Maintenance

SANY Heavy Industry Co.,Ltd. Quality Changes the World

 Content
Chapter 1 Preparation for Startup

Chapter 2 Key Points of Operation

Chapter 3 Precautions During Operation

Chapter 4 Preventive Maintenance

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 Chapter 1

Preparation for Startup

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 Preparation for Startup

1.1 Initial Check for startup

1. Check the air pressure in tyres, and inspect whether the tyres are damaged.
2. Perform the strict check around the whole truck crane to see whether the leakage
appears.
3. Check whether the cooling water, oil and fuel for engine are sufficient.
4. Eliminate the residual water from the air reservoir.
5. Check whether the terminal posts of storage battery are reliable and firm and
whether the level of electrolyte meets the regulation.

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 Preparation for Startup

6. Check whether the instruments, switches,

lamps, signal indicators and windscreen
wipers work normally.
7. Check whether the parts of steering and
braking systems are normal, safe and
reliable and whether liquid levels in
steering oil tank and liquid cup of clutch
are normal. Control
Console

Clutch
Cup

Liquid
Level in
Steering
Oil Tank

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 Preparation for Startup

8. Check whether the transmission shaft bolts, U-

bolts, hub bolts and wheel nuts are strictly
tightened, damaged or ruptured.
9. Check the maintenance indicator for air filter. If
the indicator displays in fully red, you shall
clean or replace the filter core. Also, the user
shall frequently eliminate the dust from the
dust collection disk (at the bottom of air filter).
10. Drain away the water from the bottom of fuel
filter.
Maintenance
Indicator for
Air Filter

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 Preparation for Startup

1.2 Requirements on Operation

Environment

1. The allowable wind speed of worksite

shall be less than Level 7.
2. The allowable ambient temperature: -
20℃~+40℃; (for those regions with
higher or lower temperature, we
provide special configuration for
special working conditions.
3. The supporting ground shall be firm Tyres
and capable to withstand a minimum leaves the
pressure of 3MPa. During the ground
operation, the supporting ground shall
not sink.
4. During the course of operation, the
inclination of whole truck crane shall
not be greater than 1%.
5. Make sure that the tyres leave the
ground when the truck crane is at
work. View the level gauge

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 Preparation for Startup

1.3 Requirements on Safe Operation

1. General Requirements on Safe Operation

(1) When the driver takes in his shift, he shall

check the brakes, hooks, steel wire ropes and
safety devices. Any abnormality shall be
eliminated before the formal operation.
(2) Before starting the truck crane, the driver
must sound the bell or give an alarm. When the
truck crane at work approaches other persons,
Hook, Steel
the driver shall also sound the intermittent bell
Wire Rope
or give an alarm.
and Safety
(3) The driver shall conduct the operation in
Device
compliance with the command signals. The
driver shall stop the truck crane immediately,
no matter whoever sends out the emergency
stop signal.
Flashing
Buzzer

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 Preparation for Startup

2. Technical Requirements on Safety

(1) The driver shall not conduct the operation

when any one of the following conditions
appears.
① The truck crane is overloaded or the weight of
load is uncertain.
② The structures or spare parts have the defects
or damages which adversely affect the safe
operation. Forbidden!
③ The load may slip due to the loose binding and
suspension or the unbalance; no liner is
applied between the sharp edges of load and
the steel wire ropes.
④ There are persons or floating objects on the
lifted load.
⑤ Due to obscurity of worksite, it is impossible
for driver to clearly see worksite, conditions of
lifted load, and command signals.

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 Preparation for Startup

(2) When conducting the operation, the driver shall abide

by the following requirements.
① The driver must not operate the truck crane when feeling
No drunken
physically or mentally uncomfortable or after drinking wine. driver is allowed
② It is forbidden to adjust the brakes of lifting and slewing for operation!

systems when the truck crane is laden.

③ The load lifted shall not be passed over the personnel, and
no person shall stand under the boom.
④ It is forbidden to carry out the check and maintenance
when the truck crane works.
⑤ If the weight lifted load approaches or reaches the rated
lifting capacity of truck crane, the driver shall check the
brakes before lifting the load, perform the trial lifting with
short height and trip, and then stably execute the formal
lifting.

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 Preparation for Startup

⑥ For the truck crane without ultimate descending position limiter, when
the hook reaches the lowest working position, the steel wire ropes
shall be kept in the specified safe layer on the drum.
⑦ When the truck crane works, the boom, spreader, auxiliary tools,
steel wire ropes, cables and loads shall be kept away from the power
line with a minimum distance not less that those specified in Table 1-
1.
⑧ As to the truck crane without reverse connection braking function, it
is forbidden to reverse the truck crane for the purpose of braking,
with the exception of emergencies.

Voltage <1 1~ 35 ~ 154 220 330

of Power 20 110
Line (kV)
Minimum 1.5 2 4 5 6 7
Distance
(m)

Table 1-1 Minimum Distances from Power Line

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 Preparation for Startup

1.4 Qualification Requirements on Operator

1. Operator
The truck crane shall be only operated by the following personnel:
(1) The personnel who has passed the exam and taken the practitioner certificate;
(2) The trainees (e.g. apprentices) who have learned for half a year under the direct
supervision of qualified operation personnel;
(3) The maintenance and detection personnel who are required for the purpose of a specific
task;
(4) The labor safety supervisors who are approved by the local labor safety authorities.

2. The operation personnel shall meet the following requirements:

(1) Their ages reach the adult age standard specified in their country, and they are in good
health;
(2) Their eyesight (including the corrected eyesight) shall be above 0.7, and no achromatopsia
is allowed;
(3) Their audition shall meet the requirements of specific working conditions.

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 Preparation for Startup

3. The operation personnel shall be acquainted with the following knowledge:

(1) Before the operation, read the User’s Guide for Truck Crane carefully so
as to know the structure and technical performance of each mechanism
of the truck crane to be operated.

(2) The operation regulations for truck crane and the related rules and
codes;

(3) The requirements on safe operation;

(4) The performance of safety and protection devices;

(5) The basic knowledge regarding engine, electric parts and hydraulic
parts;

(6) The command signals.

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 Chapter 2

Key Points of Operation

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 Key Points of Operation

2.1 Operation for Starting Engine

1. Set the gear lever to the “Neutral”

position.
2. Set the PTO control button to the “OFF”
position.
3. Tread the clutch pedal.
4. Lightly tread the throttle pedal, and
Gear
simultaneously turn the startup key to start Lever
the engine.
5. Do not immediately tread the throttle
pedal after the engine starts up.
Turn off the
PTO Switch

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 Key Points of Operation

2.2 Operation for Starting Truck

Crane

1. The oil pressure indicated by oil pressure

gauge shall be higher than 0.15MPa (This
value is not the same for different engines. Control
See the Engine Quality Guarantee for Handle
details.). for
2. The signal lamps for air pressure and Parking
parking brake shall go out, and the air Brake
pressure shown by air pressure gauge shall
be higher than 0.65MPa.
3. The water temperature in engine shall be
higher than 60℃;
4. The parking brake shall be released.
5. Shift the transmission handle to Gear I,
gradually release the clutch pedal, and then
lightly tread the throttle pedal to start the
truck crane.
View every
instrument

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 Key Points of Operation

2.3 Operation for Starting up Truck Crane

1. During the gear shifting, pull the gear lever to the higher or lower gears one
by one;
2. The air pressure indicated by the air pressure gauge shall be equal to or
higher than 0.65MPa, and the signal lamps for air pressure and parking
brake shall go out；
3. The oil pressure in engine shall be equal to or higher than 0.2MPa;
4. The water temperature in engine shall be kept between 70℃ and 90℃;
5. The engine and transmission shall be free of abnormal noise and
phenomenon；
6. The brakes shall work normally;
7. It is forbidden to glide the truck crane by means of shutting down engine
and pulling gear lever to “Neutral” position;
8. It is prohibited to tread the clutch pedal when the clutch is not used.

