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Zoomlion RT60 Maintenance And Service Manual

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MAINTENANCE AND SERVICE
MANUAL FOR
ROUGH TERRAIN CRANE
Address:Quantang Indust=rial Park, 2nd Yuanda Road,
Changsha Economic and Technological Development
Zone, Hunan Province, China
Postcode: 410131
Website: www.zoomlion.com

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  • Page 1 MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE Address:Quantang Indust=rial Park, 2nd Yuanda Road, Changsha Economic and Technological Development Zone, Hunan Province, China Postcode: 410131 Website: www.zoomlion.com...
  • Page 2 MAINTENANCE AND SERVICE MANUAL Edition 2 FEBRUARY 2013...
  • Page 3 FEBRUARY 2013...

  • Page 4: (Thank You Letter

    Under the copyright laws, this manual cannot be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Zoomlion Heavy Industry Science and Technology Co., Ltd.
  • Page 5 Edition 2 Page ii Feb/2013...

  • Page 6: Table Of Contents

    Contents (Thank you letter) ........................... i Contents ............................iii About This Manual ........................v Safety ............................vii Introduction ..........................1 INTRODUCTION ......................1 OPERATOR OBSERVATION ..................1 WIRE-ROPE INSPECTION RECORD ................ 3 ENGINE MAINTENANCE ................... 4 ENGINE RADIATOR MAINTENANANCE ..............7 TRANSMISSION MAINTENANCE ................
  • Page 7 ELECTRICAL SYSTEM ....................1 HYDRAULIC SYSTEM ....................3 EXTEND / RETRACT SYSTEM .................. 4 DERRICKING MECHANISM ..................5 SWING MECHANISM ....................6 HOIST MECHANISM ....................7 OUTRIGGERS ......................8 TRANSMISSION ......................9 BRAKE SYSTEM ...................... 12 2.10 STEERING SYSTEM ....................13 2.11 FRONT / REAR AXLES ....................

  • Page 8: About This Manual

    An example of a Maintenance Log and Crane Periodic Inspection Checklist is at the end of this section. Again, we at ZOOMLION appreciate your selection of our crane. User safety is most important. To complete on-site tasks safely, operators and service technicians must be responsible. Obey the instructions that follow: •...
  • Page 9 If there is anything in this manual that is not clear or which you think is necessary, write to the address that follows: Rough Terrain Crane R & D Institute Zoomlion Mobile Crane Branch Company Quantang Industrial Park, 2nd Yuanda Road, Economic and Technological Development Zone, Changsha, Hunan Province, China, 410131 You can also speak to us by telephone at 0086-84671997 (international), 0731-84671997 (in China).

  • Page 10: Safety

    Safety The safety symbol, used on the Danger, Warning and Caution labels, tells personnel of possible death, injury, or property damage. Obey all safety data that follows this symbol to prevent dangerous conditions. HAZARD CLASSIFICATION Hazard classification is a system to show different classes of possible injury levels. A safety symbol and a signal word show how dangerous the level of possible injury can be.
  • Page 11 Rules change by location and this manual does not give that data. ZOOMLION makes manuals for different construction and industrial equipment. It is policy to include applicable national consensus, industry standards and safety data with the manuals. Use this data to give applicable training to personnel who are to operate, do the maintenance and supervise the equipment correctly and safely.
  • Page 12 Nomenclature To help you understand the contents of this manual, refer to the figure below. Each numbered term can represent several components of the same main part. Edition 2 Page ix Feb/2013...
  • Page 13 CRANE PERIODIC INSPECTION CHECKLIST This inspection checklist provides supplementary data to facilitate the correct operation and maintenance of the crane. Edition 2 Page x Feb/2013...
  • Page 14 MAINTENANCE LOG Item Adjusting Condition Date Edition 2 Page xi Feb/2013...
  • Page 15 Edition 2 Page xii Feb/2013...
  • Page 16 MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE Chapter 1 Maintenance and Service...

