QY50KD Truck Crane Maintenance and Service

QY50KD
Truck Crane
Maintenance and Service
Manual
文件清单
List of Manuals
1. Safety Manual for Truck and All Terrain Cranes
QY50KD
2. 1.QY50KD
起重机安全手册
起重机
Truck Crane Physical Information and Rated Load Charts Manual
Truck
安全手册 Crane
3. 2.QY50KD
XCT25L5_1汽车起重机产品信息与性能手册
Truck Crane Operation Manual
Maintenance
4. 3.QY50KD Truck Crane Accessories Manual
XCT25L5_1汽车起重机操作手册
and Service
5. QY50KD Truck Crane Transporting Manual
Manual
4. XCT25L5_1汽车起重机安装手册
6. QY50KD Truck Crane Maintenance and Service Manual
5. XCT25L5_1汽车起重机运输手册
7. QY50KD Truck Crane Troubles and Solution Manual
6. XCT25L5_1汽车起重机维护与保养手册
7. XCT25L5_1汽车起重机故障手册
QY50KD Truck Crane Maintenance and Service Manual
QY50KD Truck Crane
Maintenance and Service Manual
First edition, July 2020
VIN
Engine number
Date
This manual is part of the crane and must be kept with the unit and accessible by the operator.
Please read and understand this manual before operating the crane.
This equipment is designed and manufactured in accordance with
Q/320301JAF420
GB/T 6067.1-2010 Safety rules for lifting appliances-Part 1: General
GB 7258-2017 Safety specifications for power-driven vehicles operating on roads,
GB/T 6068-2008 Test code for truck crane and mobile crane,
JB/T 9738-2015 Truck cranes.
All rights reserved

No part of this publication may be reproduced or used in any form by any means-graphic,
electronic or mechanical, including photocopying, recording, taping or information storage and
retrieval systems -without the written permission of XCMG.
Preface
Thank you for trusting and using this XCMG-branded Truck Crane made by Xuzhou Heavy Machinery
Co., Ltd.
This manual applies to QY50KD Truck Cranes.
This manual describes the methods of service and maintenance for QY50KD Truck Cranes (hereinafter
called crane) so as to facilitate users to understand each main part's performance and working principles.
The goal is to help the owner better service and perform maintenance on the crane to maintain the cranes
operation at its maximum efficiency and safety, and to prolong its normal service life.
The manual along with other supplied technical documents are part of the crane. These manuals must be
kept with the crane and available any time the crane is being used or serviced. Please contact the XCMG
service department or your dealer to arrange for service and repair of the crane. XCMG does not take any
liability in the case of accident or mis-operation caused by the nonobservance of this manual.
Refer to the Warranty for crane (chassis included) warranty period. When maintenance is needed, please
contact XCMG or go to the authorized service station for maintenance.
All information, illustrations and specifications in this manual are based on the latest information
available at the time of publishing. The illustrations used in this manual are intended as representative
reference views only. Products are under a continuous improvement policy. Thus, information,
illustrations and/or specifications to explain and/or exemplify a product, service or maintenance
improvement may be changed at any time without notice.
III Preface
Table of Contents
Preface ............................................................................................................................III
1 Maintenance and service instructions .................................................................... 1-1
1.1 Maintenance and service instructions ................................................................ 1-1
1.2 Systems that need to be maintained and serviced............................................... 1-2
1.3 Maintenance and service items........................................................................... 1-3
2 Oil and lubrication .................................................................................................... 2-1
2.1 Cleaning of the crane .......................................................................................... 2-1
2.2 Lubrication ......................................................................................................... 2-2
2.2.1 Lubrication working conditions................................................................... 2-2
2.2.2 Lubrication guidelines ................................................................................. 2-3
2.3 Instruction for using oil ..................................................................................... 2-7
2.3.1 Oil brands, filling amount and interval........................................................ 2-7
2.3.2 Replacement interval ................................................................................. 2-11
2.3.3 Fuel ............................................................................................................ 2-12
2.3.4 Engine oil................................................................................................... 2-14
2.3.5 Antifreeze coolant...................................................................................... 2-15
2.3.6 AdBlue solution ......................................................................................... 2-17
2.3.7 Gear oil ...................................................................................................... 2-17
2.3.8 Hydraulic oil .............................................................................................. 2-18
2.4 Disposal of used oil and grease ........................................................................ 2-22
3 Maintenance and service of chassis ......................................................................... 3-1
3.1 Power system ..................................................................................................... 3-1
3.1.1 Power system ............................................................................................... 3-1
3.1.2 Engine .......................................................................................................... 3-1
3.1.3 Oil filter ....................................................................................................... 3-2
3.1.4 Fuel pipeline and fuel filter.......................................................................... 3-4
3.1.5 Air filter ....................................................................................................... 3-9
3.1.6 Radiator ..................................................................................................... 3-14
3.1.7 After-treatment device/SCR system (for China V) ................................... 3-15
3.1.8 SCR system (for China VI) ....................................................................... 3-16
3.1.9 Trouble indicator lamp............................................................................... 3-18
3.1.10 Inspection of air intake and exhaust pipelines......................................... 3-18
3.2 Drive system .................................................................................................... 3-19
I Table of Contents
3.2.1 Transmission system.................................................................................. 3-19

