存储装备：

Preparation shall be done if storage is required afte use.

1）吊管机应停放在机库或机棚里，如果条件不具备，可以露天停放，但必须选择地势较高而干燥的平台停放，也可在地面上铺设木板，将吊管机置于木板上，并用防雨布盖好。

Park the pipelayer in warehouse or shed. If shed or warehouse is not available, it can park outdoor, but must in the platform where is higher and drier. It can park on the wood block on the ground. Cover the pipelayer with tarpaulin.

2）机库与机棚或露天停放吊管机的地方，要与其它建筑物隔开一定距离，并在其周围设置防火设备。

Keep away from the building and provide fire proof device around it.

3）储存之前，应将整机清洗干净，根据吊管机技术状态可进行三级技术保养，吊管机上所有未涂防锈层的表面，必须涂上润滑油以防生锈，脱漆的地方应补漆。

Clean the pipelayer before storage. Class 3 technical maintenance should be done according to the condition of the pipelayer. Brush the lubrication oil for exposed surface to prevent rust and paint the painting for the surface where painting is pending.

4）由吊管机上拆下的零件和随机工具，在清洗干净后包好，并保存在干燥的地方。

Parts and removed from pipelayer and tools provided with pipelayer shall be stored after clean and packing. Put it in the dry place.

6.1.2 停放及储存 Park and storage

1）入库前，加足燃油和润滑油，并换上新机油。

Before storage, add sufficient fuel oil and lubrication oil and change the fresh engine oil as well.

2）在金属表面薄薄的涂上一层润滑油。

Paint thin layer of lubrication oil for the metal surface.

3）蓄电池卸下端子，并盖好或者卸下单独存放。

Remove the terminal of battery and cover it or store it separately.

5）若估计环境温度会降到0℃以下时，应事先向冷却水加入防冻剂，确保环境温度要高于防冻冷却液配比温度20℃以上。

If it is envisaged that the temperature is below 0oC, put the antifreeze to cooling water and ensure the environment temperature is 20oC higher than the solution.

6）放松履带张紧度，按照润滑表指示点注入润滑脂，用木塞堵紧排气管和消声器口。

Release the track chain tension and inject the lubrication grease according to the Lubrication Table. Block the tail pipe and silencer by wooder stopper.

7）在各油缸活塞杆和履带张紧装置中的挺杆表面薄薄地涂一层润滑油。

Paint a thin layer of lubrication oil for the piston rod of all oil tanks and tension device of track chain.

7）各种操纵杆和踏板设定如下：

Set all the levers and pedals as follows:

 变速杆置空档，并用闭锁杆锁紧。

 Put the gear lever in neutral position and use locking lever to lock it.

 油门操纵杆置怠速位置。

 Put accelartor lever in idling position.

 制动踏板置自由位置。

 Brake pedal is in free position.

8）如果储存时间超过一个月，要坚持每月启动一次发动机，并将吊管机运行一段距离，这是为了使机器的零件和发动机各部的表面，涂上一层新的油膜。

If storage is more than 1 month, start the engine monthly and drive it for a certain distance. The purpose is to make oil film covering the parts and engine surface.

9）雨季或潮湿地区每隔40-60天，应开动吊管机分别以I、II、III、倒档，进行前进左右转向各5~10次，后退左右转向各5~10次，以防离合器片粘结。

If it is in the rainy season or in the wet area, drive pipelayer in I, II, III and reverse gear for forward left and right turn for 5-10 times each and reverse left and right turn for 5-10 times respectively to avoid the cementation of the clutch stack.

注意：如吊管机露天存放，还需注意以下事项：

Caution: if pipelayer parks outdoor, the requirement shall be considered as follows:

 吊管机的停放平台应选择在雨水、雪水易于排泄的地方，并在周围设置排水沟。在停放吊管机的平台不允许有积雪。

 The parking platform shall be in the place where is easy to drain rain and snow water. Provide drain trench around the pipelayer. No accumulated snow is allowed.

 对于底盘自动监控系统、电脑力矩限制器要采取防雨、防潮措施。各操纵杆涂抹黄油，以防生锈。

 For chassis monitor system and computer torque limiter, water proof and humidity proof measures should be taken. Paint grease to all operation lever to prevent rust.

6.1.3 吊管机存放后 After storage

吊管机存放后（如没有掩盖、或未实行每月一次的防锈操纵），在使用前必须做如下处理：

If long term storage without cover or anti rust operation monthly, before use the following shall be done:

1) 卸下机油盘及其它油箱泄油塞，排出混合水；

Remove the engine oil tray and other oil drainer to drain the mixed water.

2) 卸下气缸盖，润滑各气门及摇臂，并检查气门的动作；

Remove the air tank cap, lubricate all air valves and rocker and check the actions of all air valves.

3) 为排出液压系统中的空气，以低速运转发动机，并按下列方法操作：Run the engine in low speed to exhaust the air in the hydraulic system; operate the engine according to following method:

 往复运行配重油缸4到5次，活塞停放在距离行程终点100mm处；

 Repeatedly run the counterweight oil tank 4-5 times and stop the piston on the position in the postion100mm with the end.

 往复旋转起升及变幅绞车各4到5圈，每次转动以3/4圈为宜；

 Run lifting and luffing winch 4-5 times respectively and for each time there should be 3-4 rounds.

 接着运行配重油缸至全行程4到5次，整圈旋转起升及变幅绞车4到5圈。

 Run the counterweight oil tank fully 4-5 times and the hoist and luffing winch 4-5 times.

注意：若发动机起初就高速运转或液压执行元件运行至满行程，那么混进去的空气可能损伤活塞垫等重要元件！

Caution: if engine runs in high-speed or hydraulic elements runs fully in the initially stage, the mixed air may cause damage of essential parts such as piston gasket!

4) 发动机起动后，进行运转，直到完全升温后为止。

Run the engine continuously after start until temperature rises to working value.

6.2 长期存放 Long term storage

6.2.1 存放前 Work to be done before storage

注意：当存放机器时，要把机器调成下图中所示的姿势以保护油缸活塞杆。（防止油缸活塞杆生锈）

 Caution: If long term storage is required, make the pipelayer position as following figure to protect the oil tank piston rod (to avoid the oil tank piston rod getting rust)

当长期存放机器时。要按下列步骤去做。

When long term storage is required, do according to the procedure as follows:

 要清理和冲洗所有零部件，然后把机器放入室内。如果不得不把机器放在室外，要选择平整的地面并用罩布把机器罩起来。

 Clean and flush all components and then park the pipelayer in the warehouse. If warehouse is not available and it has to park outdoor, park it on the leveled ground and cover the pipelayer by tarpaulin.

 存放前，把燃油箱加满，进行润滑更换机油。

 Add fuel oil to oil tank fully, lubricate pipelayer and change the engine oil before storage.

 在活塞杆的金属表面涂一薄层润滑脂。

 Paint a thin layer of lubricating grease for the surface of piston.

 断开蓄电池的负极端子并把蓄电池盖好或把蓄电池从机器上卸下来单独存放。

 Disconnect the cathode terminal of battery and cover the battery or remove it from pipelayer storing it separately.

 如果预计环境温度降到低于0℃（32℉），要在冷却液中加防冻液。

 If it is envisaged that the temperature will be lower than 0℃（32℉）， add the antifreeze in the coolant.

 用锁定操纵杆和踏板锁定装置锁住各操纵杆和踏板。

 Use locking device to lock the levers and pedals.

 把机器上安装附件用的截止阀置于锁定位置。在弯头上装一个螺堵。

 Close the stop valve used for accessory installation and add a plug for elbow.

 把机器安装附件用的选择阀置于“无附件安装”的位置。

 Optional valves for pipelayer shall be put in the postion of “no accessory installation”.

6.2.2存放期间 Work to be done during storage

注意：机器在室内时，如果必须进行防锈操作，要打开门窗，促进空气流通以防止气体中毒。

Caution: if anti rust operation must be done when pipelayer is in the warehouse, open the doors and windows to enhance ventilation preventing gas poisoning.

 存放期间，每月要操作一次机器，以使运动零部件的表面上附上一层新的油膜。同时，还要给蓄电池充电。

 During storage, operate the pipelayer monthly to make the oil film on the parts surface and at the same time, charge the battery.

6.2.3 存放后 Work to be done after storage

当使用长期存放的机器时，在使用机器之前要按下列步骤去做。

After long term storage, works to be done as follows before use:

 擦掉涂在油缸活塞杆表面的润滑脂。

 Wipe the lubrication grease on the oil tank piston surface.

 给所有部位加注机油和润滑脂。

 Add engine oil and lubrication grease for all parts.

 当机器经过长期存放，大气中的水份会进入油中。起动发动机前或起动发动机后，要检查所有部位的油。如果油内有水，要更换所有的油。

After long term storage, moisture in the air may enter oil. Before engine starting or after engine starting, check all oil and if any water found, replace all the oil.

第七章维护与保养

Chapter VII Maintenance and Maintenance

正确、及时地进行技术保养，即定期对吊管机进行检查、清洗、润滑、调整、紧固等技术保养工作，可以提高生产效率，减少磨损和避免发生意外故障，提高了吊管机工作的经济性，延长了吊管机使用寿命，降低了维修费用。

Correct and timely maintenance (i.e. regularly check, clean, lubricate, adjust and tighten etc.) will improve the working efficiency, reduce wear and avoid the unexpected faults. Regular maintenance will enhance the economy, extend the life and reduce the repair cost of the pipelayer.

本机规定的保养小时时间，由计时表记载。

The pipelayer maintenance interval shall be according to the chronoscope.

在作业环境条件较差时，维护作业应比规定的保养时间提前进行。

If working condition is very poor, maintain it earlier than the interval specified in this manual.

7.1 保养注意事项 Maintenance notice

保养时须注意的事项：Items to be noticed during maintenance:

1.保养时必须遵守“安全操作规程”中的有关规定。

Comply with the related safety operation regulation during maintenance.

2.在车辆下面进行保养时，应在驾驶座上挂出标记，必要时在车辆周围做上标记。

During maintenance under the pipelayer, marks shall be provided on the operation seat and if necessary, barrier guards shall be provided on the pipelayer.

3.对车辆打扫、加油、检查风扇皮带张紧度以及对运转部分和其附近的各部分进行检查时，必须停止发动机的运转。

When cleaning the pipelayer, filling oil or checking rotory parts such as fans or belt tension device etc, engine shall be stopped.

4.对蓄电池保养检查与充电时，要关闭发动机，同时要卸下蓄电池与车连接的导线。当电池和充电器拆卸时，应将充电器开关关闭。

Shut off engine when maintenance and charging for bettary, meanwhile, remove the battery wire conneting with pipelayer. During battery and charger removing, switch off the charger.

5.在保养时严禁明火接近，包括吸烟，电焊火花等火种。

Maintenance shall be done far away from flame including smoking and welding spark etc.

6.打开齿轮箱后桥箱等，应注意不要跌落东西。

When open the boxes such as gear box and rear axle box etc., be sure there is no any thing falling from box.

7.在滤油器保养后，应将发动机以中速运转5-10分钟，排除油路内的空气。 After maintenance of oil filter, run the engine for 5-10 minutes to remove the air from the oil pipe.