Various
Pedals

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 Key Points of Operation

2.4 Operation for Engaging/ Disengaging

PTO

QC65B, QH70 and QH70C PTOs are respectively

provided for the transmissions of 20t, 25t and 50t
truck cranes.

1. Using QC65B PTO:

(1) Taking Power (unnecessary to shift gear):
① Park the truck crane;
② Tread the clutch pedal twice, and shift to the
“Neutral” gear;
③ Turn on the PTO-ON switch to make the indicator
lamp for PTO-ON light up, and then, release the PTO-
ON switch and gradually release the clutch.
(2) Disengaging PTO:
① Tread the clutch pedal and shift to the “Neutral” gear;
Switch
② Turn off PTO-ON switch;
Control
③ Turn off the PTO-OFF switch When the indicator lamp Console
for PTO-ON goes out, gradually release the clutch. In
this case, the clutch immediately stops working, and
the truck crane travels normally.

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 Key Points of Operation

2. Using QH70 PTO:

(1)Taking Power:
① Park the truck crane;
② Tread the clutch pedal twice to thoroughly
disengage the clutch, and shift to the “3” gear;
③ Turn on the PTO-ON switch;
④ After the indicator lamp for PTO-ON lights up,
release the clutch to make the PTO work
immediately.
(2) Disengaging PTO:
① Tread the clutch pedal and shift to the
“Neutral” gear;
② Turn off PTO-ON switch;
③ Turn off the PTO-OFF switch when the
indicator lamp for PTO-ON goes out, and
gradually release the clutch. In this case, the
clutch immediately stops working, and the When operating QH70
truck crane travels normally. PTO, shift the gear lever
to Gear 3 only

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 Key Points of Operation

3. Using QH70C PTO:

(1) Taking Power:
① Park the truck crane;
② Tread the clutch pedal twice to thoroughly disengage
the clutch, and shift to the “4” gear;
③ Turn on the PTO-ON switch;
④ After the indicator lamp for PTO-ON lights up,
release the clutch to make the PTO work
immediately.
(2) Disengaging PTO:
The procedures for QH70C are the same as those for
QH70.

When operating QH70C

PTO, shift the gear lever
to Gear 4 only
Note: Check the label of the control cab to
confirm which gear is used for PTO before
using the PTO.

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 Key Points of Operation

2.5 Operation Method for Superstructure

1. Operation Method for QY20 Truck Crane

(1) Operation for Starting up and Shutting down Engine
① Starting up Engine
Insert the startup key into the startup lock, and clockwise turn the key to Gear 1, and
then turn it to Gear 3 so as to start up the engine.
② Shutting down Engine
Press the shutdown switch on control panel for 1~2 seconds, and then release the
switch so as to shut down the engine.

Startup Key

Control Panel for

Superstructure
Operation

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 Key Points of Operation

H1 — Indicator Lamp for Main Power Supply;

S1 — Ignition Switch; H2 — Indicator Lamp
for Overload; S2 — Switch for Instrument
Lamp; H3 — Alarm Lamp for Too Low Oil
Pressure; S3 — Stop Switch for Engine;
H4 — Indicator Lamp for Three-layer Over-
relaxing Protector; S4 — Switch for
Outline Lamp;
H5 — Indicator Lamp for Overwinding; S5 —
Switch for Working Lamp; H6 — Alarm Lamp
for Too High Water Temperature; S6 —
Switch for Windscreen Wiper; H7 —Caution
Plate for Overload Release; S8 — Switch for
Oil Cooler; S9 — Master Switch; S10 —
Speed Governing Switch for Hoist (Optional);
S11 — Switch for Overwinding Release
(Forced Switch); S12 — Switch for Overload
Release; S13 — Switch for Auxiliary Hoist
(for QY25CY); S15 — Switch for Washing
Red

Device
the truck crane is working normally.
It is forbidden to press this switch when

Layout of
Control Panel

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 Key Points of Operation

Piloted Control
Handle Left Control Handle Right Control Handle

(2) Operation of Control Console

Mechanism Switch S11 for Free Horn Switch Horn Switch S8 Switch S10 for Free
Slewing Slewing
S8

Control panel: It displays the conditions for operation

and safety.

Right piloted control handle: It controls the operation

Front of Truck Crane Front of Truck Crane
of main hoist and the luffing mechanism.
Main Boom Extends/ Auxiliary Main Hook Descends
Hook Descends
Left piloted control handle: It controls the extension
and retraction of boom and the slewing action. Slew
Slew Rightwards
Leftwards

Push-rod-type control handle: It controls main hoist, Luffing Luffing

auxiliary hoist, luffing mechanism, extension and Mechanism Lifts Mechanism
Descends
retraction of boom, and slewing action. Main Boom Retracts/ Auxiliary Hook Lifts Main Hook Lifts

Push-rod-type
Control Handle

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 Key Points of Operation

(3) Key Points of Operation for Outriggers

a. Levelly support the truck crane.

b. Make the tyres leave the ground and suspend
in the air.
c. The truck crane, on principle, shall be levelly
supported on the even and firm ground. If it is
forced to lay the outriggers on the flaccid or
Tyres leave
inclined ground, the truck crane shall be
the ground
supported by the backup plates which are
suitable for the ground.
Outrigger
d. After supporting the truck crane, ensure that
firmly contacts
every outrigger disk strictly contacts the
the ground
ground. Any potential danger of collapse shall
be avoided.
e. It is forbidden to support the truck crane if the
horizontal outriggers have not fully extended.

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 Key Points of Operation

(4) Lifting Mechanism

① Key Points of Operation

a. It is only allowable to vertically lift the

load. Side lifting shall be forbidden.
b. The lifting mechanism shall not act in a
hurry.
c. The brake for lifting mechanism shall
work normally.
The lifting
mechanism shall
not act in a
hurry

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 Key Points of Operation

② Operation Method for Main Lifting

Mechanism

Push-rod-type Control: To descend the hook,

push the control lever for main hoist forwards;
to lift the hook, pull this control lever
backwards. The speed of lifting/descending is
regulated by the control lever and throttle.

Piloted Control: After pressing the master

switch, push the right control handle forwards
to descend the hook, or pull this handle
backwards to lift the hook. The speed of
Control Lever
lifting/descending is regulated by the right for Main Hoist
control handle and throttle.

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 Key Points of Operation

③ Operation Method for Auxiliary Lifting Mechanism

Push-rod-type Control: To descend the hook, push

the control lever for auxiliary hoist forwards; to lift
the hook, pull this control lever backwards. The
speed of lifting/descending is regulated by the
control lever and throttle.

Piloted Control: After pressing the master switch S9

and the changeover switch S13 for
extension/retraction and auxiliary hoist, push the
left control handle forwards to descend the hook, or Control Lever
pull this handle backwards to lift the hook. The for Auxiliary
Hoist
speed of lifting/descending is regulated by the left
control handle and throttle.

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 Key Points of Operation

(5) Extension and Retraction of Main Boom

① Key Points of Operation：

a. The temperature of hydraulic oil shall not rise too
much.
b. When the main boom naturally retracts, it is
available to perform the proper retraction or
extension action so as to get the expected length.
c. It is forbidden to extend or retract the boom which
is laden.
② Control Method for Extension and Retraction:
Push-rod-type Control: To extend the main boom,
push the control lever for extension/retraction
forwards; to retract the main boom, pull this lever
backwards. The speed of extension/retraction is
regulated by the control lever and throttle.
Control Lever for
Piloted Control: After pressing the master switch S9, Extension/Retraction
push the control handle forwards to extend the
main boom, or pull this handle backwards to retract
the main boom. The speed of lifting/descending is
regulated by the control handle and throttle.

