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Zoomlion RT55 Maintenance Manual

Rough terrain crane
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MAINTENANCE 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 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 MANUAL Edition 1 Dec 2013...
  • Page 3 Dec 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 Dec/2013...

  • Page 6: Table Of Contents

    Contents (Thank you letter) ......................... i Contents ............................ iii About This Manual ........................v Safety ............................vii Intro duction ..........................1 INTRODUCTION ....................... 1 OPERATOR OBSERVATION ..................1 WIRE-ROPE INSPECTION RECORD ............... 3 ENGINE MAINTENANCE ..................4 ENGINE RADIATOR MAINTENANCE ............... 7 TRANSMISSION MAINTENANCE ................
  • Page 7 ELECTRICAL SYSTEM ..................... 1 HYDRAULIC SYSTEM .................... 12 EXTEND / RETRACT SYSTEM................13 DERRICKING MECHANISM ................... 14 SWING MECHANISM ..................... 15 HOIST MECHANISM ....................16 OUTRIGGERS ......................17 TRANSMISSION ..................... 18 BRAKE SYSTEM ....................21 2.10 STEERING SYSTEM ....................22 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 Dec /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 Dec /2013...

  • Page 14: Maintenance Log

    MAINTENANCE LOG Item Adjusting Condition Date Edition 2 Page xi Dec /2013...
  • Page 15 Edition 2 Page xii Dec /2013...

  • Page 16: Chapter 1 Maintenance And Service

    MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE Chapter 1 Maintenance and Service...

  • Page 18: Introduction

    Introduction 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. Examine the condition of each battery. 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. Tires, axles and drivelines (wear or damage).

  • Page 20: Wire-Rope Inspection Record

    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 Type and Size...

  • Page 21: Engine Maintenance

    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 Maintenance

    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

    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. Quarterly: Corrosion Inhibitor Adjust the cooling system corrosion inhibitor to the correct level after 500 hours of operation.
  • Page 26 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 Check

    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! Lubricant and Filter Change Interval Refer to Section 1.13 for the lubrication schedule.

  • Page 28: Tire Maintenance Check

    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. 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

    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 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. Refer to the Service and Maintenance Manual for the Engine when it is necessary to put oil into the engine.

  • Page 34: Lubrication

    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 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. Change gear oil in the transmission.

  • 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 Always use the correct gear oil (type and viscosity) in the crane. 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 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. Edition 2 Chapter 1 Page 1-29...

  • 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 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 Dec /2013 Maintenance...

  • 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 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 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 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 •...
  • 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. Tools necessary: Wrench. 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. 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. 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. 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. Hook Inspection Do an inspection on the hook. Replace the hook if you find one of the items in the next step. Do not weld the hooks to repair the disfigurements.
  • 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 Dec /2013 Maintenance...
  • Page 64 Install the top cover with the four bolts. Figure 1-43 Top Cover Assembly 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

    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

    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. 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 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: Chapter 2 Troubleshooting

    MANUAL FOR ROUGH TERRAIN CRANE Chapter 2 Troubleshooting...