8.加注润滑油的量要适宜，不能过多也不能过少。

Fill suitable quantity of lubrication oil; do not add too much or too less.

9.对液压系统进行给油、排油与其他检查保养时，要先进行降压。其方法：把吊臂下降到地面，关闭发动机，把各操纵杆操作二、三次后，才能慢慢松开各盖子。

Reduce the pressure when maintain the hydraulic system such as oil feeding and oil discharging or other maintenance. The procedure is as follows: lower the boom on the ground, shut off the engine and operate all levers for 2 or 3 times; then open all covers slowly.

10.在调整油压时要采用专用调整工具，不然在进行难度较大的保养时，会发生事故。

Use the special tools to adjust the oil presseure, otherwise the tough maintenance will cause incident.

11.检查保养中，除必要人员外，其他人员不要接近。

Besides the necessary personnel, unauthorised persons should stay away from pipelayer during maintenance.

12.在加油部位、油标表面及所有加油容器都要保持清洁；油、黄油等要使用清洁品；在检查更换油类时，应在尘土较少的环境中进行，防止垃圾混入。

Keep clean all oil inlet nozzles, oil indicator surface and all oil vessels; use the clean oil and grease. Oil checking and replacing shall be done in the environment with less dust during maintenance.

7.2 保养表：Maintenance Table

序号SL.No 保养项目

Maintenance Item 保养内容

Maintenance Description

启动前的检查 Check before start up

1 检查漏油、漏水

Leakage of oil and water 检查

Checking

2 检查螺栓、螺母

Bolts and nuts 检查及拧紧 Checking and tightening

3 检查电路

Electric line 检查及拧紧

Checking and tightening

4 检查冷却水位

Cooling water level 检查及补充

Checking and refilling

5 检查发动机油底壳油位

Engine oil level for sump tank 检查及补充

Checking and refilling

6 检查燃油油位

Fuel oil level 检查及补充

Checking and refilling

7 检查转向离合器油位

Steering clutch oil level 检查及补充

Checking and refilling

8 燃油箱排除杂质

Remove unwanted thing from fuel oil tank 放出水及沉积物

Draining water and settling

9 检查灰尘指示剂

Dust indicator 检查及清理空气滤芯 Checking and cleaning air filter

10 检查制动踏板行程

Brake pedal 检查及调整

Checking and adjusting

最初250小时保养 Maintenance for initial 250 hours

1 燃油滤清器、机油滤清器

Fuel filter and engine oil filter 更换滤芯

Replacing the filter core

2 发动机油底壳

Engine oil sump tank 换油

Replacing oil

3 转向离合器箱（包括变速箱和变矩器） Steering clutch box(including gear shift box and torqur converter) 更换和清洗粗滤器 Replacing and cleaning coarse filter

4 工作油箱及滤清器

Working oil tank and filter 换油和更换滤芯 Replacing oil and filter

5 终传动箱

Final transmission box 换油

Replacing oil

6 发动机气门间隙

Engine air valve clearance 调整

Adjusting

每250小时保养Maintenance for every 250 hours

润滑（检查下列部位润滑及加注黄油）

Lubrication (check the lubrication oil and grease in the following position)

1 吊臂下铰轴

Boom lower hinge shaft 1处 1 Position

导向滑轮销轴

Guide pulley pin 2处 2 Positions

配重油缸上支点

Counterweight oil tank upper pivot 2处 2 Positions

配重油缸下支点

Counterweight oil tank lower pivot 1处 1 Position

变幅油缸上铰轴

Luffing oil tank upper hinge shaft 1处1 Position

变幅油缸下铰轴

Luffing oil tank lower hinge shaft 1处1 Position

起重定滑轮组铰轴

Hoist fixed pulley hinge shaft 1处 1 Position

起重动滑轮组铰轴

Hoist movable pulley hinge shaft 1处 1 Position

起重滑轮组轴承

Hoist pulley bearing 1处 1 position

吊钩轴承

Hook bearing 1处 1 position

吊钩轴承

Hook bearing 1处 1 position

钢丝绳

Wire rope 2处 2 position

滚筒 Reel 1处 1 position

2 发动机油底壳及机油滤清器

Engine oil sump tank and filter 放油及更换滤芯 Diacharging oil and replacing filter core

3 变速滤油器和转向滤油器

Gear shift oil filter and steering oil filter 更换滤芯

Replacing the filter core

4 终传动箱

Final transmission box 检查油位及补充

Checking oil level and refilling

5 工作油箱

Working oil tank 检查油位及补充 Checking oil level and refilling

6 发电机驱动皮带

Generator drive belt 调整张紧力

Adjusting tension

7 水泵驱动皮带

Water pump drive belt 调整张紧力

Adjusting tension

8 蓄电池电解液

Battery electrolyte 检查液位

Checking electrolyte level

每500小时保养 Maintenance for every 500 hours

1 燃油滤清器

Fuel oil filter 更换滤芯

Replacing filter core

2 通气帽

Ventilation cap 清洗

Cleaning

3 风扇皮带

Fan belt 调整张紧力

Adjusting tension

4 通气孔

Ventilation holes 清洗

Cleaning

5 终传动箱通气装置

Final transmission box ventilation device 检查

Checking

6 后桥箱通气装置

Rear axle box ventilation 检查

Checking

7 乙醚启动装置

Aether start device 检查（选装）

Checking (optional)

每1000小时保养 Maintenance for every 1000 hours

润滑（检查下列部位润滑及加注黄油）

Lubrication (check the following parts for lubrication and grease filling)

1 万向节联轴节

Shaft coupling and universal joints 2处

2 Positions

引导轮调整杆

Idler adjusting rod 2处

2 positions

2 水箱散热片

Water tank radiating flange 检查和清理

Checking and cleaning

3 转向离合器箱

Steering clutch box 换油、清理粗滤器Replacing oil and cleaning filter

4 终传动箱

Final transmission box 换油

Replacing oil

5 工作油箱和滤清器

Work oil tank and filter 换油、换滤芯

Replacing oil and filter core

6 行走部分

Traveling parts 检查及加润滑脂

Checking and adding lubricating grease

7 涡轮增压器

Turbo pressure booster 检查转子游隙

Checking rotor gap

8 防腐蚀器

Anti corrosion device 更换滤芯

Replacing filter core

每2000小时保养 Maintenance for every 2000 hours

润滑（检查下列部位润滑及加注黄油）

Lubrication (lubrication oil and grease shall be added for the following parts)

1 平衡梁轴

Balance beam shaft 1处

1 Position

减速踏板轴

Decelerator pedal shaft 2处

2 Positions

变速杆操纵轴

Gear lever shaft 3处

3 Positions

制动踏板连杆机构轴

Brake pedal link mechanism shaft 6处

6 Positions

油门操纵杆连杆机构轴

Accelerator lever link mechanisam shaft 3处

3 Positions

2 发动机曲轴箱通气帽

Engine crankcase vent cap 清洗

Cleaning

3 涡轮增压器

Turbo booster 清洗

Cleaning

4 气门间隙

Air valve clearance 检查和调整

Checking and adjusting

5 发动机减震器

Engine shock absorber 检查或更换

Checking and replacing

7.2.1 每日保养 Daily Maintenance

7.2.1.1 漏油、漏水检查 Oil and water leakage checking

车辆转动后，要检查是否有漏水、漏油的痕迹，特别是高压软管的接头、液压缸、浮动油封及其散热器等部位；若发现有渗漏时，应分析其渗漏原因，给以及时维修。

After start pipelayer, check oil or water leakage, particularly in joints of HP hose, hydraulic oil tank, float oil sealing and other radiator parts. If any leakage found, find out the reason and maintain it timely.

7.2.1.2 紧固件 Fastener

对各部件的螺栓和螺母的紧固程度，要进行检查：

Check the bolts and nuts tightness;

若有松动，要紧固，特别是空气滤清器、消音器、履带支重轮支架及履带板等部位螺栓。

If any loose found, tighten it (especially the bolts on the air filter, silencer, track wheel and track plate etc) immediately.

7.2.1.3 电气 Electrical

对电气部分进行检查，各线路是否正常。

Check electrical system for the electrical line.

7.2.1.4 冷却水量的检查

Checking cooling water level

补给打开加水口盖子，是否能在过滤器底部看得见冷却水，如看不见，即从加水口加水，加水至如图位置；加水时要关闭发动机。加水停止后，要使发动机急速运转 5 分钟左右，然后再次检查水量，如不符图示要求，再次加水。若发现加水量比平时增量较大，则应检查冷却系统是否漏水。在水温高时，不要立即打开盖子，以防热水喷出，要缓慢地打开盖子，让水中压力降低后再打开。

Open the water inlet cap and check the water level in the filter bottom. If it is not seen, fill up water from water inlet to the position shown in the above figure; when filling up water, shut off the engine. After filling up, run the engine in high speed for 5 minutes and check the water level again. If the level is not as high as the position in the figure, make the water up again. If the water quantity is much more than earlier, check the leakage of the system. Do not open the cap when temperature is high to avoid water ejecting out. Loosen the cap slowly and open it when the pressure becomes lower.

7.2.1.5 检查燃油 Checking fuel oil

当作业结束后，打开帽盖，用油尺 G 检查油量，从加油口处加油，要确保燃油加满。

After working, open the cap and use the oil dipstick G to check the oil level. Fill oil from oil inlet. Ensure the fuel oil is full.

7.2.1.6 发动机油底壳油量检查 Engine oil sump tank level checking

用油尺来检查油量，如油量不足，从加油口补给。在发动机停止状态中检查油量时，油尺要使用刻有“ENGINESTOPPED”的一面。Check the oil level by oil dipstick and fill the oil if it is insufficient. If checking the oil during engine stopping condition, use the dipstick side with the words “Engine Stopped”

若在发动机怠速运转状态中检查油量时，首先要使发动机油压表水温表的指针指向绿色范围，然后使用刻有“ENGINE IDLING”一面的油尺来检查油量。 If checking the oil during idling running, firstly the oil pressure gauge needle shall point to the green area and then use the dipstick side with the work “engine idling”.

7.2.1.7 转向离合器箱体内油量检查 Oil level checking in steering clutch box

此项检查包括变速箱、变矩器的油量检查。用油尺检查，油量不足时从加油口加入规定量的油。

Check the oil level in the gear box and torque convertor. If insufficient oil level found, fill the oil as per requirement of this manual.

7.2.1.8 燃油箱中水和沉淀物的排除

Discharge the water and settling in Fuel oil tank

把燃油箱底部开关打开，排除积压在底部的沉淀物和水，在排除过程中有油也随之而出。

Open the valve in the bottom of fuel oil tank and discharge the water and settling. Oil also can be discharged.

7.2.1.9灰尘指示器检查 Dust indicator checking

当空气滤清器零件产生堵塞时，灰尘指示器的红色活塞到达维修线上，这时必须清洗空滤器零件。保养后按下按钮红色活塞返回。清洗方法参照“空气滤清器的检查”

In case the piston of dust indicator points to the red area due to blocked air filter part, the filter must be cleaned. Afte cleaning, push the button and the red piston will return. Please refer to “Air Filter Cleaning”.