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 Key Points of Operation

(6) Luffing of Main Boom

① Key Points of Operation:

a. It is only allowable to vertically lift the load. It
is forbidden to draw the load which has not
left the ground yet. Side lifting shall be
avoided.
b. The elevation angle for main boom shall not
exceed its limit value.
c. It is forbidden to start or stop the luffing
action of boom in a hurry.
② Control Method for Luffing Action of Main
Boom:
Push-rod-type Control: To descend the main
boom, push the control lever for luffing
forwards; to lift the main boom, pull this lever
backwards. The speed of luffing is regulated
by the control lever and throttle.
Piloted Control: After pressing the master Control Lever for
switch S9, pull the control handle rightwards
to descend the main boom, or pull this handle
Luffing
leftwards to lift the main boom. The speed of
luffing is regulated by the control handle and
throttle.

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 Key Points of Operation

(7) Slewing Mechanism

Caution
It is required to disconnect the mechanical
locking device for slewing table before the
truck crane slews.
① Key Points of Operation：
a. It is only allowable to vertically lift the load.
b. Before the slewing operation, check the
outriggers to ensure that the transversal spans
Outrigger
between outriggers shall meet the specified
Extended
values. c. It is required to ensure an enough
working space.
d. It is forbidden to start or stop the slewing
Mechanical
action in a hurry. Locking Device
e. Before the slewing action, it is required to
disconnect the mechanical locking device for
slewing table.

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 Key Points of Operation

② Control Method for Slewing:

Push-rod-type Control: Before conducting the slewing action,

you shall disconnect the mechanical locking device. Push the
control lever forwards to slew the slewing table rightwards,
or pull this lever backwards to slew the slewing table
leftwards.

Piloted Control: Before conducting the slewing action, you

shall disconnect the mechanical locking device. Pull the left
control handle rightwards to slew the slewing table
rightwards; pull this handle leftwards to slew the slewing
table leftwards. The speed of leftward/rightward slewing is
regulated through controlling leftward/rightward
Control Lever
for Slewing
displacement of the left control handle and changing the
opening of engine throttle.

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 Key Points of Operation

(8) Key Points of Operation for Installing and Using Jib

a. The outriggers fully extent and support the truck crane on the firm ground, and the
truck crane keeps in a level status.
b. During the installation of jib, no one shall stand within the rotation range of jib.
c. Ensure enough space for operation.
d. Attention shall be paid to the following points:
I. It is forbidden to extend the main boom when the auxiliary hook contacts the top of
jib.
II. It is forbidden to operate or drive the truck crane if the fixing pins of auxiliary has
not been strictly locked.
III. When installing or withdrawing the jib, you shall not extend or retract it in a hurry.
e. A ladder shall be used if you install or withdraw the jib in a high position above
ground.

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 Key Points of Operation

(9) Method for Mounting and Dismounting Jib:

a. The jib shall be used after the main boom and outriggers have fully
extended.
b. Mount the jib.
c. Dismount the jib.
d. The luffing angle for jib is 15°.

Jib Installed at
15°

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 Key Points of Operation

Jib Installed at 0°

Installation and
Withdrawal of Jib

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 Key Points of Operation

Jib Connecting
with Main Boom

Extension of Jib

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 Chapter 3

Precautions During Operation

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 Precautions during Operation

3.1 Precautions for Shutdown

1. Release the foot throttle pedal, and then tread the foot brake pedal. After
the truck crane is stably parked, pull the control handle for parking brake
backwards till this handle is locked.
2. Shift the transmission to the “Neutral” gear.
3. Before shutting down the engine, keep the engine idly running to apply the
engine oil for two or three times so as to sufficiently lubricate every part,
and then turn off the key switch.
4. Turn off the master switch of power supply so as to prevent the storage
batteries from discharging.

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 Precautions during Operation
3.2 Precautions During Winter
1. When the truck crane is not used, if no
antifreeze has been added into the coolant,
the coolant shall be drained away.
2. Use the fuel, lubricating grease and
hydraulic oil which adapt to the lowest
local temperature.
3. For the severely chilly regions, use the
flame heating plug to warm up and start
the engine. You shall be cautious when
taking the hot water as cooling water for
the purpose of auxiliary function.
4. It is required to clean the oil tank and Air Reservoir
pipelines and drain away all water and
agglutinative matters from the air
reservoir.
5. It is required to frequently check and
maintain the electrolyte and vent holes of
storage batteries. If the temperature is
below -30℃, you shall take the heat
insulating measures for the storage
batteries, lest these batteries crack due to
frost. Storage Batteries

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 Precautions during Operation

3.3 Precautions for Using Fuel

It is required to keep the fuel clean and select different suitable fuels
according to seasons and temperatures. Refer to the following table
when actually using fuels.

Applicable Ambient Name and Grade of Fuel

Temperature
Above 4℃ 0# Diesel Oil (GB252-94)

Above -5℃ -10# Diesel Oil (GB252-94)

Above -14℃ -20# Diesel Oil (GB252-94)

Above -29℃ -35# Diesel Oil (GB252-94)

Above -44℃ -50# Diesel Oil (GB252-94)

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 Precautions during Operation
3.4 Precautions for Replacing Tyres

1. Do not bump the thread of wheel bolt.

2. The brake drum and wheel rim shall be free
from paint, lubricating grease and other dirty
matters.
3. The impacted surface of wheel nut shall be
clean. It is recommended to apply some
grease or engine oil to the threads of wheel
nuts and wheel bolts.
4. Mount the wheels, suspend the wheel in the
air, and pre-tighten the nuts according to the
cross diagonal sequence. Then, put down the
wheels and tighten these nuts.
5. The tyres of different specifications shall not
be installed to a same truck crane.
Bolts and Nuts
on Tyre

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 Precautions during Operation

3.5 Precautions for Running-in of New

Truck Crane

1. Running-in Mileage:
The running-in mileage for new truck crane is
2000km. However, the recommended running-in
mileage for SANY product is 1500km.
2. During the running-in period, the new truck shall
travel on even and good pavement.
3. Do not immediately accelerate the cold engine after
it is started. Accelerate the engine only when its
temperature has reached the normal service value.
4. Timely shift the gears, stably engage the clutch, and
avoid abrupt acceleration and emergency braking.
Before the truck crane climbs the slope, shift the
gear lever to a lower gear, and do not have the
engine working at a very low rotation speed.
5. Check and regulate the oil pressure of engine and
the normal temperature of coolant. Frequently pay
attention to the temperatures of transmission, rear
axle, wheel hubs and brake drums.

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 Precautions during Operation

6. It is required to screw down the wheel nuts with

specified torques after the first 50km traveling or
every time the tyres have been replaced.
7. Check the tightness of bolts and nuts at every part.
When the truck crane have traveled for 300km,
screw down the cylinder cover nuts according to the
specified sequence with the engine being warm.
8. The speed limits at each gear within the 2000km
running-in period are specified as follows:
For six-gear gearbox: Gear I, 5km/h; Gear II,
10km/h; Gear III, 15km/h; Gear IV, 25km/h; Gear V,
35km/h; Gear VI, 45km/h.
For eight-gear gearbox: Gear I, 5km/h; Gear II,
5km/h; Gear III, 10km/h; Gear IV, 15km/h; Gear V,
25km/h; Gear VI, 35km/h; Gear VII, 50km/h; Gear
VIII, 60km/h.
9. After the running-in period ends, it is required to
perform the compulsory maintenance for the chassis
of truck crane. This compulsory maintenance shall be
conducted in a service station designated by SANY.