3.2.2 Clutch ....................................................................................................... 3-20
3.2.3 Transmission.............................................................................................. 3-24
3.2.4 Propeller shaft........................................................................................... 3-28
3.3 Travel system ................................................................................................... 3-30
3.3.1 Axle ........................................................................................................... 3-30
3.3.2 Suspension ................................................................................................. 3-35
3.3.3 Wheel......................................................................................................... 3-36
3.4 Braking system ................................................................................................ 3-40
3.4.1 Braking system .......................................................................................... 3-40
3.4.2 Air dryer .................................................................................................... 3-41
3.4.3 Air reservoir............................................................................................... 3-43
3.5 Steering system ................................................................................................ 3-43
3.5.1 Steering system.......................................................................................... 3-43
3.5.2 Steering oil tank......................................................................................... 3-44
3.5.3 Steering gear .............................................................................................. 3-45
3.6 Hydraulic system ............................................................................................. 3-46
3.6.1 Hydraulic system ....................................................................................... 3-46
3.6.2 Hydraulic oil tank ...................................................................................... 3-46
3.6.3 Oil filter ..................................................................................................... 3-48
3.6.4 Hydraulic pump ......................................................................................... 3-56
3.7 Battery .............................................................................................................. 3-57
3.8 Driver’s cab .................................................................................................... 3-59
3.8.1 Air conditioner........................................................................................... 3-59
3.8.2 Other attachments ...................................................................................... 3-60
3.9 Electrical system .............................................................................................. 3-61
3.9.1 Electrical system in the driver's cab .......................................................... 3-61
3.9.2 Lighting system ......................................................................................... 3-61
3.9.3 Girder wiring harness assembly................................................................. 3-61
3.9.4 Battery ....................................................................................................... 3-62
4 Maintenance and service of systems for lifting operations ................................... 4-1
4.1 Maintenance and service of systems for lifting operations ................................ 4-1
4.2 Outrigger system ................................................................................................ 4-1
4.2.1 Outrigger system.......................................................................................... 4-1
4.3 Slewing system .................................................................................................. 4-3
4.3.1 Slewing system ............................................................................................ 4-3
4.4 Boom telescoping system .................................................................................. 4-9
II Table of Contents
4.4.1 Boom telescoping system ............................................................................ 4-9

4.5 Winch system ................................................................................................... 4-12
4.5.1 Winch system............................................................................................. 4-12
4.6 Superstructure hydraulic system ...................................................................... 4-29
4.6.1 Hydraulic system ....................................................................................... 4-29
4.7 Electrical system .............................................................................................. 4-32
4.7.1 Electrical system........................................................................................ 4-32
4.8 Operator’s cab assembly ............................................................................... 4-33
4.8.1 Operator’s cab assembly ......................................................................... 4-33
5 Appendix .................................................................................................................... 5-1
5.1 Maintenance and check record form................................................................... 5-1
5.2 Tightening torque table....................................................................................... 5-2
5.3 Main parts list ..................................................................................................... 5-3
III Table of Contents

Chapter 1 Maintenance and service instructions
1.1 Maintenance and service instructions

This manual is provided only for crane users. No copying is allowed for commercial reproduction.
Key parts such as structural members, hydraulic, electrical and power systems should be periodically in-
spected and maintained by professional technicians or engineers according to crane’s operation status,
service condition and operating environment. Detailed inspection record should be kept and filed. The
problems found during inspection should be corrected as soon as possible so as to ensure normal operation
of the crane. Proper inspection and maintenance are helpful to ensure operation safety and can prolong the
service life of the crane. Inspect and maintain the crane according to recommended schedule to keep the
crane operating at peek efficiency and avoid breakdowns.
Inspection interval is established on the basis that the crane is operated under the normal working
conditions. If the crane is used in severe environment (such as dusty areas, high temperature or ex-
tremely cold areas) or non-normal condition, the interval should be accordingly shortened.
• Pay attention to daily service and periodical inspection, which is helpful to find faults in early
stage and prevent accident from occurring.
• Perform daily service and periodical inspection. Remove crane from service if needed until re-
pairs can be made, and make other repairs in a timely manor.
Read the manual carefully before maintenance and service. Perform maintenance and service according to
the manual. Contact the XCMG service department for help diagnosing issues or if needing guidance on
repairs.
Maintenance and service instructions 1-1

• Prior to operation or maintenance of the machine, be familiar with all safety warnings in the
manual and safety signs on the machine, and follow related safety requirements. Otherwise, the
machine may be damaged and personal injury or death could result.
• Safety rules listed in this manual, which are based on the cognitive situation when writing the
manual, only as a guide for the reader. Our company could not predict all dangers that may oc-
cur, and users shall be responsible for the safe operation of the crane.
• If there is any stricter regulation, issued by local government or authority agency, follow the local
regulation.
• If any actions are taken that are not recommended or allowed according to this manual, conduct
a risk assessment and take necessary measures to ensure the safety of the crane. Failing to do this
will result in the maintenance personnel bearing the responsibility for all resulting damage.
If the manual is lost or damaged, contact the XCMG service department for a replacement copy.
The crane has been tested and calibrated at the factory. Changing the settings away from factory specifica-
tions will void the warranty and could effect the continued safe operation of the crane.
Please don’t carry out any modification or setting without manufacturer’s written authoriza-
tion. For example:
• Installation of safety device

• Adjusting any hydraulic settings away from factory specified settings.
Requirements for maintenance record
The lifting machinery shall be inspected and maintained during its service life. See Chapter 1 for detailed
inspection and maintenance items. Dated record should be placed on file. Refer to Appendix for record
form.
1. The records of regular inspection, special inspection and non-planned maintenance should be kept dur-
ing the service life of the crane.
2. The records of planned maintenance should be kept until next maintenance period.
1.2 Systems that need to be maintained and serviced

See the figure followed for the systems that should be maintained and serviced.
1-2 Maintenance and service instructions

• Proper daily maintenance and regular inspection are helpful to ensure operation safety and to
maintain good equipment status, as well as to find faults in early stage and prevent accident
from occurring.
• Remove crane from service if needed until repairs can be made, and make other repairs in a
timely manor.
Figure 1-1 Systems that need to be maintained and serviced
No. Name No. Name