7.2.1.10制动踏板行程检查 Checking the brake pedal stroke

1、检查

制动衬片磨损时，转向踏板行程会增加，使转向困难，当行程超过190mm（制动力减少）时，应作如下调整：

标准行程：110~130mm（发动机怠速运转时，操作力为150N）

75mm（发动机停转时的行程）

2、调整

拆卸后盖及检查盖。拧紧调整螺栓到拧紧力矩为50Nm，使衬片和制动鼓紧密接触（踩下制动踏板，认证接触状况）。然后，反方向转动调整螺栓7/6圈。应使两制动踏板行程相同，否则两侧制动灵活性不一致。如果调整螺栓的尺寸A小于71mm，则需更换新的制动衬带。

7.2.2 每隔 250 小时保养 Maintenance for every 250 hours

包括吊管机开始运转的最初的 250 小时保养，并和“每日保养”一起进行。

This maintenance includes the initial 250 hours maintenance and daily maintenance.

7.2.2.1 加润滑脂 Fill the lubrication grease

加注黄油（润滑脂）到如下黄油嘴中：

Fill the butter (lubrication grease) to the following inlet:

1.发动机风扇皮带轮1处；

1. Position of engine fan belt

2. 涨紧轮及涨紧轮托架2处；

2 Positions in tension wheel and its frame

3. 按保养表加注其余各绞点润滑脂。

3. Fill the grease to all winch joints.

7.2.2.2 油量检查 Checking oil level

检查终传动箱油量，打开盖子 G 查看，如油量达不到下孔边缘，则从给油口 F 加油。(2)液压箱检查先将配重展开，使发动机停止运转，约过 5 分钟以后，查看油指示器G。若油指示器中的油位不处在油窗的上下线之间，则须从加油口 F 加油。此项检查应在作业前进行。

Check the oil level of final transmission box. Open cap “G” to check the oil level and if the level is below lower hole edge, inject oil from oil inlet nozzle “F”; (2) before checking hydraulic box, extend the counterweight and stop the engine. After 5 minutes, if the oil indicator in the oil tank is not between the upper line and lower line, oil must be added from oil inlet nozzle “F”. Checking shall be done before working.

7.2.2.3发电机传动皮带涨紧度检查 Checking generator belt tension

如图为正常涨紧度，即用手指约（6kg）的力，只能压下约 10 毫米位移量；超过此数据，须进行调整，即将滑动螺栓、螺母旋松，然后移动发电机的位置，使之达到正常涨紧度。当三角皮带磨损及延伸失去调整余量而且出现伤痕、龟裂时，应及时给予更换。更换时两条皮带应同时换新的，更换后，须经 1 小时试运转。再进行涨紧度的检查和调整。

Refer to the picture for the normal tension i.e use your finger (around 6kg) to press down the belt, the movement shall be about 10mm; if the value is more, adjust the belt. Loosen the sliding bolt and nut and move the place of generator to achieve the normal tension. If belt abrasion, crack and unflexible happen, replace it immediately. The two belts shall be replaced at the same time. Check and adjust the tension again after 1 hour trial running.

7.2.2.4滤油器零件的清洗和更换

Filter parts cleaness and replacement

变速箱和转向离合器的滤油器零件的清洗与更换，按图；拧下螺栓 2，打开盖子 1，取出零件，然后清洗壳体内部和零件，必要时应更换新的零件。在零件更换后，要进行排气。即将发动机起动，将放气塞 3 拧松，当油喷出后立即紧固。

Refer to the picture for the cleaness and replacement of filter parts of gear box and steering clutch: remove the bolt “2” and open the cap “1”; take out the parts and then clean interior and its parts. If necessary, replace the parts. After replacement, discharge the air. Before engine start, loosen air exhausting plug“3” and when oil sprays, tighten it immediately.

7.2.2.5电池液面检查 Checking battery liquid level

若液面没有达到规定液面（过极板 10～12 毫米以上），则要补充蒸馏水。若电解液减少时，应加入同等浓度的稀硫酸。在加注稀硫酸时，不能使用金属漏斗。在检查液面时，同时须保养电池盖的通气孔。

If the level is lower than the required level (10-12mm above pole plate), add the distilled water. Thin sulfhuric acid should be added in case the electrolyte reduced. Do not use metal funnel for acid adding. When checking the liquid level, maintenance the vent hole of battery cap.

7.2.2.6履带板螺栓检查 Checking track chain plate bolt

发现履带板螺栓松弛，应紧固。其紧固扭矩为 1100±100Nm。

If loose track chain plate found, tighten it immediately. The torque of tightening is 1100±100Nm.

7.2.3 每 500 小时的保养 Maintenance for every 500 hours

每500小时保养期间，同时应进行每250小时保养内容。

During maintenance for every 500 hours, the maintenance for every 250 hours shall be done as well.

7.2.3.1 燃油滤清器 Fuel oil filter

关闭燃油箱底部的阀，用滤清器扳手将燃油滤清器芯卸掉。向新滤芯中注满干净的燃油，并在密封垫上涂少量机油，安装滤芯用手拧紧直到密封垫接触到滤清器底座为止，然后再拧紧到1/2~3/4圈（注意不要拧得过紧）Close the valve in fuel oil tank bottom and remove the fuel oil filter core with filter spanner. Inject the clean fuel oil in the new filter core and painting a little engine oil on the sealing gasket. Use your hand to tighten the filter core until you feel resistance from the filter base and then further screw it to 1/2~3/4 round (do not screw it too tightly).

7.2.3.2通气装置清洗 Air breather cleaness

取下通气装置，用清洁的柴油将内部的杂质清洗干净。

Remove the air breather and use the pure diesel to clean the impurity.

 转向离合器箱1处 1 position in steering clutch box.

 终传动箱2处 2 position in final transmission box.

7.2.3.3风扇皮带 Fan belt

检查V形皮带，若存在一下情况，则更换V形皮带：

Check the V belt and if the following condition found, replace the V belt:

 当V形皮带和皮带轮的槽底接触时；

V belt contacted with the belt wheel trough bottom

 当V形皮带磨损，且它的表面低于皮带轮的外径时；

V belt wore and the surface is lower than belt wheel outer diameter

 当V形皮带有裂纹和脱皮现象时。

Crack and drop-off found on V belt

7.2.4每 1000 小时保养 Maintenance for every 1000 hours

每1000小时保养期间，同时应进行“每 250及 500 小时保养”的内容。

When doing maintenance for every 1000 hours, the maintenance for every 250 hours and 500 hours also should be done as well.

7.2.4.1加润滑脂 Adding lubricating grease

(1)引导轮涨紧油缸（2 处）

Idler tension oil tank (2 positions)

(2)万向节联轴节（2 处），通过两处润滑油嘴加注润滑脂。

Universal joints (2 positions); Fill grease through 2 nozzles.

(3)液力变矩器主轴（1 处），通过润滑油嘴加注润滑脂

Hydraulic torque main shaft (1 position); Add grease through the nozzle.

7.2.4.2水箱散热片检查 Checking water tank radiator plate

把散热器叶片上的泥土、垃圾、树叶等用压缩空气吹净，也可用蒸汽或水代替压缩空气。对橡胶软管随时进行检查，若发现有裂纹或脆化现象要及时更换，同时检查胶管卡箍是否松动。

Blow the soil, garbage and leaves off from radiator plate by compressed air, steam or water. Replace the hose if any crack or brittlement found and check the hose clamp as well.

7.2.4.3转向离合器箱（包括锥齿轮箱）和变速箱

Steering clutch box (including bevel gear box) and gear box

(1) 拧下变速箱壳体上的放油塞，放出旧机油后拧紧;

Unplug the oil discharge nozzle from gear box and discharge the engine oil. Put the plug back and screw it up after discharging.

(2) 拧下变矩器壳体上的放油塞，放出旧机油后拧紧。

Screw off the oil discharge plug from torque convertor; screw it up after oil discharging.

(3) 经变速箱加油口，加注机油至规定油位。

Fill oil through gear box nozzle up to the required level.

按“燃油、润滑油、冷却液种类和用量表”附表中规定的油类，从加油口注入。卸下机体下部的排油塞排油，排油后再拧紧排油塞。

Fill the oil from the nozzle as per annexure “Fuel oil, lubrication oil and coolant type and quantity table”. Remove discharge oil plug to discharge the oil and screw it up after oil discharge.

卸下左地板、螺栓、盖、转向离合器粗滤器和磁铁；松开螺栓，将变矩器粗滤器和盖一起卸下。清洗壳体内部、粗滤器和其它拆下的零件之后，应将它们重新装入合适的位置。

Remove left flooring, bolts, caps, steering clutch coarse filter and magnet; loosen the bolts and remove the torque coarse filter and cap together. Clean the interior, coarse filter and other removed parts and then reinstall them.

(4) 凡是滤油器零件更换后，须按照“每 250 小时保养”内的规定，从加油口加注规定量的机油。后桥箱内的油量约 136 升；使用的润滑油类型取决于环境温度。应参考附表“燃油、润滑油、冷却液种类和用量”

After replacement of all filter parts, oil injection through nozzle must be done as per the requirement of “Maintenance for every 250 hours”. Rear axle casing has about 136 liters oil and the type of lubrication oil will depands on environment temperature. Refer to the annexture “Fuel, lubrication oil and coolant type and quantity sheet”.

7.2.4.4工作油箱内油的更换 Working oil replacement

(1)把工作油箱下部的放油塞卸下，然后拧松排油阀进行排油，排泄完毕后，将排油阀拧紧。

Unplug the discharge oil in the working oil tank bottom; loosen the valve to discharge the oil. Screw up the diacharge valve after discharging.

(2)检查滤芯是否完好,打开油箱清洗孔清理油箱底部污渍。

Check the filter oil and open the clean hole to clean the dirt in the oil tank bottom.

(5) 检查清理完成后,从加油口 F 加入规定量的液压油。工作油箱内的油量约 560升。

When complete checking and cleaning, inject hydraulic oil from nozzle “F” to the required level. Woring oil tank has about 560 liters oil.

7.2.4.5终传动箱 Final transmission box

(1)把车体两侧的放油塞打开进行排油，排油后将油塞紧固。

Remove the discharge oil plug in both side of pipelayer. After oil discharging, screw it up tightly.

(2)从加油口加注规定量的机油。终传动箱两侧内的油量各为约 55 升。Inject oil from oil nozzle about 55 liters for each side of final gear box.

7.2.4.6行走部分 Travel parts

把车子停在平坦的地上，按下述方法检查支重轮、托轮、引导轮的油量是否要加注

Park the pipelayer on the level ground and check the oil level of track wheel, carrier roller and idler as follows:

(1) 把各轮的密封螺栓慢慢地松开，如果从螺纹中有油渗出，说明可不必加注新油，立即把螺栓紧固。

Loosen the sealing bolts slowly. If oil seepage happens, that means it is not required to add fresh oil and tighten the bolt immediately.

(2) 密封螺栓若松开甚至卸掉后，仍没有油漏出，说明油量不足，须立即加注新油。

If there is no oil seepage till loosening bolts even removing, that means the oil is not sufficient and fresh oil should be added.