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 Precautions during Operation

3.6 Precautions for Coolant and

Antifreeze

1. There shall be antifreeze coolant in the

expansion water tank when the engine
operation and temperature are normal.

2. Do not get scalded when replacing the

antifreeze. Screw off the pressure cover
of expansion water tank to check the
liquid level or add the coolant only after
the coolant temperature falls below 50℃.

3. It is required to use the coolant which is

specified by the engine manufacturer.
When the antifreeze in
expansion water tank
4. During winter, add the antifreeze into the
runs off, the water
cooling system. level/temperature
alarm will sound

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 Precautions during Operation
3.7 Check Before Operation

1. Check the hydraulic oil level of truck crane.

2. Check conditions of every part, and ensure
that there is no abnormity.
3. It is forbidden to perform check or
maintenance when the truck crane is
working.
4. After the engine starts, keep the engine idly
running at a low speed so as to sufficiently
warm it up.
5. Before switching on PTO, ensure that every
control handle and every switch is in the
“Neutral” or “OFF” position.
6. When operating the unloaded truck crane,
ensure that each control handle and each
switch is free of abnormity.
7. Carry out the pre-check on moment limiter
before operating the truck crane.
8. Check all safety devices for abnormity.
9. Before operation, you shall turn on the
power supply switch inside the
undercarriage cab.
Hydraulic Oil Level
Scale and Hydraulic
Oil Level

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 Precautions during Operation

3.8 Precautions for Lifting

Operation

1. You must carry out the operation

within the rated lifting capacity of
truck crane. Overload operation is
forbidden. It is forbidden to
obliquely drag or lift the load. It is
prohibited to lift the loads which are
interweaved, jostled, embedded in
the ground or frozen on the ground.

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 Precautions during Operation

2. Generally, it is forbidden to lift a

load simultaneously by two (or
more) truck cranes. For the
exceptional circumstance, the
steel wire ropes shall be vertical,
and every truck crane shall keep
the synchronal lifting/descending
with other truck cranes. The load
of each truck crane shall not
exceed 75% of its rated lifting
capacity.

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 Precautions during Operation
3. Estimate the lifting capacity and working reach.
4. Gradually operate the truck crane when acquainting
yourself of operation instruction.
5. Concentrate your attention when performing the
lifting operation. You shall only respond to the
signals given by the designated commander.
Moreover, you shall follow any shutdown signal at
any time, no matter whoever sends out it.
6. Notice the ambient conditions to avoid accident
when performing the lifting operation. The driver Go back to cab!

shall not leave his working position when the load is

suspended.
7. Notice the temperature of hydraulic oil. It is
required to stop the operation if the oil temperature
exceeds 80℃.
8. Pay attention to the information of weather forecast.

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 Precautions during Operation

3.9 Periodical Maintenance

1. Periodically give the monthly and annual check

to the truck crane.
2. Periodically filter or replace the hydraulic oil so
as to keep its cleanness.
3. Periodically replace the gear oil and other
lubricating grease.
4. Periodically add the lubricating oil/grease to all
specified lubrication points, slewing parts and
sliding parts.
5. Periodically replace the oil filter core.
6. Check whether hydraulic oil, gear oil and other
lubricating grease meet the specified volumes.
Add these kinds of oil and grease, if necessary. Example: A Point
7. Adjust every part to the normal condition. No Added with Lubricating
Grease
damage or loose connection is allowed.

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 Precautions during Operation

3.10 Traveling

1. Withdraw the hook to the specified storage

position.
2. Make the brake of slewing mechanism stay in
braking status, and lock the fixing pin for
slewing table.
3. Switch off the PTO device.

Lock the fixing pin for

slewing table

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 Chapter 4

Preventive Maintenance

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 Preventive Maintenance

4.1 Content of Routine Check for Chassis

1. Routine Maintenance

(1) Engine
① Daily Maintenance
a. Check the oil level.
b. Check the coolant level.

Caution Neither check the coolant nor

screw off the cover as soon as the engine stops,
for the pressurized hot water and steam will
squirt to injure you.
c. Check the adhesive tape for transmission . Check the adhesive
transmission tape
d. Check the air filter.
e. Check the cooling fan.
f. Eliminate water and sediments from the fuel-
water separator.

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 Preventive Maintenance

② Maintenance After Every 250 Working

Hours
a. Replace the lubricating oil and clean
the lubricating oil filter.
b. Check the air intake pipeline.
c. Check whether the intercooler is
damaged.
d. Clean or replace the air filter.

Air Filter

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 Preventive Maintenance

③ Maintenance After Every 500 Working

Hours

a. Replace the fuel filter.

b. Bleed air from the fuel system.
c. Ventilate the low-pressure oil supply
pipe.
d. Check the antifreeze concentration.
e. Check the concentration of coolant
additive.
f. Clean or replace the coolant filter.

Coolant Filter Fuel Filter

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 Preventive Maintenance

④ Maintenance After Every 1000 Working Hours

a. Adjust the valve clearance.
b. Check the tension of drive belt.
c. Check the drive belt, tension pulley bearing and fan shaft
housing bearing.
d. Maintain the cooling system.
e. Check the shock absorber.
f. Check the air compressor.

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 Preventive Maintenance

(2) Clutch

① Check the tightening screws of pedal support.

② Check the free clearance of clutch release bearing to make sure that when
operated, the clutch shall smoothly engage and thoroughly disengage.
③ Every month, add little lithium-base lubricating grease to the (oil cup on)
pedal support.
④ Frequently check the oil pipe connectors of clutch servo system.
⑤ Frequently check the brake fluid level in oil cup of clutch servo system.
Normally, the oil level stays between the scale H and L.
⑥ Observe the abrasion of clutch plate through the air hole of clutch cone.
⑦ When replacing the clutch servo pump, it is necessary to adjust the clutch
control system after the replacement to add the static pressure oil to the
system and eliminate the air from the system.

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 Preventive Maintenance

(3) Transmission

① Periodically check the lubricating

oil and keep the correct oil level.
② Replace the lubricating oil
according to the specified A point to be
added with the
replacement cycle. lubricating oil

③ Properly use the lubricating oil.

④ Avoid dragging or gliding.
A point for
observing the level
of lubricating oil

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 Preventive Maintenance

(4) Transmission Shaft

① It is required to add lubricating grease to every joint.

② Frequently add lubricating grease to the universal
joints and the grease mouth of sliding spline pair.
③ During the life cycle of transmission shaft, check
whether the connecting nuts of flanges loosen.
④ Check the cross bearing and intermediate bearing
every time the truck crane has traveled for 20000km.
⑤ Follow the assembling/disassembling sequence, i.e.
for disassembling, from rear to front; for assembling,
from front to rear.
⑥ When reassembling the disassembled transmission
shaft, ensure that it aligns with the installation arrow.
⑦ If one part of transmission shaft is replaced, perform
the dynamic balance test for the transmission shaft
after the replacement.
⑧ When installing the transmission shaft and sliding
fork assembly, ensure that the joint of sliding spline
is arranged downwards.
Universal Joint

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 Preventive Maintenance

⑨ The transmission shaft after maintenance shall meet the requirements of maintenance data
given in the following table:

Item Maintenance Use Limit (mm)

Standard (mm)

Radial Runout of 0.75 1.5

Transmission Shaft

Tooth Clearance 0.025~0.115 0.4

Between Sliding Splines
Clearance Between 0.02~0.09 0.25
Universal Joint and
Needle Bearing
Serious Peeling and — 0.01
Abrasion of Cross Shaft
Journal
Axial Clearance Between — 0.5
Intermediate
Supportings
Abrasion of Inner Hole — 0.05
Surface of Intermediate
Supporting Bearing Seat

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 Preventive Maintenance
(5) Front (Steering) Axle

① Every time the truck crane has

traveled for 1000km, you shall check
the tightness of each connecting bolt,
and add lubricating grease to the
friction positions where oil cups are
set.