1 Hook and slings 2 Boom
Driver's cab and air
3 4 Safety devices
conditioning device
5 Operator’s cab 6 Luffing cylinder
7 Turntable 8 Slewing system
9 Counterweight 10 Winch system
11 Rear outrigger beam 12 Front outrigger beam
13 Transmission system 14 Traveling system
15 Steering system 16 Braking system
1.3 Maintenance and service items

The crane has been tested and commissioned at the factory, but some deviation will occur during operation
due to wear, corrosion and environmental change, as well as damage due to external forces and service
condition changes. So after delivery the crane should be checked every year by experienced professional
technician. Refer to Chinese standards GB/T 3811 and GB/T 6067 for details. Products, which are in-
tended to be sold to other countries or regions, shall comply with local standards.

An experienced professional technician is someone who is trained professionally and engages in work
about cranes for a long time, has abundant experience and know-how in the maintenance of lifting equip-
ment, is familiar with related standards and regulations and able to identify different crane service
conditions.
A professional engineer is someone who engages in crane design, has abundant experience in manufactur-
ing and maintaining cranes, is familiar with related standards and regulations and able to identify if a crane
is in the safe condition through inspections.
After delivery, the crane should be checked at least one time every four years by experienced professional
engineers. After being used for 12 years, the crane should be checked every year by experienced professio-
nal engineers.
After overhaul of crane or maintenance of dynamic load-bearing members and before reuse, the
crane must be approved by professional technical personnel from our company, otherwise serious
personal casualty and property loss will be caused.
XCMG will not be responsible for the crane after any non-XCMG approved modifications are
made to it.
Re-inspection of the crane is a visual check of the crane and its parts and is conducted by a professional
engineer/ technician. Potential safety hazards may be found during inspections and repairs made in order
to keep the crane operating safely. Any potential safety hazard found by professional technician/expert
should be put on record, and the crane should be removed from service until repairs are made and a re-in-
spection is performed.
The important items that should be rechecked are listed as follows. Other items are determined by profes-
sional technicians/experts according to the conditions of the crane, which will not be listed in this chapter.
• Outrigger structure;
• Crane mechanisms: boom swinging, luffing and telescoping and rope winding;
• Brake systems;
• Electrical system;
• Safety devices.
If there is any question as to the cranes fitness for service, please consult XCMG customer service
department.
If don't abide by the following check principle or don't follow the inspection interval, serious
accidents will be caused.
Daily maintenance and service

No. Inspection items Example Remark

Visually check the crane
to ensure that there are
no oil, water and rubbish
1
remained on the crane,
and no tools left on the
crane.
Visually check safety

devices to make sure
2
that they are secured and
in good condition.
Check fire extinguisher

and first aid kit to make
3
sure that they are in
good condition.
Visually check
indicating signs, plates 起重下
人
徐州工程机械集团有限公司制造
and warning decals to

MADE IN XUZHOU CONSTRUCTION MACHINERY GROUPCO.,LTD.
4
产品识别代码
PIN
品牌徐工牌型号越野轮胎起重机
BRAND XCMG MODEL ROUGH TERRAIN CRANE
发动机型号额定功率千瓦/(转/ 分)

ENGINE MODEL ENGINE RATED POWER kW/(r/min)
最大额定总起重量×工作幅度千克米
MAX.RATED LIFTING CAPACITY×WORKING RADIUS kg m
最大设计总质量千克整车整备质量千克
MAX.DESIGNED TOTAL MASS kg TOTAL VEHICLE MASS kg
制造日期年月
DATE OF MANUFACTURE YEAR MONTH
徐州工程机械集团有限
公司徐州重型机械有限
公司
make sure that they are

XUZHOU CONSTRUCTION MACHINERY GROUPCO.,LTD. XUZHOU HEAVY MACHINERY CO.,LTD.
地址中国江苏省徐州市铜山路165
号电话（Tel) +86-516-8346224
2 8346235
0
legible and not missing.

Visually check all
control levers to make
sure they are flexible
5
without blockage and
return to neutral when
released.
Visually check power
supply and switch,
lighting devices,
6
indicator lamps, gauges
and wipers to make sure
that they are functional.


It is
necessary
Visually check every
to check
system to make sure that
the anti-
there is no water (or air
freezing
or oil) leakage, as well
7 condition
as no looseness, no
of
distortion, no broken
pneumat
and aging sign in
ic circuit
pipelines.
system in
winter.
Visually check the levels
ADD
of engine coolant, b
FULL
8 AdBlue solution, fuel
and lubricant to ensure
they are sufficient.
Clean the dust cup of the

air filter; drain the water
9
in air reservoirs and fuel
filter.
Check the pneumatic

seat, horn, etc. as well as
10 control valve and safety
valve to make sure that
they are functional.
Check braking system to

11 make sure it is
operational.


Visually check the
lifting rope and rope
socket, etc. to ensure
they are in good
12
condition and secured,
and the rope around
sheave and drum is
properly wound.
If any
sign is
Check structural
found,
members to see if there
13 contact
are distortion, cracks
professio
and paint peeling off.
nals to
inspect.
If anyone
Check pins and spring
is
clips. Use only XCMG
missing,
supplied replacement
14 replace it
parts to insure continued
with the
peek operating
same type
performance.
of part.
Check angle sensor and

15
links for looseness.
With the crane set up on

a level ground,
suspensions at middle
position and steering
16 wheel at middle
position, check to see if
every steering wheel is
in straight line travel
condition.