  • Page 74: Electrical System

    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 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 Crane cannot move b) Controller burnt out Replace the controller...
  • Page 76 A. Fuse Electrical movement mechanisms are equipped with individual fuse which all been placed in fuse terminal for convenient searching and maintenance. The fuse terminal comprises of two parts: fuse terminal of chassis control ; fuse terminal of superstructure control . Layout of fuse terminal demonstrates as follows: -1FU2 -2FU2 -11FU1...
  • Page 77 -4FU1 -4FU2 -4FU3 -5FU1 -9FU1 -9FU2 -9FU3 -4FU1: Fuse forchassis controller CPU1 -4FU2:Fuse forchassis controller CPU1 -4FU3:Fuse forchassis controller CPU1 -5FU1: Fuse for sensor power supply -9FU1: Fuse forchassis controller CPU2 -9FU2: Fuse forchassis controller CPU2 -9FU3: Fuse forchassis controller CPU2 Edition 2 Chapter 2 Page 2-4...
  • Page 78 -12FU1 -12FU2 -12FU1: Fuse one for Transmission controller power supply -12FU2:Fuse two for Transmission controller power supply Edition 2 Chapter 2 Page 2-5 Dec /2013 Troubleshooting...
  • Page 79 -15FU3 -15FU7 -21FU1 -31FU1 -31FU6 -32FU4 -15FU1 -15FU5 -16FU2 -21FU3 -31FU4 -32FU2 -31FU2 -15FU2 -15FU6 -16FU3 -23FU1 -31FU5 -32FU3 -31FU7 -15FU4 -16FU1 -21FU2 -31FU3 -32FU1 -32FU5 -15FU1: Fuse for superstructure power supply -15FU2:Fuse for COBO system power supply -15FU3:Fuse for moment limiter power supply -15FU4: Fuse for display power supply -15FU5: Fuse for joystick power supply Edition 2...
  • Page 80 -15FU6: Fuse for camera power supply -15FU7: Fuse for air conditioner system -16FU1:Fuse forsuperstructure controller CPU1 -16FU2: Fuse forsuperstructure controller CPU1 -16FU3: Fuse forsuperstructure controller CPU1 -21FU1:Fuse forsuperstructure controller CPU2 -21FU2: Fuse forsuperstructure controller CPU2 -21FU3: Fuse forsuperstructure controller CPU2 -23FU1: Fuse for inductive switch power supply -31FU1: Fuse for fan of operation cabpower supply -31FU3: Fuse for on-board battery (24V/12V)
  • Page 81 B. Relay Electrical movement mechanisms are equipped with individual relay which all been placed in relay terminal for convenient searching and maintenance. The relay terminal comprises of two parts: relay terminal of chassis control ; relay terminal of superstructure control . Layout of relay terminal demonstrates as follows: Relay terminal of chassis control -1KA1 -11KA1 -11KA21 -3KA1...
  • Page 82 -3KA2 -8KA1 -8KA2 -8KA3 -8KA4 -3KA2: Relay for transmission controller power control -8KA1: Relay for engine diagnose -8KA2: Relay for engine diagnose page up -8KA3: Relay for engine diagnose page down -8KA4: Relay for low engine coolant level warning Edition 2 Chapter 2 Page 2-9 Dec /2013...
  • Page 83 Relay terminal of superstructurecontrol -14KA1 -29KA1 -31KA1 -31KA2 -32KA1 -32KA2 -32KA3 -15KA1 -14KA1: Relay for emergency stop -29KA1:Relay for air-condition -31KA1:Relay for windshield wiper low speed -31KA2: Relay for windshield wiper high speed -32KA1: Relay for warning lamp -32KA2: Relay for working lights -32KA3: Relay for horn -15KA1: Relay for superstructure power control Edition 2...
  • Page 84 -17KA1 -24KA1 -17KA1: Relay for engine start -24KA1:Relay for dead man valve Edition 2 Chapter 2 Page 2-11 Dec /2013 Troubleshooting...

  • Page 85: 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 b) Blockage in the relief valve Clean the valve element System pressure does not c) Central revolving joint Inspect the joint and increase leaks...

  • Page 86: 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 Examine e) Retraction rope and fittings defective a) Relief valve pressure is set Adjust or replace...

  • Page 87: 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 88: 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 89: 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 90: 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 91: 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 92 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 93 Part Problem Cause Remedy Part Problem Cause Remedy Loss of a) Head pressure of torque Adjust the opening converter is low traction force pressure of the safety 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 94: 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 95: 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 96 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 97 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 Unusual noise twisted while you steer b) Unstable oil pump displacement Replace oil pump Edition 2...

  • Page 98: 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 or alignment increase or decrease. Gears do not 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 99 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 2-26 Dec /2013 Troubleshooting...

  • Page 100: Drive Shaft

    2.12 DRIVE SHAFT Table 2-12 Part Problem Cause Remedy a) Universal joint cross Replace the universal joint trunnion, needle roller worn 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 101: 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 102 Part Problem Cause Remedy motion. b) Tires damaged Replace c) Tires reach the wear limit Replace Edition 2 Chapter 2 Page 2-29 Dec /2013 Troubleshooting...