7.2.4.7防腐蚀器（水滤芯） Corrosion protection device (water filter core)

关闭防腐蚀器进，出水阀门。用滤清器扳手，逆时针方向旋转，以拆下防腐蚀器滤芯。在密封面上涂少量机油，换上新元件。安装时，在密封面与盖接触后再拧紧到1/2~3/4圈（注意不要拧得过紧）。更换后，打开阀门。Close the inlet and outlet valve of corrosion protection device; use the filter span to screw the core counter clockwise to remove it. Paint engine oil on the sealing surface and then replace the new parts. During installation, screw 1/2~3/4 round after sealing surface contacting the cap (do not screw too tightly). After replacing, open the valve.

7.2.5 每 2000 小时保养 Maintenance for every 2000 hours

包括“每 250，500，1000 小时保养”一起进行。

The Maintenance should include the maintenance for every “250 hours, 500 hours and 1000 hours” as well.

7.2.5.1加注润滑脂 Inject the lubrication grease

如图所示在箭头所指方向处加注黄油。Add the grease to the arrow position.

1.平衡梁轴 1处 1 position in balance beam shaft

2.制动踏板轴 5处 5 positions in brake pedal shaft

7.2.5.2涡轮增压器 Turbo booster

粘附在涡轮增压器压泵轮上的过多炭黑或油泥可能会损坏涡轮增压器的正常性能，有时会使涡轮增压器损坏，请与销售商联系，进行必要的检查或清理。不要使用钢丝刷或类似物，以防损坏泵轮表面。

Too much carbon dirt or pleistocene may damage the turbo booster or decline its performance. Please contact dealer for the necessary checking or cleaning. Do not use the brush like wire brush to clean the dirt to prevent damage of turbo booster surface.

7.2.5.3气门间隙 Air valve clearance

检查气门间隙，如需调整，请使用专用工具。

Check the air valve clearance. If necessary, pls adjust it by the special tools.

7.2.6不定期保养及调整 Irregular maintenance and adjustment

7.2.6.1冷却水更换 Cooling water replacement

 当冷却水里加有防冻液时的更换，应在每年春、秋两季进行。

If cooling water contains antifreeze, replace it in Spring and Autumn season of every year.

 当冷却水里不加注防冻液时，须每隔 1000 小时更换一次冷却水。

If there is no antifreeze in cooling water, replace it for every 1000 hours.

更换方法如下： Replacing procedure is as follows:

（1）将车辆停放在平坦的地方，停止发动机，紧固防蚀通气装置，慢慢旋开散热器盖，让水中压力下降：特别是水温高时防止热气喷出烫手。

Park the pipelayer on the level place, stop the engine and tighten the air breather. Loosen the radiator cap slowly to reduce the water pressure. Do not hurt your hands when hot steam goes out.

（2）打开 3 处放水阀（散热器、气缸体、油冷器）进行排水。

Discharge the water from 3 positions (radiator, air cylinder and oil cooler) etc

（3）排水完毕后，用清洗剂清洗，清洗方法按商标上说明的方法做。

After water discharging, clean it as per the method shown on the trademark

（4）洗净后把水全部排净，关闭各放水阀，从加水口把清水加到要求位置。After cleaning, discharge water and close all valves. Fill water from water inlet to the desired level.

（5）将发动机作怠速运转，打开各放水阀放水，并继续从加水口加水清洗，直到放水阀里流出干净的水为止，然后关闭放水阀。

Running engine idling, open all discharge valves and add the water from inlet nozzle to clean it again until water is discharged thoroughly. Close the discharge valve.

（6）再从加水口按要求把水加满。

Fill the water from inlet nozzle fully.

（7）更换防蚀通气装置中的防蚀剂。

Replace the anticorrosive in the air breather.

（8）为了清除混入冷却水中的空气，将发动机怠速运转 5 分钟，然后再高速无载荷运转 5 分钟。

To remove the air mixed in the cooling water, run the engine idling for 5 minutes and then run it in high speed without load for 5 minutes.

（9）发动机停止 3 分钟后，再从加水口按“每日保养”第四条中的图示要求加满水量，然后紧固加水口盖子。

After 3 minute from stopping engine, add water fully according to the item 4 in “Daily Maintenance” and then tighten the water inlet cap.

7.2.6.2空气滤清器检查、清洗和更换 Air filter checking, cleaning and replacing

当灰尘指示器显示出红色标识时，就要立即清洗空气滤清器，这时发动机须停止运转。

When there is red mark in dust indicator, which means the air filter should be cleaned immediately , stop the engine and clean it.

(1) 卸下盖子①和外套筒滤网②。

Dismantle the cap ① and outer sleeve strainer ②.

(2) 清洗壳体内部和盖子。

Clean interior and cap.

(3) 清洗外套筒滤网

Clean the outer sleeve strainer.

清洗方法如下：Cleaning method is as follows:

（a）用压缩空气的清洗方法即用干燥的压缩空气（0.7MPa 以下），先从内表面沿着褶条吹气，然后从外表面沿着褶条吹气，最后再次吹内表面，使内外表面不沾尘土。 Compressed air - Use the dry compressed air (below 0.7MPa) to clean the inner surface along the pleat and then blow the outer surface along the pleat. At last, blow the inner surface again to clean inner and outer surface thoroughly.

（b）水清洗方法，即用自来水（0.3MPa 以下）从滤网的内表面沿着褶条冲洗，然后从外表面沿着褶条冲洗，最后再次冲洗内表面，待干燥后检查滤网。 Water cleaning - Use the water (below 0.3MPa) and flush the strainer inner surface along pleat and then flush the outer surface. At last flush the inner surface again and check the strainer afer when it is dry.

1) 20 升水中混入 300 克洗涤剂；

Mix 300g detergent with 20 Liter water;

2) 把滤芯在以上溶液中浸 15 分钟；

Soak the core in the solution for 15 minutes.

3) 在流动的清水中冲洗；

Flush it with flowing water.

4) 采用电风扇吹干（决不可加热烘干），待干燥后检查滤网。

To dry with a fan (do not heat); check the strainer after dry.

（d）若用 40℃左右的温水中冲洗，效果更佳。

It is better to flush it with 40oC water.

(4)滤网清洗干燥后用灯光检查，如有小孔等损坏时需更换新的。（图 5-29） After cleaning, check the stainer with the light; in case of any damage, replace it.

(5)外套筒滤网，经六次清洗后或用过一年后，即应更换新的，不允许继续使用；若虽然清洗不到六次，但清洗后使用时，灰尘指示器仍出现红色标识，也须立即更换新的。

Outer sleeve strainer shall be replaced when it has been cleaned 6 times or it has been used for 1 year. Though it is not cleaned 6 times, if the dust indicator still in the red area after cleaning, it also shall be replaced immediately.

(6) 在更换外套筒滤网时，要同时更换内筒滤网。

When replace the outer stainer, replace the inner strainer together.

7.2.6.3履带涨紧度 Track chain tension

7.2.6.3.1 检查 Checking

(1)检查履带涨紧度时，把车辆停放在水平地面上，不踩制动器，用一根直杆放在托轮和引导轮之间的履带上。当杆和履齿之间在中心处的距离是20～30mm时，表明张力合适，履带的涨紧度是标准的。

Park the pipelayer on the level ground to check the chain tension. Do not stamp on brake and put a rod on the chain between idler and carrier roller. When clearance between rod and chain grouser is 20-30mm, the tension of chain is qualified.

(2)检查引导轮导向板间隙。如果间隙太大，使引导轮产生横向窜动，造成引导轮中心线与轨距不一致。间隙 A 小于 4 毫米范围内为正常。

Clearance of idler guide plate- too great clearance will cause lateral displacement and the centre line of the idler has the deviation with the track gauge. Clearance A should be less than 4mm.

(3)检查链节节距 Track chain pitch

在履带板与链轮之间嵌入木块，使履带不松弛；然后以处于木块上的节销为基准，离开此节销二节以外的位置为起点，测量其直线部分的 4 个链节节距长度 L，其 1/4×L，即为链节的节距。（以主销为基准也可以）基本链节节距：216 毫米

Insert wood block between track chain plate and carrier roller to make the chain tension. Make the pin on the wood block as the bench mark and choose the pin at lease 2 pitches from the bench mark as the start point. Measure 4 pitches length. The pitch is 1/4×L. (main pin can be bench mark also). The basic pitch is 216mm.

(4)检查履带板齿高度 Chain grouser height

当履带板拉紧后，在履带板的中间，测量其齿高 A。标准尺高：72 mm 修理极限：25 mm

After chain tension, measure the grouser height “A” in the center of track. Standard height:72mm; repair limitation: 25mm.

(5)检查支重轮外径 Checking outer diameter of track wheel

(a)如图测量链节上下平面间高度尺寸 C； Meausre the height of chain “C” as per the figure

(b)当链节上平面和支重轮外圆完全接触时，停车，测量如图尺寸 B，支重轮外径尺寸 A，即 A=(B-C)×2 标准尺寸：222mm 修理极限：198mm

Stop the pipelayer when the chain surface totally contacts the top circle of the track wheel, meaure the length “B” and the out diameter of track wheel “A” as per the figure, i.e. A= (B-C)×2. The standard size: 222mm; repair limitation: 198mm

(6)检查各种轮子是否漏油；螺栓、螺母是否紧固，如发现问题，应立即修理。

Check oil leakage for all wheels and the tightness of all bolts and nuts. If any problem found, repair it immediately.

7.2.6.3.2调整 Adjustment

1.履带涨紧度调整 Track chain tension adjustment

若要增加履带涨紧度时，可从加油口注入黄油。其调整极限行程为 S。

Inject grease from oil inlet nozzle to increase chain tension; the adjusting limitation is “S”.

当调整到 S=0 时，若此时履带还是松弛，说明销子和销套的磨损已到极限，则必须更换全部销子和销套的安装位置，其方法是以它们原安装位置为基准，全部反转同一角度（改变原安装位置），然后再重新装配，或者更换一条新的履带。若要使涨紧度松弛，可把塞子 2 松约一圈，挤出黄油。在旋松塞子 2 时，不得超过一圈以上，但要注意决不能松动塞子以外的零件，防止内部的高压油喷射出来，造成事故。当黄油从塞子处出来如不正常时，可将车辆前后运动一下。

If the chain tension is still not achieved to the desired tension when S=0, it means the pin and its bushing has worn. In this case, installation position of all pins and bushings shall be reversed (reverse the same angle with the original one) and then reintall; or the whole chain shall be replaced. If the tension shall be loosened, screw the plug “2” one round out and grease will come out from the plug. Do not screw the plug”2” more than one round. Do not move other parts to prevent the HP oil ejection which may cause incidents. If the grease cannot come out from the plug, move the pipelayer a little bit.

2.引导轮间隙调整 Idler clearance adjustment

当引导轮在外力作用下，支架 2 可以在台车架上部沿导向板 3 前后移动，引起导板 7 及导向板 3 磨损，造成引导轮横向窜动、侧向倾斜以及引导轮与轨距不一致，以至使支重轮、托轮的法兰边及链轮的侧面等和履带发生干涉而造成过快的磨损，因此必须进行各间隙调整。

When the idler is in the force, support “2” can move along the guide plate “3” which will cause the guide plate “7” and guide plate “3” worn; the idler will move transversely, incline laterally and deviate with the track, so the flange of track wheel or carrier roller and idler profile will be rubbing with track causing the severe wear. Thus the clearance among all wheels shall be adjusted.