Observe the display

screen in the driver's cab
17 to see if there is steering
trouble or warning
message appearing.
Check tires to make sure

that tire pressure
conforms to the
18
specifications and no
foreign body in tire
groove.
Regular maintenance and service
First check and maintenance of systems for lifting operations should be done two months after the deliv-
ery. First check and maintenance of systems for travel should be done after 1500 km of traveling or after
100 hours of engine working.
Inspection results should be recorded in inspection record, which will facilitate maintenance.
• Please supply VIN, serial No., engine serial No. and delivery date when professional maintenance
is required. Refer to the preface for details.
• Shorten the interval if the crane is used in severe operating conditions and working environment,
which mean that the crane is under heavy load and/or working in dusty environments.
• Never maintain, repair and manually lubricate the crane while it is working.
• Prior to maintenance and repair, turn off main power source and position all control levers to
neutral positions. A warning board should be present where it can be easily seen.
• Use the replacement parts that have the same performance and materials as the original parts.

Table 1-1 General inspection
Inspection interval
Inspection method and
No. Inspection items Solution First Month- Quar- Remark
requirement Daily Weekly Yearly
check ly terly
Check the supplied Take
Supplied drawings, manuals, meas
1 ○
files product certificate to ures to
ensure they are complete improve
Check the inspection Take

Inspection records to ensure they are meas
2 ○
record complete, and all troubles ures to
are removed improve
Check the maintenance Take

Mainte
records to ensure they are meas
3 nance ○
complete, and all troubles ures to
record
are removed. improve
Check the other files Take
involved in equipment meas
4 Other files ○
installation, modification, ures to
maintenance and register improve
Deal
Check the working
Working with the
environment to insure
5 environ matter ○
Maintenance and service instructions

there are no conditions that
ment accord
would impair the safe
1-9
ing to
Table 1-1 General inspection(continued)
1-10
Inspection interval
check ly terly
operation or that could the
cause damage to the crane. enter
prise
manage
ment
system
and

opera
tion
proce
dures
Visually check the crane to
ensure that there are no
6 rubbish remained on the Clean ○
crane, and no tools left on
the crane.
Appear-
Visually check the crane to
ance
ensure that there are no oil
7 Clean ○
and water remained on the
crane.
Visually check the crane to Take
8 ○ ○ ○
ensure that there are no measure
Inspection interval
check ly terly
serious corrosion, damage for
and paint peeling off. corro
sion
preven
tion/
repair
Boom,
turntable,
frame,
outrigger, Take
Visually check the load-
counter measure
bearing structural
weight for
members to ensure that
and its corro
Metal there are no corrosion,
9 connect sion ○ ○ ○ ○ ○
structure cracks and plastic
ing preven
deformation, and the
device, tion/
requirement in clause 3.9
lattice jib, repair/
in GB 6067.1-2010 is met.
mecha replace
nism

supports,
etc.
1-11
1-12
Inspection interval
check ly terly
Visually check the
exposed welding seams of
10 load-bearing structural Repair ○ ○ ○ ○ ○
members to ensure that
there are no cracks.
Welding If there are dangerous
seams signs found by structural

inspections, it is necessary
Repair/
11 to remove the paint or use ○ ○ ○ ○ ○
replace
nondestructive testing
technology to determine
where the defect exists
Connect
Visually check the
ing parts
connecting shafts, plates
for
and bolts of
counter
counterweight,
Connect weight, Adjust/
12 transmission, transfer gear, ○ ○ ○ ○
ing parts travel replace
main load-bearing
system,
structural members and

main load-
safety devices for
bearing
tightness, and the
structural
Inspection interval
check ly terly
members requirement of tightening
and safety torque is met.
devices
Connect
ing parts Visually check the
for lifting, connecting bolts of winch
slewing reducer, drum, slewing
and reducer, elevating cylinder, Adjust/
13 ○ ○ ○ ○
luffing brake and coupling for replace
mecha tightness, no missing, and
nisms, and the requirement of

braking tightening torque is met
device.
Connect
Visually check the
ing parts
connecting bolts of engine,
for power,
pumps, motors, valves,
hydraulic, Adjust/
14 center rotary joint, electric ○ ○ ○ ○
pneumatic replace
motor and electric control
and
box for tightness, and no

electric
missing
systems
1-13
Table 1-2 Mechanism
1-14
Inspection interval Remark
Inspection Inspection method and
No. Solution First Quar-
items requirement Daily Weekly Monthly Yearly
check terly
Check the winch system by no load
Winch test to make sure that it runs
1 Maintain ○ ○ ○ ○ ○ ○
system smoothly, and there are no abnormal
noise or vibration.
Check the elevating system by no
Elevating load test to make sure that it runs
2 Maintain ○ ○ ○ ○ ○ ○
system smoothly, and there are no abnormal

noise and vibration.
Check the slewing system by no load
Slewing
3 test to make sure that there are no Maintain ○ ○ ○ ○ ○ ○
system
abnormal noise and vibration.
Check the boom telescoping system
Boom
by no load test to make sure that
4 telescoping Maintain ○ ○ ○ ○ ○ ○
there are no abnormal noise and
system
vibration.
Check the outrigger extending
Outrigger
system by no load test to make sure
5 extending Maintain ○ ○ ○ ○ ○
that there are no abnormal noise and
system
vibration.
Table 1-3 Safety devices
Inspection interval
No. Inspection items Solution First Quar- Remark
requirement Daily Weekly Monthly Yearly
check terly
Check the anti-two block by
function test to make sure Adjust/
1 Anti-two block ○
that it is secured and replace
operational.
Check the rated capacity
Rated capacity limiter by function test to Adjust/
2 ○
limiter make sure that it is secured replace
and operational.
Check the load moment
Load moment limiter by function test to Adjust/
3 ○ ○ ○
limiter make sure that it is secured replace
and operational.
Check the rope-end limiter
by function test to make
4 Lowering limiter Adjust ○ ○
sure that it is secured and
operational.
Visually check the indicator
Working radius to make sure that there are Repair/
5 ○ ○ ○ ○ ○