  • Page 18: Introduction

    Introduction 1.1 INTRODUCTION A set of preventive maintenance tasks is necessary to extend the serviceable life of the crane. The tasks can help to maximize efficient service and decrease the time the crane is at the repair facility. This section has checks and procedures which you are to do on daily, weekly, monthly and semi-annual intervals.
  • Page 19 Air cleaner vacuum actuated indicator Air inlet Silencer and exhaust device. C. Examine the condition of each battery. D. Examine the boom for: Sheave (wear or damage) The function of the anti-two block system Wire-rope on the winches (wear and breaks) Wear of the cylinder pin.

  • Page 20: Wire-Rope Inspection Record

    1.3 WIRE-ROPE INSPECTION RECORD WIRE-ROPE INSPECTION RECORD (See pages 1-37 and 1-38) Place of inspection _________________________ Date _______________ DESCRIPTION OF CRANE Make _____________________________ Model _________ Serial No. ___________ Type and Arrangement of Attachments ___________________________________________ Date of Last Rope Inspection ___________________________________________________ Hours and Time of Service Since Last Inspection ___________________________________ RESULT OF INSPECTION Rope Inspected...

  • Page 21: Engine Maintenance

    1.4 ENGINE MAINTENANCE For Cummins engine maintenance, refer to the EngineManufacturer’s Manual. Engine productivity, longevity and low-cost performance depend on a regular program of periodic maintenance. The materials presented here are listed in accordance with the EngineManufacturer’s Manual. Consideration may dictate a revision in scheduling for the periodic checks.
  • Page 22 Engine Oil Level You can measure the level of oil in the engine by a dipstick. The dipstick is on the right side of the engine (aft end of the crane). The engine must be OFF and sit for a short time before you can measure the oil level.
  • Page 23 Figure 1-3 Indicator A vacuum actuated indicator (See Figure 1-3) is attached on the side of the air filter assembly. Its gives you an indication of restricted airflow through the air filter. The quantity of airflow shows on the indicator at three different levels. When the light is in the green area, the air filter is good.

  • Page 24: Engine Radiator Maintenanance

    B. Quarterly Inspection Fuel Tank Drain the collected water and sediment from the fuel tank. • Remove the drain plug and let the tank drain. • Stop the flow when the fuel is clear of water and sediment. If the tank has a large quantity of sediment, do the task that follows: •...

  • Page 25: Transmission Maintenance

    B. Monthly / 160 Hours: Radiator Exterior Clean the radiator fins and through-core cooling passages. Use compressed air and water in the opposite direction of usual air flow to push the unwanted material out of the radiator core. C. Quarterly: Corrosion Inhibitor Adjust the cooling system corrosion inhibitor to the correct level after 500 hours of operation.
  • Page 26 B. Service the Transmission After Overhaul When you service the crane for the first time after vehicle installation and / or after repair, fill the unit as follows: Fill the transmission with recommended lubricant. Start the engine and set the speed at idle to let oil fill the torque converter and lines.

  • Page 27: Axle Maintenance

    Always do the transmission oil level checks with the speed of the engine at idle. The transmission must be in the neutral position and the transmission temperature between 180° F and 200° F (82.2° C and 93.3° C). Do not put too much fluid in the transmission! C.

  • Page 28: Tire Maintenance

    Check the differential oil level by removing the filler and check plug indicated in Figure 1-6. Add oil as necessary to bring the oil level to the bottom of the hole. Do a check of the level of differential oil as follows: Remove the fill plug.
  • Page 29 Punctures Abrasion. If necessary, make sure that you repair these items. Replace or repair the wheels if they are bent, contain a crack or are loose. Make sure that the wheel nuts are correctly tightened. B. Tire Pressures Always keep the correct tire pressure in all the tires. Friction makes heat that increases the pressure in the tires when you move the crane.
  • Page 30 Under Inflation The tires that do not have a sufficient quantity of pressure in them cause them to wipe and scuff over the road. Strain on the tire increases the chance to bruise. Correct Inflation When the tires have the correct pressure in them, they do not wear too quickly.

  • Page 31: Brake System Maintenance

    C. Tire Change Safety Precautions When you must make the repair on a wheel (demount and mount the rim and tire), follow these precautions: Follow the procedures (assemble and disassemble) that you find in the tire change safety guidelines or other instruction manual. Before you start to disassemble the wheel, fully deflate the tire.