由于引导轮在台车架上的移动造成有关连接件的磨损，若这些部位的间隙过大，会使引导轮横向偏摆，导致履带啃轨，重则脱轨。因此，应经常按下列方法调整。

Connecting parts may be worn due to movement of frame. If the clearance between the parts is great, the idler may swing which cause track gnawing or even digression. Therefore, adjust it frequently as per procedure as follows:

(1)左右调整 Lateral adjustment

吊管机在平地上行走 1～2 米后，若测得左右外侧（共四处）间隙 A＞4 毫米时，应调整。调整方法如下：把螺栓 1 松开三圈以下，取出调整片 a，使单侧间隙 A=0.5～1毫米，然后紧定螺栓即可。调整垫片的厚度为 1mm。

When the pipelayer drive 1-2 meters and the left and right outer clearance A＞4mm (4 positions), adjust it according to the following method:

Loosen bolt “1” more than 3 cycles, remove the adjusting shim “a”. The single side clearance A=0.5～1mm and then tighten the bolt. The adjusting shim thickness is 1mm.

(2)上下调整当间隙（B＋C）≥5 毫米时，应予以调整。调整方法如下：Up and down adjustment - when the clearance （B＋C）≥5, it should be adjusted as follows:

松开螺栓，将 c 调整片抽出，然后将其插入 b 内，使（B＋C）=2 毫米；正常状态 C=0

Loosen the bolts and pull out the adjusting shim “c” and insert it into “b”; （B＋C）=2mm and normally C=0mm.

例：当 B=5mm 时，调整量为 5-2=3mm。

For example: when B=5mm, the adjusting value should be 5-2=3mm;

注意：在调整前后，调整片 b 与 c 之和保持不变，否则会造成各橡胶弹簧支承力的不均匀；调整片厚度有 1mm 与 2mm 两种。

Caution: the value=B+C should be constant, otherwise the force of rubber spring is uneven; there are 2 types of adjusting thim thickness: 1mm and 2 mm.

调整完后，紧定螺栓。螺栓 1 与螺栓 5的紧固力矩为 645～845N·m。

After adjustment, tight the bolts.The tight torque of bolt 1 and bolt 5 is 645-845 N.m.

3.减速踏板行程的调整 Decelerator pedal stroke adjustment

若把燃油控制杆，置在总行程的 1/2处，踏下减速踏板，使间隙 A=0 毫米，此时发动机的转速应在 800～850 转/分范围以内，不在此范围以内，应按下列步骤调整：

Pull up the fuel lever in the 1/2 position and stamp on the pedal making the clearance A=0mm, if the speed is not between 800-850 r/min, it should be adjusted as follows:

（1）松开锁紧螺母 1，然后调节调整螺栓 2，一直调整到出现以下状态时为止，即：当踏下减速踏板到使之间隙 A=0 毫米时，发动机的转速能在 800～850 转/分范围内运转，说明踏板行程正常了。

Loosen the lock nut “1” and ajust the bolt “2” until the engine speed is between 800-850 r/min when stamp the decelerator pedal making the clearance A=0mm.

（2）调整后紧固锁紧螺母 1在调整时，为了正确调整发动机转速，必须使用转速表。

After adjustment, tighten the locking bolt “1”; during adjusting, revolution meter must be used to check the engine speed correctly.

7.2.6.4 制动踏板行程的调整 Adjusting brake pedal stroke

因为制动器结构是外带式，因此当制动带衬片磨损后，转向操纵杆及制动踏板的行程就增大，使制动作用减弱，为此必须调整。其调整方法如下：As it is the contracting band brake, afer brake band lining wear, the stroke of steering lever and brake pedal shall be increased and the brake action will be weakened; thus it must be adjusted as follows:

（1）、卸下后部盖子，再卸下制动器检查盖 1；

Remove the cap and then remove the brake inspection cap;

（2）、将拉紧制动带的调整螺栓 2 拧到底（感觉有阻止为止），此时制动鼓和制动带相互贴合；

Screw down the adjusting bolt “2” (until you feel resistance) and at this time the brake drum will touch the brake band.

（3）、然后将调整螺栓 2 往回退约 7/6 转；

Screw back the bolt “2” about 7/6 cycles.

（4）、发动机以怠速运转，在此状态下测量制动踏板的行程；标准行程：110～130 毫米.

Measure the brake stroke when engine is idling; the standard stroke is 110-130mm.

（5）、测量后如不在以上标准范围内，再次调节调整螺栓 2。螺栓顺时针方向旋转其踏板行程减小，逆时针方向旋转其踏板行程增大；

If the stroke is not in the above range, adjust the bolt “2” again; screw the bolt clockwise, then the pedal stroke will be decreased; screw it counter-clockwise, the stroke will be increased.

（6）、若调整螺栓 2 如图的尺寸在 71毫米以下时，即要调换制动带衬片；

If the adjustment size of the bolt “2” is less than 71mm, change the brake lining immediately.

（7）、左右两块踏板的行程，应调整的一致，即两块踏板高低差只允许在 5 毫米以内。

Both left and right padel stroke shall be same and the deviation shall be no more than 5mm.

7.2.6.5引导轮 Idler

引导轮长时间被迫旋转，侧面导板、上下板和引导板将逐步磨损，从而导致了引导轮左右摆动或因引导轮偏斜，履带链节将会从引导轮脱出，或造成引导轮和链节的不均匀磨损。因此必须按照下述程序随时调整引导轮，使其处于良好的运转状态。

The side guide plate, upper & lower plate and idler plate are worn due to long term running causing the swing of idler. Thus the track chain link may go out of idler or the uneven abrasion of idler or chain link may be happened. Therefore, the idler shall be adjusted time to time as per the following procedure to maintain it in the good condition:

1、侧面导板调整 Side guide plate adjusting

1) 车辆在水平地面上运转1~2m，使履带均匀涨紧，然后使车辆停止。检查导向板与以车架之间的间隙“A”（每侧导板共有左、右、上、下4个间隙）。

Pipelayer travels 1-2m on the level ground to make the track tension even and then stop the pipelayer; check the clearance “A” between guide plate and frame (for each side plate, there are 4 clearance including left, right, upper and lower).

2) 若任何一间隙超过4mm，则松开螺栓1，并卸去一定数量的垫片2，再调整到标准间隙：0.5~1.0mm，垫片厚度是：0.5~1.0mm。

If any clearance is more than 4mm, loosen bolt 1 and then remove a certain quantity of shim “2”, and then adjust the clearance to the standard 0.5-1.0mm. The thickness of thim is 0.5-1.0mm.

松开螺栓1时，注意不要使螺栓移动多于3圈。

When loosening bolt “1”, do not screw it more than 3 cycles.

2、导向板和上、下导板调整 Adjustment of guide plate and upper & lower plate

测量支承座（件3）和导向板（件4）之间的间隙“B”，以及上、下导板（件5）和台车架减磨板之间的间隙“C”。如两个间隙“B”和“C”之和超过5mm，应将其减少到2mm。方法是抽出垫片（件7），使其减少至要求的厚度，并把同样厚度的垫片加到垫片（件8）中。这种调整可按下述程序完成。

Measure the clearance “B” between fulcrum bearing “3”and guide plate “4” and the clearance “C” between upper & lower guide plate “5” and bogie frame antifriction plate. If the sum of “B” and “C” is more than 5mm, the value should be decreased to 2mm by means of pulling out shim “7” to make the thickness as desired; then add the shim which has same thickness of shim “7” into shim“8”. The adjustment can be done according to the following procedure:

间隙C是零（0mm）为正常。测量间隙“B”，从“B”值中减去2mm, 这个结果是被调整的垫片厚度（例如：B=5mm，调整垫片厚度是：5-2=3mm）。垫片（件7）和（件8）为可抽取式垫片。

The standard value of clearance “C” is 0mm; Measure clearance “B” and reduce the clearance “B” by 2mm. The value is the adjusting thickness of shim (for example: B=5mm and the adjusting shim thickness should be 5-2=3mm). Shim “7” and shim “8” is the removable shim.

b 松开螺栓（件9），直到感觉不到有弹簧力为止。

Loosen bolt “9” until there is no force from spring.

c 松开螺栓（件1），注意不要拧动螺栓3圈以上。

Loosen bolt “1” no more than 3 cycles.

d 用棍向上调节导板（件5），使间隙“C”为零按第1）步确定的所需垫片厚度卸下可抽取垫片（件7）。将卸下的垫片（件7）加到可抽取的垫片（件8）上调整前后，垫片（件7）和（件8）相加厚度不变。若粗心使垫片总厚度增减，将导致安装在导向装置内的弹簧的预加负荷不适宜。拧紧弹簧座螺栓（件9）。螺栓（件1）的拧紧力矩为500~620Nm。上、下导板最大允许调整量为6mm。

Adjust the guide plate “5” up with stick and make the clearance “C” =0mm. Remove the shim “7” according to step “1” to confirm the thickness. Put the removed shim “7” into removable shim “8” and then adjust it. The sum thickness (shim “7”+ shim “8”) is constant. If making the sum thickness of shims thicker carelessly, it will cause the spring force in guide device is improper. Screw the bolts “9” for spring seat tightly. The screw torque of bolt “1” is 500-620Nm. The allowable adjustment value of upper & lower guide plate is 6mm.

7.2.6.6 风扇皮带 Fan belt

因为风扇皮带带有自动涨紧装置，其涨紧度始终保持常量，与V形皮带伸长无关，至其皮带损坏而不需要调整。更换V形皮带时，应同时更换两根皮带。

As the belt has the automatically tension device, the tension is aways constant and has nothing to do with the V belt. Hence it is not required to replace until damage. Replace both belts at the same time.

7.2.6.7 液压油的使用和更换 Using and replacing hydraulic oil

7.2.6.7.1 液压设备的故障和液压油的关系

Relation between hydraulic device fault and hydraulic oil

统计资料表明：液压设备的故障有70-75%与液压油有关，其中主要原因是液压油的选择、使用不当和管理不善引起的。

Statistics show that about 70-75% device faults of hydraulic device is arising from hydraulic oil, the main reason is improper oil selection, use and management.

液压油的使用性能变化（粘度升高降低，防锈性不良，抗乳化不良，变质、污染、腐蚀、抗泡性不良等），对液压设备的性能有着各种各样的影响。反过来，液压设备的各种因素也会影响液压油的使用性能，所以在合理选择液压油的基础上，还要注意液压油的合理使用和管理。

Hydraulic oil performance variation (viscosity variation, poor anti rust performance, poor anti emulsifying performance, deterioration, contamination, corrosion or poor anti-froth quafity) will affect the device and vice versa. Thus use and manage the hydraulic oil well based on the correct choose of oil.