indicator no deformation and damage replace
and it is operational.
1-15
Table 1-3 Safety devices(continued)
1-16
Inspection interval
check terly
Visually check the level
gauge to make sure that Repair/
6 Level gauge ○ ○ ○ ○ ○
there is no damage and it is replace
operational.
Check the backstop to make
sure that there is no Repair/
7 Backstop ○
deformation, damage or replace

looseness.
Check the electric controlled
Electric con-
interlock protector by func- Repair/
8 trolled interlock ○ ○
tion test to make sure it is replace
protector
functional.
Check the grounding device
Grounding by function test to make Repair/
9 ○ ○ ○
protector sure that it is in good replace
condition and functional.
Visually check the electric
protectors, which may
10 Electric fuses prevent short circuit, loss of Replace ○

voltage, zero position and
over-current from occurring
Inspection interval
check terly
to make sure that they are in
good condition.
Check each control unit of
Management
the management system to Adjust/
11 system of safety ○ ○ ○ ○ ○
make sure they properly repair
monitoring
works.
After the emergency stop
switch is actuated, the
engine should stop. The
Emergency stop switch shall not Repair/
12 ○ ○ ○ ○ ○
switch automatically reset. After replace
manually resetting, the
engine can be restarted and
run properly.
Limiting device Check the limiting device
of boom by function test to make Adjust/
13 ○ ○ ○ ○
telescoping sure that it is secured and replace
system operational.
Check the mechanical

Outrigger jack Repair/
14 locking devices to make ○ ○ ○
locking device replace
sure that there is no
1-17
1-18
Inspection interval
check terly
deformation,damage,loose
ness; check hydraulic valves
to make sure that they are
effective.
Visually check the locking
Slewing locking device to make sure that Tighten/
15 ○
device there are no deformation, replace

damage and looseness.
Check the limiting device
Slewing position by function test to make Adjust/
16 ○ ○ ○ ○
limiting device sure that it is secured and replace
operational.
Check the mechanical
locking devices to make
Counterweight Repair/
17 deformation, damage, ○
locking device replace
looseness; check hydraulic
valves to make sure that
they are effective.

Inspection interval
check terly
Warning device Check the warning device
Adjust/
18 (Audio and by function test to make ○ ○ ○
replace
visual alarm) sure that it is functional.
Visually check the
indication and warning
Indication and Clean/
19 labels to make sure that they ○ ○ ○ ○ ○
warning labels replace
are clearly identifiable, and
there are none missing.
Visually check the ladder,
Ladder,
guardrail, platform and
guardrail, Tighten/
20 walkway to make sure that ○
platform and repair
they are in good condition
walkways
and are secured.
Visually check the covers to
Protective cover, make sure that they are Tighten/
21 ○
rainproof cover secured and there is no repair
damage.

1-19
1-20
Inspection interval
check terly
Check the monitoring
Monitoring
device by function test to Repair/
22 device for blind ○ ○
make sure that there is no replace
working area
damage and it is operational.
Visually check the fire
equipment to make sure that Adjust/
23 Fire equipment ○
it is properly located and not replace

expired.
Table 1-4 Key parts
Inspection interval
check terly
Check the hook block to
make sure that there are no
Repair/
1 wear and deformation that ○ ○ ○ ○
replace
will impair safety, and no
abnormal sound.
Visually check the pin shaft
Tighten/
of the hook block to make
2 repair/ ○ ○ ○ ○
sure that it is tightened and
replace
secured
Visually check the safety Adjust/
3 Slings latch of the hook to make repair/ ○ ○ ○ ○

sure that it is functional replace
Check the surface cracks,
deformation, wear and
corrosion of the hook block
Repair/
4 to make sure that the ○ ○ ○
replace
requirements in clause 3.2
in GB/T 10051.3-2010 are
met.

Check the trunnion of the Repair/
5 ○ ○ ○ ○ ○
hook block to make sure replace
1-21
Table 1-4 Key parts(continued)
1-22
Inspection interval
check terly
that there are no cracks and
plastic deformation on it
Check the swivel to make Adjust/

6 ○ ○ ○ ○ ○ ○
sure it is functional replace
Visually check the hydraulic
Tighten/
refill
7 there is no leakage and the ○ ○ ○ ○ ○ ○

hydraul
hydraulic oil in the
ic oil
hydraulic tank is sufficient.
Visually check the other
Repair/
8 parts of the hook to make ○ ○ ○ ○ ○ ○
replace
sure that there is no damage.
Check the wire rope for
broken wire,wear and
corrosion to make sure that
9 Replace ○ ○ ○ ○
the requirements in the
Wire rope clause 3.5 in GB/T 5972-
2009 are met.
Visually check the wire rope

Tighten/
10 sections around the drum ○ ○ ○ ○ ○ ○
adjust
and sheave to make sure
Inspection interval
check terly
that there is no rope out of
groove.
Visually check the end
attachment of wire rope to
Tighten/
11 make sure the requirements ○ ○ ○ ○
adjust
in the clause 4.2.1.5 in GB
6067.1-2010 are met.
12 Lubrication of wire rope Maintain ○ ○ ○
Visually check the drum to
make sure that the
requirements in the clause

13 Drum 4.2.4 in GB 6067.1-2010 are Replace ○ ○ ○
met and there is no
deformation on drum
flanges.
Visually check the sheave to
make sure that the
Repair/
14 Sheaves requirements in the clause ○ ○ ○
replace
4.2.5 in GB 6067.1-2010 are

met.
1-23
1-24
Inspection interval
check terly
Visually check the sheave to Lubri
15 make sure that it moves cate/ ○ ○ ○
smoothly. adjust
Visually check rope guard to
Repair/
16 make sure that it is ○ ○ ○
replace
functional.
Check the flexibility of each
Adjust

17 ○ ○ ○ ○ ○
slewing and swing point
Check the brake by no load
test to make sure that it is
18 Maintain ○ ○ ○ ○ ○
sensitive and reliable, and
works properly.
Brake During slewing, check the
19 reliable separation of the Adjust ○ ○ ○ ○ ○
brake
Visually check the brakes to
make sure the requirements
20 Replace ○ ○ ○ ○
in the clause 4.2.6 of GB
6067.1-2010 are met.