  • Page 32: Air System Maintenance

    Examine the brake pedal annually and replace the parts that show wear or damage. If you push the service brake pedal and the distance to stop is more than usual, the system can have a malfunction. When the service brake indicator illuminates, the pressure in the system can be low.

  • Page 33: Fuel, Coolant And Torque Converter Hydraulic Transmission Oil

    Figure 1-9 Battery 1.12 FUEL, COOLANT AND TORQUE CONVERTER HYDRAULIC TRANSMISSION OIL A. Fuel Selection Always use the correct light diesel fuel and engine oil. Make your selection on the lowest ambient temperature where you are to do the work. Refer to the Operator’s Manual for the fuel sulfur content standards.

  • Page 34: Lubrication

    C. Torque Converter Hydraulic Transmission Oil Selection For torque converter hydraulic transmission oil selection and change interval, refer to the Operating Instructions for the Torque Converter. 1.13 LUBRICATION You can increase the service life of the crane if you obey the preventive maintenance schedule and use the correct lubricants.
  • Page 35 Table 1-1 Lubrication Number of Ser. Lubricating Lubricating Lubricating Lubricating Description Point Intervals Method Grease Type 3106 miles Add grease (5000 km) Central reducer GL-5 80W/90 for front axle 6213 miles Change the (10000 km) grease Steering knuckle 3106 miles Inject with ZL-2 lithium of front and rear...
  • Page 36 The engine oil add or change interval (in your preventive maintenance schedule) cannot be more than the interval you find in the diesel engine maintenance specifications in the Engine Manufacturer’s Manual. When you add or change grease, you must clean the grease off and around the plug (grease nipple) and check for leaks.
  • Page 37 When you change the gear oil, only drain the remaining gear oil while it is warm. The first time you replace the middle and rear axle gear oil (after the break-in period) of a new crane: Drain the gear oil and add engine oil to the axle to the correct level. Lift the axles off the ground (support with jack stands).
  • Page 38 Lubricate the rear suspension. Refer to Figure 1-13. Figure 1-13 Rear Suspension Points Lubricate the steering system. Refer to Figure 1-14. Figure 1-14 Steering System Lubrication Points C. Lubrication – 500 Hours Change engine oil. On a warm engine, remove the oil pan drain plug and drain the oil from the engine and oil filter assembly.
  • Page 39 Install the oil pan drain plug and add oil to the engine through the oil filler port. Refer to Figure 1-15. The weather in the area that you operate the crane determines what type of oil to use in the engine. The oil viscosity decreases in areas of heat and increases in areas of cold.
  • Page 40 • The service life of the engine decreases when you operate the engine at high speeds or the operating load is high for long intervals. • When the crane is new, change the engine oil after the engine operates between 30-50 hours.

  • Page 41: Hydraulic Oil

    Zoomlion cannot be legally responsible for the damage you cause when you do not obey the data in this manual with reference to: oil and oil filter change.
  • Page 42 Screw down the plug fitted on the brake disc to drain the hydraulic oil in brake return lines every 6 months. Flush the expired (initial) oil out of the system as follows: The function of this procedure is to remove all the initial oil out of the system. Start the engine and operate it at a low speed.
  • Page 43 Change the oil when the oil is found to be contaminated. Do not wait for the scheduled service. Always use the correct oil for the temperature the crane operates in. You cannot mix oil of different brands (specifications) or types. You must change the oil every 24 months.
  • Page 44 Table 1-3 Hydraulic Oil Performance and Type Ambient Ambient Ambient Ambient Temperature Temperature Temperature- Temperature Item Above 104° F -4° F - 104° F 22° F - -4° F Below -22° F (40° C) (-20° C - 40° C) (-30° C - -20° C) (-30°...