  • Page 103: Engine Error Code

    2.14 ENGINE ERROR CODE Engine abnormity would be displayed via fault code through inspection switch,increase, and decrease bottoms on bus gauge in driving room, meaning convied by code as follows: Engine fault code meaning (0001)------ Exhaust pressure sensor 1 circuit- voltage above normal value, or shorted to high source (0002)------ Exhaust pressure sensor 1 circuit- voltage below normal value, or shorted to low source...
  • Page 104 (145b)------ #1 engine Coolant Temperature Sensor Circuit – Voltage below Normal, or Shorted to Low Source (145bm)------ #1 engine Coolant Temperature Sensor Circuit – Voltage below Normal, or Shorted to Low Source (146)------ Engine Coolant Temperature selection (146b)------ Coolant Temperature High - Data Valid but above Normal Operational Range - Moderately Severe Level (146bm)------ Coolant Temperature High - Data Valid but above Normal Operational Range - Moderately Severe Level...
  • Page 105 (227b)------ Sensor Supply Voltage #2 Circuit – Voltage above Normal, or Shorted to High Source (227bm)------ Sensor Supply Voltage #2 Circuit – Voltage above Normal, or Shorted to High Source (234)------ Engine Speed/position selection (234b)------ Engine Speed High - Data Valid but Above Normal Operational Range – Most Severe Level (234bm)------ Engine Speed High - Data Valid but Above Normal Operational Range -Most Severe Level...
  • Page 106 (296)------ Auxiliary Pressure Sensor Input 1 – Special Instructions (297)------ Auxiliary Pressure Sensor Input # 2 Circuit – Voltage above Normal, or Shorted to High Source (298)------ Auxiliary Pressure Sensor Input # 2 Circuits – Voltage below Normal, or Shorted to low Source (319)------ Real Time Clock Power Interrupt - Data Erratic, Intermittent, or Incorrect (322)------ Injector Solenoid Cylinder #1 Circuit –...
  • Page 107 (442)------ Battery #1 Voltage Low - Data Valid but below Normal Operational Range – Moderately Severe Level (443)------ Accelerator Pedal or Lever Position Sensor Supply Voltage Circuit – Voltage below Normal, or Shorted to Low Source (449)------ Fuel Pressure High (449b)------ Fuel Pressure High - Data Valid but Above Normal Operational Range –...
  • Page 108 (597)------ Electrical Charging System Voltage Low – Data Valid but Below Normal Operational Range – Moderately Severe Level (598)------ Electrical Charging System Voltage Low – Data Valid but Below Normal Operational Range - Most Severe Level (599)------ Auxiliary Commanded Dual Output Shutdown –Special Instructions (649)------ Change Lubricating Oil and Filter –...
  • Page 109 (1241)------ Accelerator Pedal or Lever Position Sensor 2 Circuit -Voltage below Normal,or Shorted to Low Source (1242)------ Accelerator Pedal or Lever Position Sensor1 and 2 – Data Erratic, Intermittent,or Incorrect (1633)------ Komnet Datalink can not be delivered- data erratic, intermittent or incorrect (1639)------ #3 auxiliary equipment sensor input (OEM switch)- original cause uncertain (1654)------ Engine1 cylinder misfire- problem exists (1655)------ Engine 2 cylinder misfire- problem exists...
  • Page 110 (1698)------ Aftertreatment #1 air activator- voltage below normal value or shorted to low source (1699)------ Catalytic cylinder level sensor- data erratic, intermittent or incorrect (1711)------ Dose control sector Datalink- abnormal update rate (1712)------ Catalytic cylinder heater circuit- data valid but below normal operational scope (moderate severe level) (1713)------ Catalytic cylinder heater circuit- data valid but above normal operational scope (moderate severe level)
  • Page 111 (2311)------ Fueling Actuator #1 Circuit Error – Condition Exists (2321)------ Engine Speed / Position Sensor #1 - Data Erratic, Intermittent, or Incorrect (2322)------ Engine Speed / Position Sensor #2 - Data Erratic, Intermittent, or Incorrect (2345)------ Turbocharger speed (2345b)------ Turbocharger rotate speed- invalid change of speed is inspected (2345cl)------ invalid change of speed is inspected- abnormal speed change rate Turbocharger speed invalid rate of change detected - Abnormal Rate of Change (2346)------ Outlet temperature...
  • Page 112 (2555)------ Intake Air Heater #1 Circuit - Voltage above Normal, or Shorted to High Source (2556)------ Intake Air Heater #1 Circuit - Voltage below Normal, or Shorted to Low Source (2557)------ Auxiliary PWM Driver #1 - Voltage above Normal, or Shorted to High Source (2558)------ Auxiliary PWM Driver #1 - Voltage below Normal, or Shorted to Low Source (2771)------ Aftertreatment outlet nitroxygen compound sensor- abnormal update rate (2772)------ Aftertreatment outlet nitroxygen compound-data valid but above normal valueleast...