Test the clutch with no
21 Clutch Adjust ○ ○ ○ ○
load,to make sure it can be
Inspection interval
check terly
smoothly and reliably
disengaged.
Test the clutch while lifting
a rated load,to make sure it Adjust/
22 ○ ○ ○ ○
is reliable and there is no replace
slipping.
Visually check the coupling
to make sure that there is no
defect, looseness and oil Tighten/
23 Coupler ○ ○ ○ ○ ○
leakage, and there are no adjust
abnormal vibration and

noise during operation.
Visually check the running
reducer to make sure that
Tighten/
24 there are no abnormal ○ ○ ○ ○
repair
vibration and noise, oil
Reducer leakage and overheating.
Check the level of reducer

oil to make sure that it
25 Refill ○ ○ ○ ○
conforms to the relevant
requirement.
1-25
1-26
Inspection interval
check terly
26 Replace the reducer oil Replace ○ ○

Visually check the gear
teeth to make sure there are
no plastic deformation,
cracks, tooth surface
spalling and pitting
27 Replace ○ ○ ○
corrosion, etc.; and the

requirements in the clause
Gear
4.2.8 in GB 6067.1-2010 are
met in terms of tooth root
wear.
Adjust
Check the meshing by
28 ○ ○
clearance of the open gear. professio
nal
Visually check the rope
guider to make sure that it Adjust/
29 Rope guider ○ ○ ○ ○
works properly and there is tighten
no loosened bolt.
Visually check the rope
30 Rope holder Adjust ○ ○ ○
holder to make sure that it
Inspection interval
check terly
works smoothly and
properly.
Visually check the bearing
Repair/
31 Bearing to make sure that there are ○ ○ ○
replace
no abnormal sound.
Visually check the
connecting parts of cabs to
Tighten/
32 make sure that there are no ○ ○ ○ ○
repair
sealing off, looseness and
cracks.
Visually check the doors,

Driver’s cab windows, wipers, protective
and operator’s railings and door locks to Clean/
33 ○ ○ ○ ○ ○ ○
cab make sure that they are in replace
good condition, and glasses
are clean.
Visually check the tilting
cylinder of the operator's Tighten/
34 ○ ○ ○ ○ ○
cab to make sure that it is repair

safe and reliable.
1-27
Table 1-5 Operation of electric system
1-28
Inspection interval
No. Solution First Quarter- Remark
check ly
Test the battery to make Clean/
1 Battery ○ ○ ○ ○ ○
sure it is functional. refill
Visually check all
buttons to make sure they
are flexible and effective,
Repair/
2 and check the insulation ○ ○ ○ ○ ○
replace
protection of control

levers to make sure that
there is no damage.
Check all control levers
to make sure they are
Control Adjust/
3 flexible without ○ ○ ○ ○ ○
devices replace
blockage, and spring
back to neutral.
Visually check remote
control device to make
sure its housing is
Repair/
4 complete without ○ ○ ○ ○
replace
damage, control buttons

are functional and labels
are legible.
Table 1-5 Operation of electric system(continued)
Inspection interval
check ly
Main Check the main power
Adjust/
5 power switch to make sure it is ○ ○ ○ ○ ○
replace
switch functional.
Visually check control
cabinet door make sure
Adjust/
6 that it is easily opened ○ ○ ○
replace
and closed and door lock
is reliable.
Check the electric circuit
Control and components in the
cabinet/sta- control cabinet make

tion and sure that there is no
electrical overheating, burning and
facilities melting signs, and there
is no damage on
component appearance.
Visually check the
electric connection and Adjust/
8 ○ ○ ○
grounding cable to make replace

sure that they are reliable
1-29
1-30
Inspection interval
check ly
and there are no cracks
and damage on the cable.
Visually check each
section of wire to make
Clean/
9 sure that wire marking is ○
tighten
clear and wiring is
secured.

Check the electric circuit
by function test to make
Repair/
10 overheating sign and ○
replace
insulation resistance and
grounding resistance
conform to requirements.
Check terminals,
contactors and relays by
Adjust/
11 function test to make ○ ○
replace
sure that they are in good
condition.
Communi Check the
12 Maintain ○ ○ ○ ○ ○
cation communication between
Inspection interval
check ly
the main machine and
center control
compartment by function
test to make sure that it is
working correctly.
Lighting Visually check the

and lighting and signaling Repair/
13 ○ ○ ○ ○ ○
signaling devices to make sure replace
devices they are functional.
Visually check the air
Air condi-
conditioner for the
14 tioning Maintain ○ ○ ○ ○ ○
operator's cab to make
system
sure that it runs properly.