7.2.6.7.2 液压油的选择 Hydraulic oil selection

液压系统一般都采用矿物油，在选择时，除了按照泵、阀等元件出厂规定外，还应考虑如下因素：

Mineral oil is normally choosed for hydraulic system. When selecting, the following elements to be considered apart from the requirement of pump and valve manufacturing requirement:

1、环境温度：环境温度高时应采用粘度高的液压油，反之，采用粘度较低的液压油。

Environment temperature: use the high viscosity oil when temperature high and vice versa.

2、系统工作压力：工作压力高，宜选用高粘度的油，工作压力低时，则宜选用低粘度的油。

System work pressure: use the high viscosity oil when under high pressure and vice versa.

3、工作装置运动速度：速度高，为减少压力损失，宜选用低粘度油。反之，则选用较高粘度的油。液压吊管机多采用抗磨液压油或低温度液压油，如下表：

Working parts running speed: when it is in high speed running, use the low viscosity oil to reduce the pressure loss and vice versa. Anti-wear oil or low temperature oil is mostly used for pipelayer as follows:

抗磨液压油 Anti-wear hydraulic oil

新牌号

New label number 旧牌号

Old label number 粘度（50℃厘斯）Viscosity (50oC centisthene)

L-HM32抗磨液压油 L-HM32 Anti-wear hydraulic oil 20 17～23

L-HM46抗磨液压油 L-HM46 Anti-wear hydraulic oil 30 27～33

L-HM68抗磨液压油 L-HM68 Anti-wear hydraulic oil 40 37～43

L-HM 100抗磨液压油L-HM32 Anti-wear hydraulic oil 60 57～63

低温液压油 Low temperature hydraulic oil

新牌号 New label number 旧牌号

Old label number 粘度（50℃厘斯）Viscosity (50℃ centisthene)

L-HS15抗磨液压油

L-HS15 Anti-wear hydraulic oil 10 8～12

L-HS22抗磨液压油

L-HS22 Anti-wear hydraulic oil 20 17～23

L-HS32抗磨液压油

L-HS32 Anti-wear hydraulic oil 30 27～33

L-HS 46抗磨液压油

L-HS46 Anti-wear hydraulic oil 40 37～43

7.2.6.7.3液压油的更换 Replacement of hydraulic oil

1.在使用过程中，液压油性能的变化：

The hydraulic oil performance will be changed during use.

液压油在使用一段时间后，其性能就会发生变化：

Hydraulic oil performance will be changed after use:

1) 外观上：颜色变深以至变黑，油中有沉淀物，产生刺激性臭味。

Apperance: the colour is getting dark and settling is in the oil which leads to fume.

2) 机械杂质增加，液压件磨损加快。

Machanical impurity will be increased and the elements abrasion will be occurred faster.

3) 水分土增加。

Water content and soil will be increased;

4) 酸值增高。

Acid value will be increased;

5) 乳化性和抗泡性变差，这些性能的变化会引起液压机械的故障损坏。所以在一定时期就需要更换液压油。

Emulsification and anti-froth performance is getting poor. The above variation will cause the hydraulic system faults, thus replace the hydraulic oil time to time.

2.换油期的确定方法 How to confirm the oil replacement interval

目前确定换油期的方法有三种：规定固定的换油期；根据经验和对油样的观察决定是否换油；抽样化验。其中以抽样化验更为科学合理。

There are three methods to confirm the interval of oil replacement: 1. Specified scheduled oil replacing interval; 2. checking oil sample visually and confirm according experience; 3. Sampling test. Among these 3 methods, sampling test method is the best way to confirm the interval.

1)规定固定的换油期：这种方法确定换油期的决定因素是：油箱大小，使用条件（环境），机器类型等，吊管机换油期规定为纯运转1500小时以上或使用约12个月左右。

Specified scheduled interval - the decisive factors is oil tank size, using environment and machine type etc. For pipelayer, the oil replacement period is above 1500 hours or around 12 months.

2)根据经验和对油样的观察：如与新油对照，根据外观和气味决定是否换油。或在滤纸上观察油品斑痕等。注：必须在机器工作时抽样。 Confirm it according to experience and oil sample such as comparing with the fresh oil method, appearance and smell method or sample spot on the filter paper method. Note: sampling should be done when machine is working.

7.2.6.7.4液压油的加注 Hydraulic oil filling up

1.液压油加注前的准备工作 Preparation before filling up

1）验明油种、牌号 Determine the oil type and label number

购买的液压油应抽样化验。确认是选定的牌号，性能指标符合要求。（按厂家技术文件检验）最好化验其中几个关键项目，如粘度、防锈性、铜片腐蚀试验等。注意：抽样时应将油搅拌均匀。 For new purchased oil, sampling test is required to confirm the number lalel and standard performance. Test it as per the manufacturer’s technical document for essential items such as viscosity, antirust or Corrosiveness to copper--Copper strip test etc. Caution: mix the oil evenly when sampling.

2）过滤：如运输、贮运过程，油桶中进入水分和杂质，应使用工业滤纸进行过滤。

Filter: during transportation and storage, water or unwanted material may enter oil barrel. Before use, filter it with industrial filter paper.

3）清洗液压机械 Clean the hydraulic system parts

放出液压系统的旧液压油后，应对液压系统进行运转冲洗并使泵时转时停。冲洗可使用清洗油（50℃时，粘度为10～20厘斯的环烷基油）汽转机油或者液压油，并不时更换滤网，先粗后精，直到滤网上无杂质为止。

When the used hydraulic oil is discharged, flush the hydraulic system and run the pump time to time. Use cleaning oil (naphthenic oil with 10-20 centisthene when temperature is 50oC) for flushing and replace the strainer from coarse to fine until there is no impurity on the strainer.

2.液压油的加注 Hydraulic oil filling

冲洗液压系统后，放掉油箱中的冲洗油。将油箱冲洗干净，加入新油将油箱上回油管拆下接入另一容器。使泵运转，依次操纵各机构，加注的新油将各机构的旧油顶出，待整个液压系统都充满新油以后，再将油管接到油箱上，同时补充油箱中新油至规定油面。至此，加油完毕。

After flushing, discharge the flushing oil from oil tank and maintain the tank clean. Fill up the fresh oil; then remove and connect the upper return oil pipe to other vessel. Run the pump and operate all mechanism in sequence. The fresh filling oil will push off all used oil. Again connect the oil pipe to the oil tank after oil filling into all hydraulic system; at the same time, fill the oil as required. By now, oil filling completed.

注意：必须保证液压油箱内有足够的液压油；

不得使用不同牌号的液压油。

Caution: ensure the sufficient oil in the hydraulic oil tank;

Do not mix the oil in different label number.

附表：燃油、润滑油和冷却液种类和用量表

Annexed table: Fuel, lubrication oil and coolant type and quantity

部位 Component 环境温度及适用油品 Environment temperature and applicable oil

-30 -20 -10 0 5 10 1 5 20 30 35 40 45

℃ 额定用量（升）

Rated quantity (Liters)

发动机燃油箱 Engine fuel tank

370

-10～-35轻号柴油 -10～-35# Light Diesel oil

发动机油底壳 Engine sump tank 45

SAE10W-30

*SAE15W-40

变矩器 Torque convertor

变速箱 Gear box

后桥箱Real axle casing 122

SAE10W-30

*SAE15W-40

SAE30

液压油箱

Hydraulic oil tank 310

注：Note：

1) 标※的油品为其栏内油品的代用品，没有上一格的油品，可用带※的油品代用。

The oil marked “※” is the substitute of the standard oil. If the standard oil is not available, the substitute with ※ can be used.

2) 润滑油品牌号均为 CF-4 级。

Lubrication oil label number is class CF-4.

3) 当环境温度低于-20℃时，发动机油底壳的油换成 SAE5W-30。

When the environment temperature is lower than -20oC, change the sump tank oil into SAE5W-30.

4) 加油时应先从加油口抽出过滤网，用干净柴油清洗干净后，放回加油口，才可以加油。

When refilling the oil, remove the filter and then clean it with the fresh diesel oil. Put the cleaned oil into nozzle and refilling can be started.

5) 油、油脂的加入量要符合要求，不可过多或过少。

Quantity of oil or grease shall be according to the required standard, not too much or not too less.

6) 加油、水的用具一定要干净，用后存放在盖严的箱子或柜子中。

The tools for adding water or oil should be clean and after use, put it in the coverd box or cabin.

7) 排油时要使油温预热至 30～40℃为宜。SAE 油品为国际通用油品号。Preheat the oil to 30-40 oC when discharing oil. SAE oil is the internation general label number.

第八章故障原因及排除方法

Chapter VIII Fault causes and resolution

吊管机常见故障及排除方法见下表。

The pipeplayer fault causes and resolution are as follows:

8.1电器部分 Electrical part

故障现象 Fault 主要原因Fault causes 排除方法 Resolution

当发动机高速运转期间，灯光暗，发动机运转期间，灯光不稳定

Dim light during engine high speed running and instable light during engine running 接触不良；

发电机皮带松动。

Poor contact;

Loose engine belt. 检查端子有无松动及线路有无断开；

调整发电机皮带涨紧度。

Whether the terminal became loosened or the wire circuit disconnected;

Adjust the engine belt tension.

交流电机有异音发生。

Abnormal sound of AC motor happens 交流电极不良

Weak AC motor 更换、修理发电机。

Replace or repair the generator

在发动机运转中，钥匙插入起动开关小齿轮就有声音。

During engine running, sound of pinion happens when keys insert into the “START”switch 接触不良，电池充电量不足 Poor contact or insufficient battery capacity 检查、修理线路；

给蓄电池充电。

Check and repair the wire circuit;

Charge the battery.

钥匙插入起动开关后电机不转动

Motor does not run when key is on “START” 接触不良，电池充电量不足，起动开关不好，电池开关不好.

Poor contact; insufficient battery capacity; weak“START”switch; poor battery switch. 检查、修理线路及继电器；

给蓄电池充电；

更换启动马达。

Check and repair the wire circuit and relay;

Charge the battery;

Replace start motor.

起动发动机转速低

lower running speed when start engine 接触不良；

电池充电量不足。

Poor contact;

Insufficient battery capacity. 给蓄电池充电；

更换启动马达。

Charge the battery;

Replace start motor.

发动机起动前，起功齿轮已脱离

Start gear has separated before engine start 接触不良，电池充电量不足

Poor contact and insufficient battery capacity 检查、修理线路；

给蓄电池充电。

Check and repair the wir circuit;

Charge battery.

全部仪表灯不亮

Indicator light is now working 断线，保险丝断电池充电量不足

Wire disconnection;

Fuse burn out;

Insufficient battery capacity 检查、修理线路；

给蓄电池充电。

Check and repair wire circuit;

Charge the battery.

在发动机停止时，发动机机油压力表不在0位

When engine stop, the oil pressure indicater is not in 0 position 机油压力传感器损坏

线路接触不良

Engine oil pressure sensor damaged;

Poor contact of Wire circuit 更换机油压力传感器；

检查、修理线路。

Replace the oil pressure sensor;

Check and repair the line

发动机高速运转时，电压表指示不充电

When engine in the high speed, 线路接触不良

Poor contact of wire circuit 检查发电机；

检查修理线路。

Check generator;

Check and repair wire circuit.