  • Page 45: Gear Oil

    1.15 GEAR OIL A. Always use the correct gear oil (type and viscosity) in the crane. B. When the crane comes out of the factory, the gear oil level is full. You must use the data from Table 1-4 when you choose the type of oil for the crane. Table 1-4 Gear Oil Performance Kinematic viscosity at...
  • Page 46 C. Oil Change Parts Winch Reducer Figure 1-19 Fill, Check and Drain Ports Fill the gear oil to the top. Swing Reducer Fill oil after removing the plug of oil fill aperture. Figure 1-20 Swing Reducer Fill and Drain Ports Fill the gear oil to the top.

  • Page 47: Lubricating Grease

    1.16 LUBRICATING GREASE When you lubricate the crane, use only ZL-2 or ZG-3 types of grease. There are two procedures to lubricate the crane: • Use a grease pump to put (inject) lubricant through a grease fitting (nipple). • Apply the grease directly to the part by hand. Figure 1-21 Grease Pump Table 1-5...

  • Page 48: Lubricating Points

    1.17 LUBRICATING POINTS A. You can use Table 1-6 and Figure 1-22. Table 1-6 Lubrication Intervals and Points Lubricant Description Intervals Method Type Upper pulley block (shaft) on 10 Days Grease ZL-2 main boom Grease or inject Slider pads of main boom 10 Days ZL-2 with grease pump...
  • Page 49 Figure 1-22 Crane Lubrication Points Edition 2 Chapter 1 Page 1-32 Feb/2013 Maintenance and Service...

  • Page 50: Adjust, Clean And Replace The Parts

    Before you put lubricant (grease) on a part by hand, clean the part then add the lubricant. Clean and lubricate all the sliding surface areas (bare metal, includes cylinder pistons), not in the table, at a regular interval. You cannot mix grease of different brands (specifications) or types. When you inject lubricant (grease) with a grease pump, continue the procedure until you see old grease come out of the joints.
  • Page 51 B. Clean the Chassis Intervals Table 1-8 Intervals Semi- Item Daily Monthly Quarterly Yearly Annual Drain brake system. Pull the draw • ring of manual water drain valve downwards to drain water. • Clean the fuel filter. • Clean the water tank. Clean the air cleaner filter •...
  • Page 52 Do not wash the filter element! Examine the filter element. If it is dirty or full of contamination, discard it. If this is a 1000 hours inspection, discard the element. If you install a new filter element, replace the washer and O-ring. Assemble the fuel filter in sequence as follows (See Figure 1-24): •...
  • Page 53 D. Clean the Cooling System Operate the engine until it increases to the usual temperature of 185° F (85° C). If the water temperature is too low, the thermostat cannot open and the coolant cannot flow through the radiator. Clean the cooling system as follows: Loosen the radiator drain cock to fully drain the engine coolant.
  • Page 54 F. Chassis Parts – Replacement Intervals Table 1-9 Replacement Intervals Every Every 2 Every 4 Item 1 year years years Diaphragm and rubber parts of pressure • regulating valve of air dryer • Air cleaner filter element • Shims and rubber parts of service brake valve Hose connecting the air compressor and •...
  • Page 55 • Torsion resistant wire-rope breaks: two steel wires of rope diameter in less than 0.2 in. (6 mm) or four steel wires of rope diameter in less than 1.2 in. (30 mm). • A break in the wire-rope on the external rope layer at the core position (causes rope core to extrude or in circle).
  • Page 56 Operate carefully to avoid the rope from disordering on the drum. Remove the press nipple from the boom (top section) or the main hook. 1 Tools necessary: Wrench. 2 Set the parts to the side until they are necessary. Figure 1-26 Main Hook and Nipple Remove the wire-rope from the press nipple.
  • Page 57 Figure 1-28 Pull Wire-Rope The 3 wrap warning alarm comes ON when only 3 hoist rope wraps are left on the main winch. Push the bypass key switch until the wire-rope stops. Remove the wire-rope from the main winch drum. 1 Tools necessary: Steel rod (punch) and hammer.
  • Page 58 Put thin steel wire or ethylene plastic strap on the end of the wire-rope. Install the new wire-rope onto the main winch drum with the chock. 1 Tools necessary: Hammer. Figure 1-31 New Wire-Rope on the Drum • Make sure that the chock is in the correct position before you make the wire-rope tight.
  • Page 59 Do not spool-up the wire-rope too quickly. Make sure that the rope collects on the drum correctly. Reeve the wire-rope through the top boom head sheave and hook pulley block in the related line parts. Make sure that you attach the wire-rope in the correct sequence. Figure 1-33 Wire-Rope Wrap Sequence Install the becket and wedge onto the wire-rope.
  • Page 60 (m) Install the becket to the end of the boom or to the main hook. 1 Tools necessary: Wrench. Figure 1-35 Becket Attachment Derrick the boom and fully extend the boom. Reel-off the wire-rope from the main winch until the 3 wrap alarm sounds.
  • Page 61 Figure 1-37 Spool-Up Wire-Rope Do not lift more than the lift capacity of the wire-rope. Remove the load from the main hook. H. Hook Inspection Do an inspection on the hook. Replace the hook if you find one of the items in the next step.
  • Page 62 Replace the Return-Line Filter Element The hydraulic tank (reservoir) has a return-line filter on the input connection (return-line). The filter stops contamination of the hydraulic fluid, such as particles of metal and rubber. Make sure that you are careful when you add fluid to the system.
  • Page 63 Remove the spring and the permanent magnetunit. Figure 1-40 Disassemble Remove and replace the filter element. Figure 1-41 Filter Element Install thepermanent magnetunit and spring. Figure 1-42 Assemble Edition 2 Chapter 1 Page 1-46 Feb/2013 Maintenance and Service...
  • Page 64 Install the top cover with the four bolts. Figure 1-43 Top Cover Assembly K. Boom Extend / Retract Troubleshoot Problem: The top boom section does not fully retract. Cause: The boom extend / retract rope is not at the correct length. Correction: Adjust the rope.
  • Page 65 top section locking nut Adjusting nut Figure 1-44 Adjust and Lock nuts Adjust the retract rope on the boom section 2 as follows: Use the same procedure that you used to adjust the top section retract rope. The adjustment nut is on the side of the boom head. •...
  • Page 66 Torque sequence: When you do a check of the torque on the bolts, follow the sequence in Figure 1-45. Tighten the bolts on the inner ring (chassis frame). Tighten the bolts on the outer ring (superstructure). Figure 1-45 Torque Sequence Edition 2 Chapter 1 Page 1-49...