  • Page 113: Transmission Error Code

    2.15 TRANSMISSION ERROR CODE Lighting up of H4 red light indicates transmission fault, fault codes shows in table below Fault Causes Reaction Remedies code DANA Causes Reaction Remedies Input number ‘O’ might 00.1F Input number 0, Refer to other error reports to obtain attributes error to display pin more relevant information.
  • Page 114 should not be 55: failure exists. information: operate resumed until this available basic program or correct error problem is rectified. manually. Input number ‘5’ might 05.1F Input number 5, Refer to other error reports to obtain attribute error to display pin more relevant information.
  • Page 115 electric level. value or high program (component) electric level 10.04 Input analog quantity Input analog Check circuit connection between O might receive value quantity 0, ECONA system and sensor. below min. display pin 25-24: Inspect installation and operation measurement range voltage status of sensor.
  • Page 116 Input number ‘6’ might 06.1F Input number 6, Refer to other error reports to obtain attribute error to display pin more relevant information. ECONA program 53: failure exists. Rectify problem according to acquired which should not be information: operate resumed until this available basic program or correct problem is rectified.
  • Page 117 10.10 Input analog quantity 0 Input analog Inspect sensor and its installation. might receive value quantity 0, Calibrate sensor output value. beyond standard max. display pin 25-24: Refer to other error reports to measurement range. Data valid determine effected program Sensor broken or but beyond max.
  • Page 118 problem is rectified. error manually. 12.03 Input analog quantity 2 Input analog Check circuit connection between might receive value quantity 2, ECONA system and sensor. beyond max. display pin 29-28: Inspect installation and operation measurement range voltage status of sensor. Refer to other and input surpass normal error reports to determine effected...
  • Page 119 value 12.12 Input analog quantity 2 Input analog Inspect sensor and its installation. might receive value quantity 2, Calibrate sensor output value. below standard min. display pin 29-28: Refer to other error reports to measurement range. Data valid determine effected program Sensor broken or but below max.
  • Page 120 voltage of low electric value or low program (component) level. electric level 13.0D Function input from Input analog Calibrate sensor output function. Refer sensor to instrument is quantity 3, to other error reports to calibrated rather than display pin 14-13: determine effected program the sensor.
  • Page 121 level value or open error reports to determine effected circuit program (component) Fault Causes Reaction Remedies code DANA 1A.06 Speed sensor value Input Speed rate Check circuit connection between above normal value, 0, display pin ECONA system and sensor. high 10-09, current Inspect installation and operation electric level...
  • Page 122 level value or open error reports to determine effected circuit program (component) 1B.06 Speed sensor value Input Speed rate Check circuit connection between above normal value, 1, display pin ECONA system and sensor. high 12-11, current Inspect installation and operation electric level below normal status of sensor.
  • Page 123 value or high electric level 20.04 When the power output Power output Check circuit connection between stays 0, low electric volume 0, ECONA system and sensor. level is detected by display pin 33-34, Inspect installation and operation ECONA dynamic voltage status of sensor.
  • Page 124 examine. volume or high electric level 21.04 When the power output Power output Check circuit connection between stay 1, low electric volume 1, ECONA system and sensor. level is detected by display pin 31-32, Inspect installation and operation ECONA dynamic voltage status of sensor.
  • Page 125 Fault Causes Reaction Remedies code DANA 22.04 When the power Power output Check circuit connection between output stays 2, low volume 2, ECONA system and sensor. electric display pin 48-49, Inspect installation and operation level is detected by voltage status of sensor. ECONA dynamic below normal examine.
  • Page 126 23.04 When the power Power output Check circuit connection between output stays 3, low volume 3, ECONA system and sensor. electric display pin 18-19, Inspect installation and operation level is detected by voltage status of sensor. ECONA dynamic below normal examine.
  • Page 127 examine. volume or high electric level 24.04 When the power output Power output Check circuit connection between stays 4, low electric volume 4, ECONA system and sensor. level is detected by display pin 46-47, Inspect installation and operation ECONA dynamic voltage status of sensor.