8.2发动机部分 Engine part

故障现象 Fault 主要原因 Main cause 排除方法Solution

发动机熄火后，油压表指针不退回到零位

After engine stop, the oil pressure gauge does not drop to zero 油压表不良

Poor oil pressure gauge 更换油压表 Replace the oil pressure gauge

发动机启动后，油压表指针指向红色范围（左侧）

After engine start, the needle of oil pressure gauge indicates the red area (left) 油底壳油水不足；

油管联接不良或损坏漏油；

油压表不良；

Oil sump tank has insufficient water and oil;

Poor or damaged oil connector;

Poor oil pressure gauge 加机油至规定油位；

检查.修理；

更换油压表

Add engine oil as require;

Check and repair;

Replace oil pressure gauge

发动机机启动之后，其转速提高时，油压表指针仍指向红色范围（左侧）

Oil pressure gauge needle indicates red area (left side) when engine speed up 油粘度太高，油压表不良；

管路和接头处漏油；

机油油量不足；

机油滤清器阻塞。

Great oil viscosity and poor oil pressure gauge;

oil leakage in oil pipe and connector;

insufficient oil;

engine oil filter blocked 更换规定用油，更换油压表；

检查管路和接头处有无漏油；

加机油至规定油位；

更换机油滤清器滤芯。

Replace the oil and oil pressure gauge; check the pipe and connector; add the oil to the required level and replace the engine oil filter core.

散热器顶部（压力阀处）喷出蒸气

Steam gushing from radiator top (pressure valve)

冷却水不足或渗漏；

风扇皮带松池；

在冷却系统中沉积水货和沉土

Insufficient cooling water or seepage happens; fan belt loose; impurity and settling in cooling system 检查补充冷却水；

调整风扇皮带涨紧度；

清洗冷却系统内部；

清洗或修理水箱散热片；

更换节温器；

牢固拧紧水箱盖或更换其密封垫。

Check and make up the cooling water;

Adjust fan belt tension;

Clean cooling system interior;

Clean or repair water tank radiator;

Replace the thermostat; tighten water tank cap or replace it sealing gasket

发动机启动后，水温表指针仍指向右侧红色范围

Water temperature gauge needle indicates the right red area after engine start 水温表不良；

散热器中散热片阻塞；

恒温器密封不良

Poor water thermometer;

Blocked radiator stack;

Poor sealing of thermostat 检查水温表、水温传感器；

清洗、修理；

更换节温器；

更换密封垫。

Check the water thermometer, temperature sensor; clean and repair;replace thermostat; replace sealing gasket

起动马达转动，但发动机不启动

Engine not start when start motor 燃油不足，燃油系统混入空气

Insufficient fuel or air mixed in fuel system 补充燃油；

排除空气；

启动马达低速（参考电气部分）；

检查气门间隙；

校正或更换油泵和油嘴。

Add fuel; vacuum the air; start motor in lower speed (refer to electrical part);

Check air valve clearance;

Calibricate or replace oil pump or oil nozzle.

燃油经常停止

Fuel stop frenquently 燃油箱出油管路阻塞

Fuel outlet pipe blocked 清洁管路

Clean the oil pipe

发动机起动运转无规律、不稳定

Instably engine running 燃油系统中混入空气

Air mixed in fuel system 排除空气

Vacuum the air

不正常的燃烧噪音或机械噪音 Abnormal burn noise or machinery noise 使用质量差的燃油、过热；

消音器内部磨损。

Poor quality fuel; superheating;

Inter abrasion of silencer 更换规定燃油；Replace the fuel;

更换消音器；Replace the silencer;

调整气门间隙。Adjust the air valve clearance

发动机排气为白色或清白色 Emission of engine is white 油底壳油量过多、燃油不足；涡轮增压器油管路阻塞 Too much or too less oil in sump tank;

Turbo booster oil pipe blocked 更换指定的燃油；

按规定调整油底壳油量；

检查增压器是否漏油。

Replace the fuel as required;

Adjust sump tank oil level;

Check any leakage of booster

发动机排气为黑色Engine emission is black color 空滤器阻塞、排气压力过大 Filter blocked and exhaust pressure too greater 清理空气滤芯；

更换油嘴；

清理或更换增压器。

Clean air filter core;

Replace the oil nozzle;

Clean or replace the booster.

8.3底盘部分 Chassis part

故障现象Fault 主要原因 Main cause 排除方法 Resolution

变矩器油压不上升（车辆不能起步）Torque covertor oil does not rise (pipelayer cannot start up) 油管或管接头漏气

齿轮泵损坏

变速箱内缺少油

变速箱滤清器阻塞

Air leakage in oil pipe or connector;

Gear pump damaged;

Less oil in gear box;

Gearbox filter blocked 检查油管或管接头漏气处；

检查或更换齿轮泵；

向变速箱中加油；

清洗并更换变速箱滤清器。

Check the leakage of oil pipe or connector;

Check or replace the gear pump;

Add oil to gear box;

Clean and replace the gear box filter

液力变矩器过热 Hydraulic torque convertor overheating

风扇皮带松弛；

发动机水温过高；

油冷却器阻塞；

齿轮泵磨损以至油循环不足

Fan belt loosening;

Engine water temperature too high;

Oil cooler blocked;

Gear pump wore causing oil circulating is insuffient.

涨紧或更换风扇皮带；

参照“发动机部分”；

清洗或更换油冷器；

更换齿轮泵

参考“变矩器油压不上升”部分。

Tight or replace the belt fan;

Refer to “engine part”;

Clean or replace oil cooler;

Replace gear pump;

Refer to “torque convertor oil pressure not rise part”

变速杆置于变速档位，

但车辆不能起步

Gear shift lever is on the gear shift position, but pipelayer does not travel 液力变矩器与变速箱无油压上升；

阀管路接缝处密封不好，混入气体或漏油；

齿轮泵磨损、卡住；

变速箱滤油器滤网阻塞

Oil pressure does not rise in hydraulic torque convertor and gear shift box;

Air mixed or oil leakage happened due to poor sealing of joints between valves and pipes;

Gear pump wore or jammed;

Gear box oil filter stainer blocked 向转向离合器箱里加油；

参考“变矩器油压不上升”部分；

检查或更换齿轮泵；

清洗油滤器。

Add oil to steering clutch box; refer to “torque convertor oil pressure not rise part”;

Check or replace the gear pump;

Clean the oil filter

拉单侧转向杆，机车不转弯继续向前行驶。

Pull up single side steering lever and pipelayer go ahead but not turn 转向阀不良或转向杆调节不灵或失效

Poor steering valve; steering lever not working or losing effectiveness

调整制动器

Adjust the brake

踩下制动踏板而机车不停止

Stamp on brake pedal, but pipelayer does not stop 制动踏板调整不良或制动助力阀不良

Poor brake pedal adjustment or weak brake servo valve 调整制动器

Adjust the brake

履带脱轨

Track chain digression 履带张力过松，引导轮左右松动

Track chain is too loose; ider is also loose in left and right side 调整履带涨紧度；

轮异常磨损，更换引导轮。

Adjust track chain tension;

If track wear, replace the idler

链轮异常磨损

Worn carrier roller 履带过松或过紧

Track chain is too loose or too tight 调整履带涨紧度

Adjust the track chain tension

8.4上车部分 On board part

故障现象 Fault 主要原因 Main cause 排除方法 Resolution

油路漏油

Oil pipe leakage 接头松动

密封件损坏

管道破裂

Connector loosened;

Sealing parts damaged;

Pipe broken 拧紧接头

更换密封件

更换

Tighten connector;

Replace sealing part;

Replace pipe

油压升不上来

Oil pressure does not rise

油箱液压油油位过低或吸油管堵塞；

溢流阀开启压力过低；

油泵排量不足；

压力管路和回油管路串通或元件泄漏。

Too less oil or oil inlet pipe blocked;

Too low start pressure of over flow valve;

Oil pump capacity is insufficient;

Pressure pipe and return oil pipe links or elements leaked. 加油检查；

调整溢流阀；

加大发动机转速；

检修油路，特别注意各阀，马达等处；

检修油泵。

Add oil and check;

Adjust overflow valve;

Speed up engine;

Check oil pipe, particulary in all valves and motors;

Maintain oil pump.

油路噪声严重

Severe noise of oil pipe

管道内有空气；

油温太低；

管路及元件没有紧固；

滤油器堵塞；

油箱油液不足；

空气滤清器有油污。

Air mixed in oil pipe;

Oil temperature is too low;

Pipe and elements not tightened;

Oil filter blocked;

Less oil in oil tank;

Oil stain on the air filter. 多动作几次，排除元件内部气体井排除吸油管漏气；

低速转动油泵，加热油；

紧固；

更换滤芯；

加油；

清洗或更换。

Move several times to vacuum the air in the oil inlet pipe and elements and check leakage of oil pipe;

Run oil pump in low speed and heat the oil;

Tightening;

Replace the filter core;

Refill oil;

Clean or replace.

油路发热严重

Severe overheating of oil pipe 内部泄漏过大；

压力过高；

环境温度过高；

油量不足；

油箱滤清器或油路局部堵塞油液太脏。

Several inner leakage;

too high pressure;

too high environment temperature;

inadequate oil;

Oil filter or pipe blocked by dirty oil. 检修元件；

调节溢流阀；

停车冷却；

加油；

清洗滤网、油箱和管路，更换油液。

Maintain elements;

Adjust overflow valve;

Stop working and cool down;

Refill oil;

Clean strainer, oil tank and pipe. Replace the oil.

压力表不指示

Pressure gauge is not working 阻尼接头堵塞；

压力表损坏。

Damp connector blocked;

Pressure gauge damaged. 检修清洗；

检修更换。

Maintain and clean;

Maintain and replace.

空载油压过高

Too high oil pressure of no load running

管路有异物堵塞；

滤油器堵塞。

Pipe blocked by impurity;

Oil filter blocked. 排除异物。

Remove the impurity.

起升机构制动器打不开

Hoist mechanism brake cannot open 双向梭阀卡死；

双向梭阀内漏；

制动器活塞密封不良；

制动器阀有脏物。

Double way Shuttle valve sticking;

Double way shuttle valve interior leakage;

Poor sealing of brake pison;

Dirt in brake valve. 检修双向梭阀；

检修双向梭阀；

检修制动器、更换密封件；

检修制动器阀。

Maintain doule way shuttle valve;

Maintain brake and replace the sealing parts;

Maintain brake valves;

马达转动而卷筒不转动或制动不住

Reel does not rotate or brake when motor running 快放阀打开或故障；

离合器内部故障。

Quick release valve opened or damaged;

Clutch interior damaged; 检修快放阀；

检修离合器。

Maintain quick release valve;

Maintain clutch.

卷扬机构发卡或发抖

Winch mechanism jamming or shaking 制动器没有完全打开；

卷扬机构轴承研坏。

Brake not opened fully;

Winch mechanism bearing damage. 调整双向梭阀或更换；

更换轴承。

Adjust or replace double way shuttle valve;

Replace bearing.