  • Page 67: Battery Maintenance And Service

    1.19 BATTERY MAINTENANCE AND SERVICE The batteries in the crane align with national standard GB/T 5008.1 - 2005. If the electrical system is free of malfunctions, keep the batteries fully charged. If the batteries do not charge or cannot hold voltage, examine the generator and voltage regulator for malfunction.

  • Page 68: Battery Maintenance - Winter

    E. Do an equalizing charge procedure if one of the items that follows occurs: • Monthly, when the crane operates in usual conditions. • When the battery charge interval is too long or unusually high loss of power in the battery. •...

  • Page 69: Operation In Winter

    E. If you do not operate the crane for a long time, remove the battery from the crane and make sure that it is charged at all times. F. Before you start the engine, make sure that all items that use battery power are in the OFF position.

  • Page 70: Operation In Summer

    If you find that the coolant is bad, make sure that you follow the procedure(Clean the Cooling System). Always use the correct type of diesel fuel. For more data on the correct fuel to use, refer to the Engine Manufacturer’sManual. The fuel must be winterized when the crane operates in a cold area.
  • Page 71 F. When you move the crane, make sure that the coolant temperature is not more than 203° F (95° C). If the temperature is too high, stop the crane to decrease the coolant temperature. In special conditions, you can open the engine hood to help decrease the temperature.
  • Page 72 MANUAL FOR ROUGH TERRAIN CRANE Chapter 2 Troubleshooting...