1-31
1-32
Inspection interval
check ly
Visually check the
pipelines and connectors
of the air conditioning
Repair/
15 there are no water ○ ○ ○ ○ ○
replace
leakage and oil dirt.
Check the condenser to

make sure that it is clean
and there are no damage.
Table 1-6 Hydraulic system
Inspection interval
check ly
Visually check the
hydraulic pipelines to
make sure that there are Repair/
1 ○ ○ ○ ○ ○ ○
no damage, leakage, replace
looseness, deformation
and aging.
System
Check the hydraulic
it works properly, and
2 Maintain ○ ○ ○ ○ ○
there are no unusual
noise or signs of
overheating.
Check and maintain
suction filter, return Clean
3 Filters ○ ○ ○
filter, air filter, and /replace
replace filter elements.
Check the hydraulic oil
tank to keep its inner
Hydraulic Clean

4 clean; check sight glass ○
oil tank /replace
to make sure that it may
1-33
indicate properly.
Table 1-6 Hydraulic system(continued)
1-34
Inspection interval
check ly
Visually check the level
5 of oil in the hydraulic Refill ○ ○ ○
tank.
Check and replace
Filter/
6 hydraulic oil according to ○ ○
replace
JB/T9737.
Check the oil cooler by

function test to make Repair/
7 Radiator ○ ○
sure that it works replace
properly.
Accumula Check accumulator

8 Adjust ○ ○ ○
tor pressure.
Table 1-7 Power system
Inspection interval
check ly
Check and maintain the
engine strictly according
1 to the instructions in Maintain According to Engine maintenance manual
Engine maintenance
manual.
Visually check engine
there are no water Clean/
2 ○ ○ ○ ○ ○ ○
leakage, oil leakage, air maintain
leakage and electric
Engine leakage.
Visually check the levels
of coolant, AdBlue and
3 fuel to make sure that Refill ○ ○ ○ ○ ○ ○
they conform to related
requirements.
Visually check the air The

inlet and exhaust circuits, nylon
Repair/
4 fuel pipelines and ○ ○ ○ ○ ○ ○ pipe

adjust
connectors to make sure should be
that there are no replaced
1-35
Table 1-7 Power system(continued)
1-36
Inspection interval
check ly
looseness, torsion, every 7
damage and blockage. years or
every
40,0000
km. The
rubber
hose

should be
replaced
every 3
years or
every
10,0000
km
(whichev
er is first
to come).
Check the engine by no
load test to make sure that

5 Maintain ○ ○ ○ ○ ○ ○
it is running smoothly,
gauges are indicating
Inspection interval
check ly
properly. Check engine
electric system to make
sure that there are no
abnormal phenomenon
and smell.
Visually check engine oil
6 level to make sure that it Refill ○ ○ ○ ○ ○ ○
conforms to requirement.
Visually check engine oil,
7 and replace the oil and oil Replace ○ ○ ○
filter element if necessary.

Check fuel filter and oil
filter, and replace filter Clean
8 ○ ○ ○
elements according to /replace
maintenance interval.
Clean the dust cup of air
9 Filters Clean ○ ○ ○
filter
Visually check the
pressure differential Clean/

10 ○ ○ ○ ○
indicator of the air filter. replace
Clean the main element
1-37
1-38
Inspection interval
check ly
of the air filter when the
pressure differential
indicator indicates.
Replace the main element
and safety element of the
air filter after 2 times of
cleaning the main filter

element or when the main
element is damaged.
Clean the inner of the fuel
11 Fuel tank Clean ○ ○
tank.
Check the oil cooler by
Repair/
12 function test to make sure ○ ○
replace
that it works properly.
Heat dissi- Clean the radiator/ let it
Clean/
13 pation counterclockwise rotate ○ ○ ○ ○ ○ ○
maintain
system for dedusting
Regularly replace coolant.
Clean
14 Drain out the used ○

/replace
coolant and clean the
Inspection interval
check ly
cooling system before
refilling new coolant.
SCR Check the after-treatment
15 Adjust ○ ○ ○
system system for malfunction.
The belt tension shall be
16 Others Adjust ○ ○ ○ ○
qualified.

1-39
The inspection and maintenance interval of power system depends on the time interval and engine
working time, whichever expires earlier. Please refer to the following table:

Time interval First check Weekly Monthly Quarterly Half-yearly Yearly
Engine working
100 hours 20 hours 70 hours 200 hours 400 hours 800 hours
time

1-41
Table 1-8 Interval mileage of chassis routine check and maintenance Unit: 1,000 km
1-42
1st class 2nd class 1st class 3rd class
Daily checks Daily checks Daily checks Daily checks
maintenance maintenance maintenance maintenance
5 10 15 20 25 30 35 40
85 90 95 100 105 110 115 120
165 170 175 180 185 190 195 200
245 250 255 260 265 270 275 280
325 330 335 340 345 350 355 360
405 410 415 420 425 430 435 440
485 490 495 500
1st class 2nd class 1st class 4th class
Daily checks Daily checks Daily checks Daily checks

maintenance maintenance maintenance maintenance
45 50 55 60 65 70 75 80
125 130 135 140 145 150 155 160
205 210 215 220 225 230 235 240
285 290 295 300 305 310 315 320
365 370 375 380 385 390 395 400
445 450 455 460 465 470 475 480
Table 1-9 Chassis inspection and maintenance
Inspection
Inspection interval
items
No. Solution 1st class 2nd class 3rd class 4th class Remark
requirement First
Daily mainte- mainte- mainte- mainte-
check
nance nance nance nance
Check the clutch oil cup for
1 Refill ○ ○
oil level
Clutch
Check the clutch release fork
2 Refill ○ ○ ○ ○ ○
and bearing for lubricating oil.
Check the lubricating oil level
3 to make sure that it is Refill ○ ○
sufficient.
Check the quality of the
Transmis-
4 lubricating oil and replace the Replace ○ ○
sion, trans-
lubricating oil if necessary.
fer gear
Check the breathers of the
transmission and transfer gear Clean/
5 ○
(air filter) to make sure that maintain
they are unobstructed.
Lubricate drive axle and make
6 sure that grease nipple is full Maintain ○ ○ ○ ○ ○ ○
Propeller