重物不能上升或下降 Lifting material cannot hoist or lower 高度限位器重锤发卡,不能自由下垂

Height limiter hammer jamming happens and it cannot fall down freely 放下吊臂使其恢复正常

Lower the boom and make it work properly

配重收起后缓慢下降 Counterweight drop down slowly after rectraction 油缸内泄；

平衡阀泄漏。

Oil tank leakage;

Balance valve leakage. 更换密封件或总成；

更换或清洗。

Replace the sealing parts or kits;

Replace or clean.

卷扬机构吊重时下滑

Winch mechanism drops when lifting load 制动器间隙太大；

离合器油管泄漏。

Great brake clearance;

Clutch oil pipe leakage 调整（应以吊最大起重为准）；

更换。

Adjust (based on the maximum hoist load);

Replace

蓄能器压力下降快

Accumulator pressure drops rapidly 单向阀泄漏；

离合器阀内泄严重。

Single way valve leakage;

Severe clutch valve inside leakage. 研磨结合面或更换；

更换阀或密封件。

Grind the surface or replace it;

Replace valve or sealing parts.

上车无压力

No pressure for on board part 溢流阀卸荷；

电磁阀搭铁引起溢流阀泄荷；

泵内泄严重；

齿轮泵轴上的键滚掉。

Overflow valve offloading;

Overflow valve offloading due to solenoid earthing.

Severe pump interal leakage;

Keys on gear pump shaft dropped. 清洗或更换；

检查；

更换；

检查更换。

Clean or replace;

Check;

Replace;

Check or replace.

附录1 起重吊钩及钢丝绳—保养与维修 Annex 1 Pipelayer hook and wirerope- maintenance and repair

起重吊钩和钢丝绳是易损耗的重要零件，当检验其强度已削弱，再使用将是不安全的，就需要予以更换。周期性的检查是必需的，以便在出现失效前就更换这些零件。

Hook and wirerope is the consumable and when the strength is weakened, replace it as it is unsafe. Regular inspection is required so that before losing effectiveness, you can have the wire rope replaced.

缺乏维护是钢丝绳寿命简短的重要因素之一，特别是当机器在具有腐蚀性环境中工作，或者进行非常规作业下更应当加大维护保养力度及缩短维护保养周期。

Inadequate maintenance is the major reason of wire rope life decreasing, particularly when the pipelayer working in the corrosive environment or it is doing unconventional operation, enhancing maintenance and shortening the maintenance interval is a must.

FL1.1 起重吊钩 Hoist hook

起重吊钩有裂纹、或规定的吊钩开口值α的增量大于15%、或吊钩在开口的垂直平面内的扭转角β超过10%时就应更换吊钩。

If crack is on the hoist hook, “α”is more than 15% or the angle “β”is more than 10%, the hook should be replaced.

FL1.2 钢丝绳 Wirerope

FL1.2.1

由于包含许多可变因素，因此无法给出精确的准则来确定更换钢丝绳的具体时间。按ISO4309:1990的规定，检查在使用的钢丝绳所暴露的损伤是允许的以后，其继续使用在很大程度上依赖于一个主管人员对可用钢丝绳剩余强度值的可靠判断。

The exact time to replace the wirerope cannot be provided due to variable factors can affect the time. As per ISO4309:1990, after checking the allowable damage, whether wirerope is continued to use will be decided by concern responsible personnel as he is experienced.

FL1.2.2

如出现下列条件，应更换钢丝绳或增加检查频率:

Replace the wirerope or check it more frequently in case of following factors occurred:

1) 在钢丝绳的使用期间，在一绞里随机地分散着6根断钢丝，或在一绞里的一股中有三根断钢丝；

During use, 6 fractured wire in one wirerope or 3 fractured wire in a strand found;

2) 外侧各钢丝已磨损了钢丝原始直径的三分之一；

The wire in the outer surface has worn 1/3 of wire diameter.

3)扭结、轧扁、断口、松散或任何其他损伤导致钢丝绳结构的变形；Deformation such as knod, flatting, fracture, friability etc.

4)加热或电弧损伤的痕迹;

Damage spot due to heating or arc

5)外部或内部的锈蚀;

Pitting rust interior or exterior

6)锈蚀、剥裂、弯曲、磨耗或绳的连接方式不正确;

Rust, spalling crack, bending, wear or incorrect connecting way

7)钢丝绳的磨损相对新钢丝绳的公称直径超过了7%。

Worn part is more than 7% of new wirerope nominal diameter.

FL1.2.3

更换侧臂的钢丝绳应选用机器和钢丝绳制造厂推荐的尺寸、等级或结构。套环、扎头和紧固件应使用钢丝绳、紧固件或机器制造厂推荐的型号及规格。The wirerope size, class or feature shall be selected according to manufacture’s advice. The collar, thimble and fastener shall be selected as per the specification and size as well.

FL1.2.4

假如保养好钢丝绳，使其处于良好的润滑状态，以减小内部磨损和防止锈蚀，则其寿命将会延长。维护保养过程中所使用的润滑剂应与原用润滑剂一致。

Wirerope life will extend in case it is always in the lubricated condition to reduce the inside wear and avoid the rusting. The lubricationshall be same as the original one during maintenance.

FL1.3 推荐的钢丝绳检验周期及内容 Recommended wirerope test interval and items

吊管机用钢丝绳属重要零部件，需每日对其进行检查、维护及保养。

Pipelayer wirerope is the essential part, so check and maintain it daily.

FL1.3.1日常观察 Routine observation

每个工作日都要尽可能对钢丝绳的任何可见部位进行观察，以便发现损坏与变形的情况。特别应留心钢丝绳的固定部位及钢丝绳缠绕在卷筒上的部位，发现有任何明显变化时，应予报告并由主管人员确定检验周期并按照3.2款进行检验。

Check wirerope visible parts in each working day to find the damage or deformation, especially for the fixed parts and winding parts on the reel; if any obvious change found, report to responsible personnel to confirm the replacing interval and then test it as per clause 3.2.

FL1.3.2检验部位 Test parts

FL1.3.2.1一般部位 Common parts

对钢丝绳应作全长检验，但还应特别留心下列部位:

Check whole wirerope and pay more attention to the following parts:

钢丝绳运动和固定的始末端部位，通过滑轮组或绕过滑轮的绳段及卷筒上缠绕的部段。在机构进行重复作业的情况下，应特别注意机构吊载期间绕过滑轮的任何部位。位于平衡滑轮的绳段。由于外部因素可能引起磨损的绳段。腐蚀及疲劳的内部检验。

Wirerope moving and fixing ends; the wirerope which is through pulley or rounding the pulley and the parts winding on the reel; pay more attention to the wirerope rounding the pulley parts when hoist; wirerope on the balance pulley; wirerope has the possibility of wear due to force; for the above wirerope parts, the inner test of wear and damage shall be conducted.

FL1.3.2.2绳端部位 Wirerope end

应对从固接端引出的那段钢丝绳进行检验，因为这个部位发生疲劳(断丝)和腐蚀是危险的。还应对固定装置本身的变形或磨损进行检验。

Test the wire rope from fixed end as it is easy to be fractured and corrosion. The deformation and abrasion of fixed device also should be tested.

可拆卸的装置(楔形接头、绳夹、压板等)应检验其内部和绳端内的断丝及腐蚀情况，并确保楔形接头和钢丝绳夹的紧固性，检验还应确保绳端装置符合相应标准的要求。

Removable device (Cuneiform connector, clamp and clamping plate etc) shall be tested for fracture and corrosion inside or at end of wirerope. Ensure the tightness of Cuneiform connector and clamps. The wirerope ends shall comply with the standard as well.

接头的固接部位应随时用肉眼检查其断丝情况。如果断丝明显发生在绳端装置附近或绳端装置内，可将钢丝绳截短再重新装到绳端固定装置上使用，并且钢丝绳的长度必须满足在卷筒上缠绕的最少圈数的要求。

The fixed parts of connector shall be tested visually. If wire fracture happens in the wirerope end device or around the end, wirerope can be shortened and then fix it again on the device. The length of wirerope shall meet the requirement for minimum winding circles on the reel.

FL1.3.2.3卷筒部位 Wire rope reel

除上述部位外，应重点检验吊管机卷筒（包括变幅与起升卷筒）部位钢绳的使用情况，每次使用前都应有专人检验钢绳在卷筒上的排列情况，如发现严重乱绳、挤压及咬绳现象应禁止使用并重新缠绕钢绳。

Apart from the above parts, the wirerope reel area also shall be checked (including luffing and hoist reel). Before use, dedicated persons shall be engaged to check the wirerope range on the reel. If severe disordered and extruded wirerope found, do not use it for work; have it rewound immediately.

FL1.3.3检验内容 Test items

FL1.3.3.1断丝检验 Wire fracture test

一个节距内断丝统计，可以只统计外表面断丝，即使同一条钢丝上有两处断丝，应按两根断丝统计。钢丝绳断裂部分超本身半径时，应做断丝统计。

The wire fracture shall be counted on the wirerope outer surface in a pitch, i.e if there are 2 fractures found in 1 wire, the fractured wire shall be considered as 2 wires. If the fracture is more than its radius, fracture statistic shall be done.

一个节距是指每股钢丝绳缠绕一周的轴向距离，其量法如下图所示。

A pitch means the axial distance of one strand winding one circle distance. The measure method is as follows:

FL1.3.3.2磨损检验 Wear test

磨损状态有同心磨损和偏心磨损两种。用宽钳口的游标卡尺测量钢丝绳直径。在钢丝绳无张力的情况下，于钢丝绳端头15m外直线部位上进行，在相距离至少1m的两截面上，在同一截面不同方向上各测量一个直径。测量四个结果的平均值作为实测直径。

The wear includes concentric wear and eccentric wear. Measure the diameter of wirerope with wide jaw slide caliper under no tension condition; Choose 2 measuring sections at least 15m from the wirerope end and the distance between the sections should be at lease 1m, take the diameter in the different direction of section and get the value for each direction. The measured diameter should be the average value of four diameters.

FL1.3.3.3腐蚀检验 Corrosion test

目测钢丝绳生锈、点蚀，钢丝绳松弛状态。钢丝绳直径较细时（小于20mm）可用手把钢丝绳弄弯曲进行检验，如果直径较大，可用检验钉进行内部检验，然后把钢丝绳恢复原状，当整根绳外表受腐蚀麻面凭肉眼显而易见时，钢丝绳就能使用。

Visually measure the rust, pitting and the flexible condition. If the wirerope is less than 20mm, bend the wirerope to check; if it is more than 20mm, put the test pin inside of the wirerope and then recover the wirerope. If the pitting is visible on the wirerope surface, the wire rope can be used.

FL1.3.3.4变形检验 Deformation test

对钢丝绳打结、波浪、扁平进行目测。

Measure the wire rope knot, wave or flat by visual measurement.

波浪变形，取绳径25倍区段，测量绳径，要求d1/d≤4/3，否则应该报废。Wave deformation- measure the rope diameter in the position of 25 times of rope diameter; the requirement is D1/D≤4/3, otherwise the wire rope shall be replaced.

偏平度，测量最大直径dmax和最小直径dmin，当dmax/dmin≥3/2时应报废。

Flat – take the maximum diameter dmax and the minimum diameter dmin, when dmax/dmin ≥3/2, it should be replaced.

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