  • Page 74: Troubleshooting

    Troubleshooting 2.1 ELECTRICAL SYSTEM Table 2-1 Part Problem Cause Remedy a) Bulb damaged Replace b) FU811 burnt out Repair Work light does not c) Poor grounding Repair illuminate d) Conducting wire broke Repair e) Switch defective Replace Bulb damaged Replace Vehicle length indicator g) Switch defective Repair...
  • Page 75 Part Problem Cause Remedy d) Anti-two block switch Replace defective e) Rope for counterweight Replace attached to the switch broke f) Solenoid valve defective Repair or replace g) Solenoid valve is not Repair grounded correctly a) Inspect FU12, FU13 and Replace or notify the FU14 manufacturer...

  • Page 76: Hydraulic System

    2.2 HYDRAULIC SYSTEM Table 2-2 Part Problem Cause Remedy a) The fluid level in the Add hydraulic oil hydraulic tank is too low Blockage in the relief valve Clean the valve element System pressure does not Central revolving joint Inspect the joint and increase leaks seal ring...

  • Page 77: Extend / Retract System

    2.3 EXTEND / RETRACT SYSTEM Table 2-3 Part Problem Cause Remedy a) Balance valve defective Repair b) Electrical system defective Repair c) Main valve leaks internally Repair Boom cannot retract d) Pilot control valve defective Repair solenoid coil e) Retraction rope and fittings Examine defective a) Relief valve pressure is set...

  • Page 78: Derricking Mechanism

    2.4 DERRICKING MECHANISM Table 2-4 Part Problem Cause Remedy a) Main relief valve pressure Adjust is set too low Cylinder cannot extend b) Main valve leaks internally Repair c) Cylinder leaks internally Repair the seal ring a) Derricking-control balance Repair or replace valve defective Cylinder cannot retract b) Electrical system defective...

  • Page 79: Swing Mechanism

    2.5 SWING MECHANISM Table 2-5 Part Problem Cause Remedy Brake defective. Brake pad is worn. Adjust or replace a) Relief pressure of outrigger Adjust control valve is too low b) Relief valve pressure for Adjust Superstructure cannot swing valve is set too low move left or right c) Swing valve defective Repair or replace...

  • Page 80: Hoist Mechanism

    2.6 HOIST MECHANISM Table 2-6 Part Problem Cause Remedy a) Relief valve pressure for Set the pressure to 27 the main valve is set too MPa. low. b) Hydraulic motor defective Replace Hook cannot go up c) Main valve defective Repair d) Electrical system defective Repair...

  • Page 81: Outriggers

    2.7 OUTRIGGERS Table 2-7 Part Problem Cause Remedy a) Relief pressure of outrigger Adjust the pressure control valve is not adjusted correctly. Do not move b) Solenoid coil of outrigger Replace the solenoid control valve defective coil a) Chassis multiple unit valve Repair leaks internally Move too slow...

  • Page 82: Transmission

    2.8 TRANSMISSION Table 2-8 Part Problem Cause Remedy a) Pressure gauge defective Replace the pressure gauge Control b) Control oil pipeline leaks Examine oil pipeline and pressures in replace control valve the full gear c) Oil pump pressure is not sufficient Repair or replace oil pump range are low d) The control valve mount bolts are Tighten bolts...
  • Page 83 Part Problem Cause Remedy b) If the balls or rollers in the Replace bearingsare damaged, there can be spots and scale on the roller bed, which causes noise when each gear is at low rotational speed. c) A knocking sound (at low Replace turning speed) and screaming sound (at high...
  • Page 84 Part Problem Cause Remedy Part Problem Cause Remedy Loss of a) Head pressure of torque Adjust the opening converter is low pressure of the safety traction force valve for torque converter. or increase in b) Pressure of the fuel supply Clean or replace the fuel temperature system for the engine is low...

  • Page 85: Brake System

    2.9 BRAKE SYSTEM Table 2-9 Part Problem Cause Remedy a) Brake force is not even Examine and adjust the brakes (clearance between brake disc and brake caliper around 0.020 - 0.028 in (0.5 - 0.7 mm)). b) Different tire inflation pressures Inflate the tires to the Brake for different tires...