② Every time the truck crane has

traveled for 5000km, you shall replace
the lubricating oil for wheel hub and
adjust the wheel hub bearings.

③ Timely adjust the length of steering tie

rod to ensure that the toe-in angle of
front wheels meets the requirement.

④ Periodically check the steering limit

screw on steering knuckle so as to
obtain the specified maximum rotation
angles for inner wheels and outer
wheels.

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 Preventive Maintenance
(6) Rear (Drive) Axle

① Every month, check the volume and

viscosity of lubricating oil and the content
of metallic impurity in wheel reductor and
main reductor. Replace or add the
lubricating oil, as the case may be.

② Every time the truck crane has traveled

for 10000km, you shall replace the
lubricating oil for middle and rear axles.

③ When replacing gear oil, drain away the

used oil when it is still hot. At the time of
first oil replacement after the expiry of
running-in period for new truck crane,
you shall drain away the waste oil and
then add the new thin engine oil;
meanwhile, jack up the rear wheels of
truck crane, start the engine, shift the
gear lever to the forward gear, make the
engine run for 5 minutes, drain way the
engine oil for cleaning, and finally add the
new gear oil.

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 Preventive Maintenance
(7) Suspension System

① When mounting the leaf spring, you

shall tighten the rear and front U-
bolts till the leaf spring comes into
the full-load status under the
pressure.
② Frequently check the tightness of
bolts for suspension system.
③ If the truck crane is parked for a long
time, its outriggers shall be extended.
④ Every time the truck crane has
traveled for 2000km, you shall add
the lubricating oil to the front ear of
leaf spring, the center bearing seat
and the ball-head seat of balance
beam.
⑤ Every time the truck has traveled for
Front Steel Plate
10000km, you shall dismount the
leaf springs and clean them, and
then apply the graphite lubricating
grease to every spring.

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 Preventive Maintenance

(8) Tyres and Wheels

① Frequently check the tyre pressure

and ensure it meets the requirement
specified in User’s Guider.
② Frequently check the tyre nuts. Position Change
③ For the even abrasion of tyres, the for Tyres of
Three-axle
tyre positions shall be changed as Truck Crane
shown in right figure every time the
truck crane has traveled for
20000km.
Position Change
for Tyres of
Four-axle Truck
Crane

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 Preventive Maintenance
(9) Braking System

① Frequently check the clearance between the

circumference surface of brake drum and
the friction surface of brake shoe.
② Frequently check the temperature of brake
drum.
③ Frequently check whether air leaks from
the drum diaphragm and seals of brake
slave chamber.
④ Add lubricating grease to the brake cam
and the sliding bush for support every time
the truck crane has traveled for 1500km.
⑤ Check the connecting distance from brake
pedal to double-chamber brake valve, and
adjust the limit screw for brake pedal so as
to confine the brake pedal.
⑥ Release the spring braking air chamber Brake
from automatic braking.
It is allowable to screw off the adjusting bolts of spring braking air chamber only
when an emergency occurs. Once the emergency has been eliminated, screw down
Cauti these bolts so as to ensure the parking braking and emergency braking functions of
on truck crane.

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 Preventive Maintenance
(10) Steering System

① When the truck crane travels, it is forbidden to

shut down the engine for the purpose of gliding. In
the case of an abrupt turning, timely decelerate the
truck crane and shift the gear lever to a lower gear.
② Check the air tightness of hydraulic steering
system.
③ Frequently check the tightness at joints of steering
tie rod, steering link rod and steering connecting
rod, and perform the lubrication and maintenance
according to the rules.
④ Periodically check the level and quality of oil in
steering gear and steering oil tank.
⑤ When replacing oil, drain away the oil from the oil
tank and oil cylinder, and then repeatedly turn the
steering wheel to the limit positions at both sides
so as to thoroughly discharge the oil.
⑥ When adding oil, fully bleed the air in order to fill
the whole steering system with oil.
⑦ Check the steering wheel.

Steering Oil Tank

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 Preventive Maintenance

Lubrication for Chassis

The proper lubrication for the truck crane may reduce the abrasion of parts.

(1) Lubrication Method for Different Parts of Chassis

(2) The lubrication method for chassis of 20t truck crane is shown in the following
figure. Also, this figure can be used as a reference for the chassis of 25t and 50t
truck cranes.

Schematic Diagram for

Lubricated Positions of
20t Truck Crane

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 Preventive Maintenance
(3) During the course of Lubrication, notice
the following aspects:
① Perform the lubrication according to the
maintenance period. In case of the
terrible ambient conditions, shorten the
maintenance period.
② Use the specified lubricating oil. Shorten
the lubrication period when using the Engine Oil Filter
substitute lubricating oil.
③ Replace the used engine oil when it is hot
so as to fully drain it.
④ Before the lubrication, clean the inlet for
lubricating oil. After the lubrication, clean
the surface of relevant parts.
⑤ When replacing the engine oil filter core,
add new engine oil till it reaches the
upper limit of oil gauge.
Oil Gauge
⑥ When replacing the engine filter cores,
simultaneously replace two parallel
engine filter cores, apply a thin layer of oil
to the packing plates and tighten these
filters.
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 Preventive Maintenance
4.2 Check for Hydraulic System
Hydraulic Oil 1. Loosening and damage; 2. Crack and oil leakage; 3. Oil volume, pollution degree and
Tank viscosity.

Filter 1. Jam in filter and replacement of filter core.

1. Abnormal noise, quiver and fever; 2. Abnormal oil supply pressure; 3. Loosening and oil
Hydraulic Pump
leakage of pipeline connectors.
1. The setting pressure for overflow valve in main oil circuit of superstructure shall be
22MPa; the setting pressure for overflow valve in oil circuit of undercarriage outrigger shall
Overflow Valve
be 20MPa; 3. The setting pressure and piloted control pressure for overflow valve in slewing
oil circuit shall be 20MPa and 3.5MPa respectively.
1. Damage and abrasion of pin-connected joint shaft; 2. Loosening of locking plate bolt for
Luffing &
pin-connected joint shaft; 3. Periodical grease lubrication for articulated pin-connected joint;
Telescopic
4. Oil leakage; 5. Quiver and noise; 6. Natural retraction of oil cylinder during overload
Cylinders
operation; 7. Aging and deformation of hose.
1. Loosening of joint; 2. Oil leakage; 3. Loosening and crack; 4. Aging, distortion and
Pipeline
damage of hose.
Slewing
1. Oil leakage; 2. Abnormal noise, quiver and fever in case of slewing.
Connector

Balance Valve 1. Internal leakage; 2. Loosening and oil leakage of oil tube connector.

Vertical Cylinder 1. Natural retraction during lifting operation; 2. Natural descending during traveling; 3. Oil
of Outrigger leakage; 4. Noise and quiver; 5. Deformation and damage of outrigger disk.