  • Page 128 ECONA dynamic voltage status of sensor. examine. surpass normal volume or high electric level 25.04 When the power Power output Check circuit connection between output stays 5, low volume 5, ECONA system and sensor. electric display pin 17-16, Inspect installation and operation level is detected by voltage status of sensor.
  • Page 129 electric volume 6, ECONA system and sensor. level is detected by display pin 25-50, Inspect installation and operation ECONA dynamic voltage status of sensor. examine. surpass normal volume or high electric level 26.04 When the power Power output Check circuit connection between output stays 6, low volume 6, ECONA system and sensor.
  • Page 130 examine. volume or high electric level Fault Causes Reaction Remedies code DANA 27.04 When the power Power output Check circuit connection between output stays 7, low volume 7, ECONA system and sensor. electric display pin 01-02, Inspect installation and operation level is detected by voltage status of sensor.
  • Page 131 program which should error information: operate not be existed available basic program or correct resumed until this error manually. problem is rectified. 28.03 When the power Power output Check circuit connection between output stays 8, high volume 8, ECONA system and sensor. electric display pin 03-04, Inspect installation and operation...
  • Page 132 observed feedback exceeds sensor and each component. value exceeds the normal level or in Max. short circuit permissible effective value. 28.1F Input power output Power output 8, Refer to other error reports to obtain volume 8 will result in display pin information about this ECON.A application 03-04: failure...
  • Page 133 31.09 No information “Switch Digital input Check whether the clutch between manual / function: switch disengagement related input included automatic mode” is between manual / obtained from CAN automatic CAN information is transmitted to the 31.13 No information can be Digital input Check whether the CAN system obtained from CAN...
  • Page 134 DANA 33.1F Digital input function: Digital input Refer to other error reports to obtain neutral position is function: Neutral information about this locked, resulting in position is locked: program. ECON.A application error exists. Rectify the problem according to program failure. obtained information: make the 34.09 No idle-speed Digital input...
  • Page 135 39.13 No information can be Digital input Check whether the CAN system obtained from CAN function: parking related source information about system or the parking brake: error parking brake is valid. 39.1F Digital input function: Digital input Refer to other error reports to obtain parking brake, resulting function: parking information about this...
  • Page 136 3D.1F Digital input function: Digital input Refer to other error reports to obtain transmission in the function: information about this Neutral position transmission in program. overtime, resulting in the Neutral Rectify the problem according to ECON.A application position overtime: obtained information: make the 40.09 No abnormal running Digital input Check whether abnormal running...
  • Page 137 42.13 No information can be Digital input Check whether the CAN system obtained from CAN function: related source information about system or acceleration acceleration acceleration prevention is valid. prevention information prevention: error 42.1F Digital input function: Digital input Refer to other error reports to obtain acceleration prevention, function: information about this...
  • Page 138 ECON.A program can obtained information: make the not resume working feasible fundamental programs in until this problem is operation or rectify the program rectified. manually. 60.02 Analog quantity input: air Analog quantity Refer to other error information to find door pedal. input: air door out failures in the electrical Electrical errors occur...
  • Page 139 60.1F Analog quantity input: air Analog quantity Refer to other error reports to obtain door pedal, resulting input: air door information about this in ECON.A application pedal: error program. program failure. exists. Rectify the problem according to ECON.A program can obtained information: make the not resume working feasible fundamental programs in...
  • Page 140 information obtained data. from CAN system invalid. 61.1F Analog quantity input: Analog quantity Refer to other error reports to obtain brake pedal, resulting input: brake information about this in ECON.A application pedal: error program. program failure. exists. Rectify the problem according to ECON.A program can obtained information: make the not resume working...