  • Page 86: Steering System

    2.10 STEERING SYSTEM Table 2-10 Part Problem Cause Remedy a) Oil level in the hydraulic system Examine oil level in is too low or the oil has a low hydraulic tank, add oil viscosity (causes low pressure or as necessary. Use the air in the system (cavitations)).
  • Page 87 Part Problem Cause Remedy a) Floating brass bush of steering Repair oil pump pump is blocked and does not Steering touch the wheel end-face all the time. sometimes hard or b) Hydraulic oil is seriously polluted Replace oil or remove sometimes or air is inhaled into the system air from the system...
  • Page 88 b) O-rings Examine and replace O-ring c) Oil pipes damaged Examine or replace oil pipelines d) Oil pipe fittings Look for connection that leaks, tighten fitting e) Low oil viscosity Replace oil Joint face of hydraulic elements Examine and tighten loosen a) Oil pipe of hydraulic pipeline Examine and replace...

  • Page 89: Front / Rear Axles

    2.11 FRONT / REAR AXLES Table 2-11 Part Problem Cause Remedy a) Noise sounds like (si) during speed Adjust the clearance increase or decrease. Gears do not or alignment interconnect correctly(clearance of gears too small or poorly aligned). b) New gear poorly meshed Monitor after breaking-in c) Noise sounds like clash on...
  • Page 90 Part Problem Cause Remedy c) Oil level too high Drain oil to the correct level d) Seal gasket damaged Replace e) Bolts loose Tighten Vent cap soiled Clean Edition 2 Chapter 2 Page 2-17 Feb/2013 Troubleshooting...

  • Page 91: Drive Shaft

    2.12 DRIVE SHAFT Table 2-12 Part Problem Cause Remedy a) Universal joint cross Replace the universal trunnion, needle roller worn joint Unusual noise when and loosen or needle roller the crane begins to broken. move, increase speed b) Drive shaft spline and Replace and decrease speed.

  • Page 92: Tires

    2.13 TIRES Table 2-13 Part Problem Cause Remedy Toe-in too small or in negative Adjust the tie rods of value front steer axles The inner part of tires along the stretching on the two steer axles direction and have the same increase the toe-in quantity of wear.
  • Page 93 Part Problem Cause Remedy a) Overload: too much weight Decrease load, move on the crane when it is in slower. Replace tire motion. Tire blow-out b) Tires damaged Replace c) Tires reach the wear limit Replace Edition 2 Chapter 2 Page 2-20 Feb/2013 Troubleshooting...
  • Page 94 MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE Chapter 3 Inspection...

  • Page 96: Inspection

    Inspection 3.1 PRE-START INSPECTION The following items should be checked each day before start-up and the start of operations. Examine the items below each day before you start or operate the crane. ENGINE OIL The level must be at the full mark. COOLANT The level must be near the top of the radiator tank.
  • Page 97 Table 3-1 Maintenance Checklist DAILY (8 HOURS)   Do daily lubrication tasks Drain the air reservoir of moisture   Examine the hydraulic reservoir fluid Examine the wire-ropes and related level components   Fill fuel tank Examine the air cleaner, the air intake pipelines and clamps ...
  • Page 98  Examine the level of axle oil (after initial change)   Examine the battery condition Examine the Engine Manufacturer’s Manual for additional maintenance requirements   Inspect the tire pressure and condition Examine the hydraulic cylinders and piston rods ...
  • Page 99 SEMI-ANNUAL (1000 HOURS)   Do the daily, weekly, monthly and Examine the brake disk for wear condition quarterly inspections   Clean the crankcase breather Examine safety valve pressure settings   Replace the oil in winches Examine the Engine Manufacturer’s Manualfor more maintenance requirements ...