Pressure Gauge 1. Zeroing and normal pressure measuring of pressure gauge hand; 2. Loosening of joint.
Horizontal
1. Deformation and damage; 2. Loosening of fixing pin and pin bush of movable outrigger
Cylinder of
case; 3. Noise and quiver; 4. Oil leakage
Outrigger

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 Preventive Maintenance

4.2.1 Hydraulic Oil Tank (check the following

items)

1. Loosening and damage;

2. Crack and oil leakage;

3. Oil volume, pollution degree and viscosity.

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 Preventive Maintenance

4.2.2 Filter (check the following

items)

1. Jam in filter and replacement

of filter core.
Filter

4.2.3 Hydraulic Pump (check the

following items)

1. Abnormal noise, quiver and

fever;
2. Normal oil supply pressure; Hydraulic
3. Loosening and oil leakage of Pump
pipeline connectors.

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 Preventive Maintenance

4.2.4 Overflow Valve (check the following

items)

1. The setting pressure for overflow valve

in main oil circuit of superstructure
shall be 22MPa.
2. The setting pressure for overflow valve
in oil circuit of undercarriage outrigger
shall be 20MPa.
3. The setting pressure and piloted
control pressure for overflow valve of
slewing oil circuit shall be 20MPa and
3.5MPa respectively.
Overflow
Valve

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 Preventive Maintenance

4.2.5 Pipeline (check the following

items)

1. Loosening of joints;
2. Oil leakage;
3. Loosening and crack;
4. Aging, distortion and damage of
hose. Pipeline

4.2.6 Slewing Connector (check the following

items)
Slewing
1. Oil leakage; Connector
2. Abnormal noise, quiver and fever in case
of slewing.

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 Preventive Maintenance

4.2.7 Balance Valve (check the following

item)

1. Internal leakage;
2. Loosening and oil leakage of oil tube
connector.
Balance Valve

4.2.8 Pressure Gauge (check the

following item)

1. Zeroing and normal pressure

measuring of pressure gauge hand;
2. Loosening of joint.
Pressure
Gauge

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 Preventive Maintenance

4.2.9 Hydraulic Oil

1. Check the pollution degree of hydraulic oil.

2. Check the quality of hydraulic oil.
3. The standard model for hydraulic oil is Great Wall Long-time (ashless)
Antiwear Hydraulic Oil 6146 (cleanness grade: NAS8).
4. Check the temperature of hydraulic oil. The maximum working
temperature for hydraulic is 80℃.
5. Check the volume of hydraulic oil. Add adequate hydraulic oil
according to the requirement of corresponding truck crane model.
6. If the core of oil return filter is found jammed, you shall timely clean
or replace it.

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 Preventive Maintenance

4.3 Check for Electrical System

(See below for the description on

control functions such as moment
limiter, electromagnetic valve and
height limiter)

1. Moment Limiter
In the case of overload, the moment
limiter will stop all actions that increase
the lifting torques; at the same time,
the moment limiter will reserve all
actions that decrease the lifting torque.

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 Preventive Maintenance

2. Height Limiter:

It is composed of the end limit switches and

the plumb for main boom and jib. When the
hook rises to reach the anticollision block of
height limiter, the height limiter switch will be
turned on, and the moment limiter will send
out an acousto-electric alarm and prevent the
truck crane from operating towards the
dangerous direction.
Height Limiter

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 Preventive Maintenance

3. Electromagnetic Valve:

Two electromagnetic valves are set in

the piloted control oil circuit in order to
provide safety protection. They functions
to limit the height, protect the main
hoist against overrelaxing (by the three-
layer overrelaxing protector) and control
the torque. When the dangerous action
appears, the corresponding device will
send signals to the electromagnetic
valve, which will then change the
direction and cut off the control pressure
oil to make the main change valve
return to the neutral position and finally Electromagnetic Valve
stop the dangerous action.

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 Preventive Maintenance

4.4 Routine Check for Important Structural Parts

1. Crack, bending and damage.

2. Loosening of locking lock bolts for pin-connected joint shaft at
bottom of main boom.
Main Boom 3. Scratch on sliding surface.
4. Abrasion and damage of shaft sleeve at pin-connected joint.
5. Lubrication of sliding surface.
6. Deformation and crack of main boom.
Auxiliary 1. Crack, bending and damage.
Boom 2. Lubrication of connecting pins and pin sleeve.
1. Loosening and crack of mounted parts.
2. Noise.
3. Crack, deformation and oil leakage of gearbox.
Reductor
4. Abrasion of bearing.
5. Lubrication.
6. Oil leakage.
1. Abrasion of brake pedal and liner.
Brake 2. Loosening and oil leakage of oil tube connector.
3. Deformation of spring.

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 Preventive Maintenance

1. Crack.
Drum 2. Entanglement of steel wire rope.
1. Loose connection.
Slewing 2. Abnormal noise during slewing with load.
Mechanism 3. Lubrication.
4. Overflowing and leakage of slewing reductor.
1. Slewing of hook.
2. Deformation.
3. Swing of crossbeam.
Hooks 4. Connection between crossbeam and hook.
and 5. Deformation of anti-falling device.
Sheaves 6. Slewing of sheaves (with abnormal noise or not) .
7. Crack and damage of sheaves.
8. Bending and damage of sheave support and protective cover.
9. Lubrication.

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 Preventive Maintenance

1. Diameter.
2. Broken thread.
3. Entanglement.
4. Deformation.
Steel Wire
5. Rust and corrosion.
Rope
6. Correct positions of rope bush and wedges.
7. Connection of steel wire rope and rope bush.
8. Abrasion and crack on liner of rope bush.
9. Normal winding of steel wire rope round sheave.
Control 1. Functions.
Handle and 2. Oil clearance.
Pedal
Fixed 1. Deformation and damage.
outrigger 2. Loosening of fixing pin and pin bush for moveable outrigger
and case.
moveable 3. Crack and deformation of bracket.
outrigger 4. Noise and quiver.
1. Scratch and deformation in appearance.
Level
2. Installation.
Gauge
3. Condition of air bubbles.

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 Preventive Maintenance

4.4.1 Main Boom (check the

following items)

• 1. Crack, bending and damage.

• 2. Loosening of locking lock bolts
for pin-connected joint shaft at
bottom of main boom.
• 3. Scratch on sliding surface.
• 4. Abrasion and damage of shaft
sleeve at pin-connected joint.
• 5.Lubrication of sliding surface. Pin-connected
Main Boom Joint of Truck
• 6. Deformation and crack of main Crane
boom.

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 Preventive Maintenance

4.4.2 Jib (check the following items)

• 1. Crack, bending and damage.

• 2. Lubrication of connecting pins

and pin bush.

Jib

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 Preventive Maintenance

4.4.3 Reductor (check the following

items)

• 1. Loosening and crack of

mounted parts.

• 2. Noise.

• 3. Crack, deformation and oil

leakage of gearbox.

• 4. Abrasion of bearing.
Slewing
• 5. Lubrication. Reductor

• 6. Oil leakage.

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 Preventive Maintenance

4.4.4 Brake (check the following

items)
• 1.Abrasion of brake pedal and
liner.
• 2. Loosening and oil leakage of
oil tube connector.
• 3. Deformation of spring. Brake

4.4.5 Drum (check the

following items)
• 1. Crack.
• 2. Entanglement of steel
wire rope. Drum

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 Preventive Maintenance

4.4.6 Slewing Mechanism (check

the following items)

• 1. Loose connection.

• 2. Abnormal noise during

slewing with load.

• 3. Lubrication. Slewing
Mechanism

• 4. Overflowing and leakage of

slewing reductor.