  • Page 141 Fault Causes Reaction Remedies code 62.10 Transmission cooler Analog quantity Stop the vehicle to cool down the temperature exceeds the input: transmission oil tank. Max. Permissible value. transmission If the problem still exits, check temperature: transmission cooler. It is possibly caused by excessively frequent information is effective but...
  • Page 142 63.02 Analog quantity input: Analog quantity Refer to other error information to find transmission cooler input: out failures in the electrical temperature. Electrical transmission line. errors occur during cooler Check voltage input on the line inputting signal into temperature: between ECON.A and transmission ECON.A.
  • Page 143 until this problem is manually. rectified. 7A.02 Speed sensor input Speed sensor Refer to other error information to find function: engine RPM. input function: out failures in the electrical Electrical errors occur engine RPM: line. during inputting signal irregular and Check voltage input on the line into ECON.A.
  • Page 144 application program error exists. Rectify the problem according to obtained information: make the failure. feasible fundamental programs in ECON.A program can operation or rectify the program not resume working manually. until this problem is rectified. 7C.0 Speed sensor input Speed sensor Refer to other error information to find function: speed ratio.
  • Page 145 during inputting signal irregular and line. into ECON.A. As a intermittent Check voltage input on the line result, ECON.A can not signals. Error between ECON.A and output speed determine effective value exits. sensor. of the brake pedal. Check installation and operation of sensor and each component.
  • Page 146 Fault Causes Reaction Remedies code 90.10 Permanent power supply Controller Check power supply for functional for controller permanent power work. supply – pin 45: exceeds the Max. permissible value. information is effective but exceeds the Max. permissible value. 90.12 Permanent power supply Controller Check power supply for functional for controller is...
  • Page 147 permissible value. ECON.A can not work information is normally that the effective but is closed item is activated. below the Min. Permissible value. Fault Causes Reaction Remedies code 91.10 Power supply for Controller Check power supply for functional controller switch is permanent power work.
  • Page 148 the Max. permissible controller - pin quantity input function. value. 15: information Check all the components between is effective but ECON.A and power supply exceeds the electrical lines. Max. permissible value. Check installation and operation of all the components connected to the power supply electrical lines.
  • Page 149 92.12 Power supply for External 5V Check all the components between controller switch is below power supply for ECON.A and external power controller - pin supply. Min. permissible value. 15: information Check installation and operation of all is effective but is the components connected below the to the external power supply.
  • Page 150 permissible damaged: replace ECON.A. value. 93.12 Controller inner sensor is Controller inner Check whether the problem is below the Min. sensor: permanent or temporary. permissible value. information is If the problem can not be rectified, effective but is ECON.A is permanently below the Min.
  • Page 151 9A.0 Data damaged during Seriously If the problem can not be rectified, initialization. confused ECON.A is permanently controller ECON.A is switched off. damaged: replace ECON.A. data: intelligent elements or equipment damaged. 9A.1 Part or all of data Seriously If the failure is caused by the damaged during confused component which supplies...
  • Page 152 Fault Causes Reaction Remedies code A0.1 Components are not Configuration Use correct and compatible tools for compatible. error: DANA to download effective ECON.A can not be unmatched and compatible data documents. started until the problem components: If the problem can not be rectified, is rectified.
  • Page 153 not be started until the operation or rectify the program problem is rectified. manually. Fault Causes Reaction Remedies code A4.1 ECON.A configuration Configuration Refer to other error information to failure occurs during error: determine category of the initialization caused by impossible I/O erroneous configuration.
  • Page 154 and received; failure abnormal Check CAN information repetition rate. after timeout. correction rate. C6.0 System-CAN information CAN information: Check whether CAN information has can’t be transmitted EEC2: be input into CAN bus. and received; failure abnormal Check CAN information repetition rate. after timeout.