  • Page 100: New Crane Special Break-In Requirements

    3.2 NEW CRANE SPECIAL BREAK-IN REQUIREMENTS 8 HOURS - During the first 185 miles (300 km) of travel or after a tire is changed, make sure that the wheel nuts are tight. 40 HOURS - Make sure that the swing bearing bolts are tight. If you tighten some of the bolts, do this inspection after one more 40 hour period.
  • Page 101 Table 3-2 Periodic Inspection Interval NewVehicle Component Inspected ENGINE Examine each part of • • • engine for air, water and oil leaks Examine the engine • • • starting state and unusual sound Examine the engine • • • RPM and exhaust state Tighten the air cylinder •...
  • Page 102 Periodic Inspection Interval NewVehicle Component Inspected For maintenance and service of parts for engine, refer to related chapters in Engine Manufacturer’s Manual. Antifreeze, anti-rust and anti-corrosion additives, which are toxic, are added in the engine coolant and engine oil. Do not contact with skin repeatedly for a long time. Dispose of them in accordance with local environmental laws and regulations.
  • Page 103 Periodic Inspection Interval NewVehicle Component Inspected Examine the • • transmission control system Examine the parts that • • connect the drive lines for correct connection Examine the drive lines • for swing and the spline for vibration Examine the drive line •...
  • Page 104 Periodic Inspection Interval NewVehicle Component Inspected Examine the front wheel • hub bearing for vibration Examine the rear wheel • hub bearing for vibration Examine the pressure, tire tread depth, look for unusual abrasions, • metal, stones and foreign matter in the tread •...
  • Page 105 Periodic Inspection Interval NewVehicle Component Inspected BRAKE SYSTEM Examine each part of • • • the brake system for air and oil leaks Examine each part of the brake system for the • • • correct seating and abrasion Examine the play of •...
  • Page 106 Periodic Inspection Interval NewVehicle Component Inspected Examine the level of • • • battery acid Measure the proportion • of acid in the battery Examine the starter • commutator and electrical brush • Examine the generator Disassemble the starter and generator. Look for worn and damaged components.
  • Page 107 Periodic Inspection Interval NewVehicle Component Inspected Examine the function of • all switches Examine the PTO • • switch and indicator function Replace lubricating • grease for PTO If you replace the PTO, drain and replace the lubricant after 20 hours of operation.

  • Page 108: Periodic Crane Inspections

    3.4 PERIODIC CRANE INSPECTIONS A. Keep the mechanisms of the crane in satisfactory condition to make sure that it can operate safely. Examine the items in Table 3-3. Do the necessary repairs. Before you lift a load, do an inspection on the parts that follow: •...
  • Page 109 Table 3-3 Parts Inspected items Parts Inspected items Examine the function of Derricking cylinder the left and right • Examine the joysticks. articulated pin spindle for wear and damage. • Examine it for • Examine the lock tight fit and leaks. bolt of articulated •...
  • Page 110 Parts Inspected items Parts Inspected items correct. them. • • Examine the pipe Examine the boom fittings for correct support for seating and deformation and leaks. crack. Examine Cylinder thesuperstructure for • Make sure it works cracks and distortion. correctly. Inspect it Reducer and swing for pulse, noise and bearing...
  • Page 111 Parts Inspected items Parts Inspected items • • Tension state. Make sure thatthewire-rope reeves over the sheave correctly. Hydraulic motor Wire-rope guard • • Examine it for Examine the tight fit and clearance between cracks. the wire-rope guard • and the hook. Examine it for •...
  • Page 112 Parts Inspected items Parts Inspected items • the wire-rope on Examine it for the drum winds leaks. • uniformly. Examine the pipe clamp for tight fit Hook and sheave and cracks. • • Examine the hose Make sure that for aging, the hook rotates deformation and easily.
  • Page 113 Parts Inspected items Parts Inspected items outrigger floats for deformation and damage. Outrigger box, outrigger beam and cylinders • Examine them for • deformation and Examine the damage. bolts and nuts for • tight fit. Examine the • securing pins for Examine the the outrigger beam windows and...
  • Page 114 Parts Inspected items Parts Inspected items wrap indicator Examine the chassis frame for deformation, bends and • Examineit for cracks. functional work. • Make surethat Examine the accessories Others the solenoid for damage and missing valve and parts. switches function correctly.

  • Page 115: Inspections And Maintenances During Break-In Period

    3.5 INSPECTIONS AND MAINTENANCES DURING BREAK-IN PERIOD Do these inspection and maintenance tasks after 200 hours of lift operations. • Examine the hoist and swing mechanism gear meshing. Replace the grease and clean the case. • Drain and flush the hydraulic tank. Replace the filter element and hydraulic oil.

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