Slewing
Reductor

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 Preventive Maintenance

4.4.7 Hooks and Sheaves (check the

following items)

• 1. Slewing of hook.
• 2. Deformation.
• 3. Swing of crossbeam. Hook
• 4. Connection between crossbeam and
hook.
• 5. Deformation of anti-falling device.
• 6. Slewing of sheaves (with abnormal
noise or not) .
• 7. Crack and damage of sheaves.
• 8. Bending and damage of sheave
support and protective cover.
• 9. Lubrication.
Sheave

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 Preventive Maintenance

4.4.8 Steel Wire Rope (check the

following items)

• 1. Diameter.
• 2. Broken thread.
• 3. Entanglement.
• 4. Deformation.
• 5. Rust and corrosion.
• 6. Correct positions of rope bush and
wedges.
• 7. Connection of steel wire rope and
rope bush.
• 8. Abrasion and crack on liner of rope
bush.
• 9. Normal winding of steel wire rope
round sheave. Steel Wire
Rope

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 Preventive Maintenance

4.4.9 Control Handle and Pedal (check the

following items)

• 1. Functions.

• 2. Oil clearance.

Control Handle
and Pedal

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 Preventive Maintenance

4.4.10 Fixed and Movable Outriggers (check the

following items)

• 1. Deformation and damage.

• 2. Loosening of fixing pin and pin bush for

moveable outrigger case.

• 3. Crack and deformation of bracket.

• 4. Noise and quiver.

Outrigger

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 Preventive Maintenance

4.4.11 Level Gauge

• 1. Scratch and deformation in

appearance.

• 2. Installation.

• 3. Condition of air bubbles.

Level
Gauge

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 Preventive Maintenance

4.5 Lubrication Points and Lubrication Method

No. Lubrication Point Lubrication Period Lubrication Method

1 Sheave Block of Main Hook Every week Injection by oil gun

2 Lifting Sheave Block of Main Boom Every week Injection by oil gun
Sliding Blocks for Second, Third and Fourth Spreading and injection by
3 Every week
Sections of Main Boom oil gun
Surfaces Passed by Sliding Blocks for Second,
4 Every week Spreading
Third and Fourth Sections of Main Boom
Upper and Lower Pin-connected Joint Shafts of
5 Every week Injection by oil gun
Luffing Cylinder
6 Jib Sheave Before use Injection by oil gun
Spreading and injection by
7 Rear Pin-connected Joint Shaft of Main Boom Every week
oil gun
8 Slewing Bearing Every week Injection by oil gun
9 Pinion of Slewing Mechanism Every week Spreading
10 Auxiliary Hook Before use Spreading

11 Steel Wire Rope Every week Spreading

Steel Wire Rope (for extension/retraction of

12 Every week Spreading
main boom)

13 Outrigger Disk Every week Injection by oil gun

14 Hoist Bearing Seat Every week Injection by oil gun

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 Preventive Maintenance

4.6 Periods for Various Routine Check and Maintenance

1. Equivalent Periods for Maintenance and Check

Interval
Mileage 1.5 5 10 20 40 80
(1000km)
Engine
40 ~
Working 125 250 500 1000 2000
50
Time (hour)
Elapsed
Natural
0.5 1.5 3 6 12 24
Time
(month)

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 Preventive Maintenance

2. Interval Mileages for Various Routine Check and Maintenance of Truck Crane
(Unit: 1000km)

First Rout First- Rou Secon Rou First- Rout Third- Rou First-
Rou Seco Rout First- Routi Fourth
Check ine grade tine d- tine grade ine grade tine gradetine nd- ine grade ne -grade
Chec Mainte Che grade Che Maint Chec Maint Che MaintChe grade Chec Maint Chec Mainte
k nance ck Maint ck enan k enanc ck enanc ck Maint k enanc k nance
enanc ce e e enan e
e ce
1.5 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

(1) First-grade Maintenance

For the first-grade maintenance, lubrication and tightening are key points.

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 Preventive Maintenance

(2)Second-grade Maintenance
For the second-grade maintenance, adjustment and check are key points. In
addition, all items for first-grade maintenance shall be performed for the
second-grade maintenance.

(3)Third-grade Maintenance
The third-grade maintenance is composed of various maintenance, check,
adjustment and repair items:
① Perform the specified maintenance items.
② Perform the possible troubleshooting.
③ Running-in Maintenance: Refer to first-grade maintenance.
④ Seasonable Maintenance: in combination with second-grade maintenance.

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 Preventive Maintenance

4.6.1 Maintenance for Engine 2. Replace the engine oil filter

when performing the first check
1. Replace the engine oil at or every time replacing engine
least once every year. oil.

Engine Oil
Filter

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 Preventive Maintenance

3. Check and adjust the valve

clearance every time performing
check and maintenance.

4. Check the opening pressure for

oil nozzle when performing the
third-grade maintenance.

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 Preventive Maintenance

5. Replace the fuel filter core

every time performing 6. Replace the coolant filter every
maintenance. time performing maintenance.

Coolant
Filter

Fuel
Filter

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 Preventive Maintenance

7. Check the volume of

coolant and sufficiently
add the coolant every
time performing
maintenance. Replace
the coolant once per 24
months.

Check the
coolant volume
in coolant tank

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 Preventive Maintenance

8. Air Filter
① Clean the dust cup of air filter every
time performing routine check or
maintenance.
② Clean the main filter core every time
the indicator for negative pressure
of air filter displays or 100 hours
have elapsed.
③ Replace the main filter core when it
is damaged.
④ Replace the safety filter core when
the main filter core is damaged or
the main filter core has been
cleaned for 5 times. Air Filter and
Display
Indicator

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 Preventive Maintenance

9. Check the intercooler 10. Check and tighten the V-belt when
every time performing performing the first/routine check or
maintenance. every time executing maintenance.

V-belt

Intercooler

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 Preventive Maintenance

4.6.2 Maintenance for Transmission

1. Check the level of

View the
transmission lubricating oil level of
once every week. lubricatin
g oil from
this point

2. Replace the transmission

lubricating oil at least once every
year.The first replacement shall
be performed when the truck
crane has traveled for 1000km;
henceforth, replace the
lubricating oil every time the
truck crane has traveled
20000km.

Oil Filler Hole

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 Preventive Maintenance

3. Replace the transmission

ventilation device when
performing the second-grade or
third-grade maintenance.

Transmission
Ventilation
Device

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 Preventive Maintenance

4.6.3 Maintenance for Chassis

1. Check fixing and action of towing

hook.

Towing
Hook

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 Preventive Maintenance

2. Tighten the crossbeam

bolts.

3. Tighten the U-bolts for

front and rear leaf
Various Bolts
springs and their
supports.

U-bolts and Their

Supports

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 Preventive Maintenance

4. Check the fixing position

of spare tyre.

5. Check the fixing of storage Spare

batteries. Tyre

Fixing of Storage
Batteries

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 Preventive Maintenance

6. Check the fixing of fuel tank

when performing the
second-grade or third-grade
maintenance.

Fuel Tank

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 Preventive Maintenance

4.6.4 Maintenance for Front

and Rear Axles 2. Check the lubricating oil levels in main
reductor and wheel reductor, and replace
1. Replace the lubricating the lubricating grease.
grease for wheel hub 3. Carry out such oil level check at the time
when performing the
third-grade maintenance. of first check, routine check or every
maintenance. Perform the replacement at
the time of first check or every
maintenance.

Wheel Hub Main Reductor Wheel

Reductor

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 Preventive Maintenance

4.6.5 Maintenance for Transmission Shaft

1. Re-tighten the transmission

shaft bolts. Tighten these bolts
at the time of first check.

2. Check the connection and

abrasion of transmission shaft
visually when performing the
Tighten the bolts
second-grade or third-grade
Transmission Shaft
maintenance.

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 Preventive Maintenance

4.6.6 Maintenance for Cab

1. Check the action of

windscreen wiper every
time performing check and
maintenance.