  • Page 156: Chapter 3 Inspection

    MAINTENANCE AND SERVICE MANUAL FOR ROUGH TERRAIN CRANE Chapter 3 Inspection...

  • Page 158: Pre-Start 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 159 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 160 ¨ Examine the level of axle oil (after initial change) ¨ ¨ Examine the Engine Manufacturer’s Manual Examine the battery condition for additional maintenance requirements ¨ ¨ Inspect the tire pressure and condition Examine the hydraulic cylinders and piston rods ¨...
  • Page 161 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 ¨ ¨ Examine the Engine Manufacturer’s Manualfor Replace the oil in winches more maintenance requirements ¨...

  • Page 162: 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 163 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 164: Power System

    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 165: Drive System

    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 bearings for vibration Examine the...
  • Page 166 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 167: Suspension System

    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 • •...
  • Page 168 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 169 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 170: Periodic Crane Inspections

    3.4 PERIODIC CRANE INSPECTIONS 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 171 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 172 Parts Inspected items Parts Inspected items pressure is have lubricant on 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.
  • Page 173 Parts Inspected items Parts Inspected items • of press nipple for Lubrication state • wear and cracks. 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.
  • Page 174 Parts Inspected items Parts Inspected items Drum Pipeline • • Examine it for Examinethe pipe cracks. fittings for tight fit. • • Make sure that Examine it for the wire-rope on leaks. • the drum winds Examine the pipe uniformly. clamp for tight fit and cracks.
  • Page 175 Parts Inspected items Parts Inspected items • Examine the pipe Examine the interior fittings for tight fit. illumination for functional • Examine it for work. unusual noise and vibration. • Examine the outrigger floats for deformation and damage. Outrigger box, outrigger beam and cylinders •...
  • Page 176 Parts Inspected items Parts Inspected items • • Examine the state Examine it for of the bubble. proper seating. • Examine the contact switch for functional work. wrap indicator Examine the chassis frame for deformation, bends and • Examineit for cracks.

  • Page 177: 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.

  • Page 178: Filter Elements Lists

    3.6 FILTER ELEMENTS LISTS RT35 RT55 RT60 Ser. Descripti Descripti Code QTY. Code Description QTY. Code QTY. 10106003 Hydraulic 10106 Hydraulic oil 10106 Hydraulic oil filter 00308 filter 00308 oil filter Return-line Return-line 10106004 10106 Return-line 10106 filter filter 00444...
  • Page 179 RT75 RT100 Ser. Code Description QTY. Code Description QTY. High- 10106003 pressure 10106 Hydraulic oil hydraulic oil 00308 filter filter element 10106004 Return-line 10106 Return-line filter element 00444 filter element Transmission Transmission 10106003 10106 oil filter oil filter 00302 element element High- High-...

  • Page 180: Fluid Volume Requirements

    3.7 FLUID VOLUME REQUIREMENTS Engine oil type and volume Ser. No. Crane series Oil type Volume (L) Remarks RT35 SAE 15W-40/CH-4 RT55 SAE 10W-40 RT60 SAE 10W-40 RT75 SAE 10W-40 RT100 SAE 15W-40/CH-4 Engine coolant type and volume Ser. No.
  • Page 181 Ser. No. Crane series Oil type Volume (L) Remarks RT35 8# Great Wall hydraulic oil RT55 8# Great Wall hydraulic oil RT60 8# Great Wall hydraulic oil RT75 8# Great Wall hydraulic oil RT100 8# Great Wall hydraulic oil Drive axle gear oil type and volume Crane Ser.
  • Page 182 Winch reducer gear oil type and volume Ser. No. Crane series Oil type Volume (L) Remarks RT35 L-CKD220 RT55 L-CKD220 RT60 L-CKD220 RT75 L-CKD220 RT100 L-CKD220 Swing reducer gear oil type and volume Ser. No. Crane series Oil type Volume (L)

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