Windscreen
Wiper

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 Preventive Maintenance

Air Reservoirz

4.6.7 Maintenance for Braking

System

1. Drain off water from the air

reservoir every time performing
check and maintenance.

2. Check the air tightness of air

pressure system.

3. Check the thickness of brake

plate and adjust the brake
clearance.
Brake
4. Clean the wheel brake.

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 Preventive Maintenance

5. Check the vulnerable parts of brake

pipeline and hoses.

6. Check the function of brake chamber.

7. Check the functions of foot, hand and

exhaust brakes.

Hand Brake
Handle

Foot Brake Pedal

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 Preventive Maintenance

4.6.8 Maintenance for Steering System

1. Replace the steering gear oil (the truck crane has

traveled 20000~25000km) when performing the
first check.

2. Check and adjust the positions of front wheels

when performing the first check.

3. Check the oil level in steering oil tank when

performing the first check and the maintenance of
any grade.

4. Check the oil filter of steering oil tank when

performing the third-grade maintenance. Steering Oil Tank

5. Check the function of steering system when

performing the third-grade maintenance.

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 Preventive Maintenance

6. Check the clearance between steering

rods when performing the second-
grade or third-grade maintenance.

7. Check the bolts, connectors and

locking parts of steering rods when
performing the first check.

Steering
Rods

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 Preventive Maintenance
4.7 Routine Maintenance (performed by operators before, during and after
each shift of work)
No. Maintained Part Operation Item Technical Requirement

1 Hydraulic oil tank Check, and add oil No pollution or leakage

2 Hydraulic elements Check No seizure or leakage; accurate action and reliable effect

3 Operation mechanism Check and adjust No declination or seizure; reliable effect

4 Clutch Check No smear or quiver; reliable effect

5 Brake Check and adjust No smear or quiver; reliable effect

6 Locking device Check No damage or declination; reliable effect

Mechanisms and their

7 Check and tighten No obvious deformation, falling off or loosening
structural parts

No obvious deformation or damage; normal extension and

8 Main boom and jib Check
retraction

Steel wire rope, sheaves and No obvious abrasion or entanglement; no seizure at

9 Check
hook sheaves

Check and No obvious loosening; add the lubricating grease once per
10 Axis pins and bushings
lubricate 8 hours

Connecting parts for main

11 Check and tighten No loosening, loss or damage
positions

Safety protection and alarm

12 Check Normal and effective
devices

Check, and add

Check lubrication oil/grease levels, add the lubricating oil,
13 Lubrication points lubricating
and add the lubricating grease to every lubrication point.
oil/grease

Clean truck crane body; no sight barrier; no foreign

14 Whole truck crane Clean
matter in cab.

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 Preventive Maintenance

4.8 Monthly Maintenance (mainly performed by professional maintenance

personnel with participation of operation personnel)

Maintained
No. Operation Item Technical Requirement
Part
Unpolluted oil tank, smooth pipeline, and
strict switches. Conduct the quick analysis
Check; quickly analyze on oil quality. For oil quality ranked at
Hydraulic oil
1 the oil quality; clean or Grade 10, filter the oil; for oil quality
tank
replace the filter core ranked at Grade 12, replace the oil. Clean
the filter core once per 50 hours, and
replace it once per 1200 hours.
Operation No damage or deformation; easy and
2 Check and adjust
mechanism convenient operation; smooth return.
1. Check and tighten the
Tightening torque: 440N·m
Slewing slewing bearing bolts.
3 Clearance between slewing brakes:
mechanism 2. Adjust the clearance
0.25mm
between brakes.
Replace the steel wire rope when it meets
1. Check the steel wire
the rejection standard.
rope.
Lifting Tighten these bolts with the specified
4 2. Check and tighten the
mechanism tightening torques.
connecting bolts.
Clearance between brake plate and brake
3. Adjust the brake.
drum: 0.8 ~1.0mm.

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 Preventive Maintenance

Check sealed No damage in pipeline; no leakage at

hydraulic pump in connectors; smooth and stable
pipeline, operation of pump and motor; no
5 Hydraulic Elements hydraulic motor, abnormal noise or over temperature; no
hydraulic cylinder, over wearing or leakage in hydraulic
hydraulic valves cylinder; no leakage or seizure at valves;
and accumulator. effective accumulator pressure.
Main boom, jib, No obvious deformation or damage; no
6 Check
sheave and hooks seizure at sheaves.
Axis pins and Check and No overwearing; add the lubricating
7
bushings lubricate grease once per 8 hours.
Check the oil quality and oil volume for
Check, and add
each drive gear; add the lubricating
8 Lubrication points the lubricating
grease to each lubrication point in order
grease
to avoid leakage.
Smooth action; complete alarm mark;
Safety protection and
Check and test error of moment limiter no higher than
9 alarm device
±5%.
Normal operation of each drive
mechanism; accurate indication of
instruments; reliable effect of brakes;
10 Whole truck crane Check and test
clean appearance of whole truck crane;
complete and effective accessories;
good action of outriggers.

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 Preventive Maintenance
4.9 Annual Maintenance (performed by technicians and maintenance personnel
with cooperation of operation personnel)

No. Maintained Part Operation Item Technical Requirement

Unpolluted oil tank, smooth pipeline, and strict

Check; quickly analyze the switches. Conduct the quick analysis on oil quality.
1 Hydraulic oil tank oil quality; clean or replace For oil quality ranked at Grade 10, filter the oil; for oil
the filter core quality ranked at Grade 12, replace the oil. No
damage or jam at filter core.

1. No leakage at connectors; no damage at rubber

hoses.
2. No scratch on action surface of oil cylinder piston
rod; uneven abrasion no higher than 0.2mm;
Check sealed hydraulic
good air tightness; internal leakage less than
pump, pipeline, hydraulic
Hydraulic 1.5mL/min
2 motor, hydraulic cylinder,
elements 3. No damage, external leakage, over temperature
operation valve and
or abnormal noise at hydraulic pump and motor.
accumulator.
4. No damage, deformation or external leakage at
operation valve; convenient operation and
smooth return of operation valve.
5. Charged pressure of accumulator: 6.5MPa.
Operation No seizure or loosening; easy operation and smooth
3 Check and adjust
mechanism return.
Main frame and No damage or deformation; complete accessory
4 Check and tighten
fasteners mechanisms; firm connection.
Check the abrasion of Abrasion of gears and gear rings shall not exceed
Slewing gears and gear rings; 0.25mm; screw down the fixing bolts (specified
5
mechanism tighten the bolts, add the tightening torque: 860N·m); add the sufficient
lubricating grease lubricating grease.

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 Preventive Maintenance

6 Main boom and jib Check and test Normal extension and retraction

1mm Firm fixing of rope ends; abrasion and broken

thread within specified range; smooth rotation of
Steel wire rope, sheaves
7 Check and test sheaves; no loosening at bearings; abraded section
and hooks
of hook shall not larger than the original size of
hook for 1mm.

No bending or damage; abrasion no higher than

8 Axis pins and bushings Check
1mm.

Check and
Replace the oil according to the specified grades and
9 Lubrication points replace the gear
volumes.
oil for reductors

Eliminate the
Coated surface of whole
10 rust and repair Clean surface; no bubble or rust.
truck crane
the paint
Perform full non-disassembly tightening; the error
Check and
11 Bolts and tube connectors deviating from specified torque is allowed within
tighten
±10%.
Smooth and stable operation of acting mechanisms;
no over temperature, abnormal noise or leakage at
12 Whole truck crane Check and test hydraulic systems; accurate indication of
instruments; effective safety protection device;
reliable effect of brakes.

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 Quality Changes the World!

Thank you!

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