but not overflowed.
shaft
Visually check drive axle and Maintain/
7 ○ ○
1-43
coupling to make sure that adjust
Table 1-9 Chassis inspection and maintenance(continued)
1-44
Inspection
Inspection interval
items
requirement First
check
they are in good condition and
work properly.
Check the propelling
mechanism (crawler frames
included) by no load test to

make sure that there is no
8 Maintain ○ ○ ○ ○ ○ ○
abnormal noise and vibration,
and the drive sprocket, lower
roller, upper roller and idler
wheel are functional.
Propelling
Check the pins of leaf springs
mechanism
and suspension cylinders to
9 Refill ○ ○ ○ ○ ○ ○
see if it is necessary to coat
lubricant.
Check U-type bolts to make Tighten/
10 ○ ○ ○ ○ ○ ○
sure that there is no looseness. replace
Check the mid-position

11 leveling function of the hydro- Adjust ○ ○ ○ ○
pneumatic suspension,and the
Inspection
Inspection interval
items
requirement First
check
tightness of crawler propelling
unit to make sure that they are
effective.
Check the lubricant levels of
12 Refill ○ ○
main reducer and rim reducer.
Replace the lubricant of the
13 Drive axle Replace ○ ○ ○ ○
main reducer and rim reducer.
Clean or replace the drive axle Clean/
14 ○ ○ ○ ○
breather. maintain
Replace the wheel hub grease
of driven axle.
Visually check the wheel hubs
and wheel hub bearing
Driven clearance of drive axle and
Professio
shaft driven axle to make sure that
16 nal ○ ○ ○
there are no damage,
service
deformation or cracks on the

wheel hubs, and the wheel hub
bearing clearance is proper.
1-45
1-46
Inspection
Inspection interval
items
requirement First
check
Check tire pressure and
17 abrasion to make sure that Adjust ○ ○ ○ ○ ○ ○
related specifications are met.
Check wheel nuts and half
shaft nuts to make sure that
Adjust/

18 Wheel they are tightened according ○
replace
to the specified tightening
torque.
Adjust by
19 Tire alignment professio ○
nal
Check the hand brake and foot
brake and air chambers to Repair/
20 ○ ○ ○ ○ ○ ○
Braking make sure that they are replace
system functional.
Drain off the water in the air
21 Maintain ○ ○ ○ ○ ○ ○
reservoir
Inspection
Inspection interval
items
requirement First
check
Check the air dryer to make
22 sure that it is functional. Replace ○ ○ ○ ○
Replace the desiccant.
Check and adjust the output Professio
23 pressure of pressure regulating nal ○ ○ ○ ○ ○
valve. service
Check the thickness of brake Professio
24 shoe friction disc, and adjust nal ○ ○ ○
brake clearance. service

25 Clean the wheel brakes Maintain ○ ○
Check and adjust the toe-in of
26 front wheel and the location of Adjust ○
front wheel.
Steering Check the function of the
27 Adjust ○ ○
system steering system.
Check and adjust the tightness
Adjust/
28 of the steering gear, drop arm, ○ ○

Maintain
steering linkage, bolts and
1-47
1-48
Inspection
Inspection interval
items
requirement First
check
nuts. Check the clearances of
the steering linkage system.
Lubricate the pivots of
29 steering knuckle, drop arm, Maintain ○ ○ ○ ○
steering linkage.

Check the pneumatic system
by no load test to make sure
Repair/
30 that the system pressure is ○ ○ ○ ○ ○
replace
proper, pressure gauge is
functional.
Pneumatic
Check the pneumatic system
system
to make sure that its sealing is
proper and there are no Repair/
31 ○ ○ ○ ○ ○ ○
damage, torsion, looseness replace
and aging in piping elements
and connectors.
Inspection
Inspection interval
items
requirement First
check
Check the pneumatic seat,
horn, etc. as well as control Repair/
32 ○ ○ ○ ○ ○
valve and safety valve to make replace
sure that they are functional.

1-49
In order to facilitate to maintain and service the crane, to improve the working efficiency of the crane and
ensure safety and normal service life, instructions for check, adjustment and replacement of main chassis
parts are supplied as follows. Don’t reluctantly use the crane with any faults or abnormalities. What you
should always keep in mind is “Safety Is a Top Priority”!
Special inspection
1. Inspection conditions
After a lifting appliance itself or the outside environmental condition has changed or after a standstill
for a long time, before reuse, special inspections are required. Special inspections should be done
1) if any of the following items change:

• Safety devices;
• Rated load;
• Main load-carrying members;
• Mechanism;
• Control cabinet and control system;
• Power source;
• Wire rope or short lifting chain;
• Lifting attachment;
• Chassis, base and support structure.
If the said items are maintained and repaired in our company, all inspections will be
performed and then the crane can be directly put into service. If the said items are repaired or
replaced by users, necessary tests must be done to ensure the smooth and normal function of
the crane.
2) If the outside environmental condition changes, which is not suitable for normal operation:
• Extreme weather conditions (such as rainstorm, etc.);
• Earthquake;
• Foundation (crane rail included)
• Fire, flood;
• Non-normal operations such as overload, emergency stop or impact.
A cranes structural parts and mechanisms may become damaged due to storm, earthquake or
accident. This may result in reduced strength, rigidity, and stability.
3) After a standstill for a year or more, before reuse

If an equipment stands idle for a long time, the grease on part pivots and tire pressure will
become insufficient.
2. Inspection guideline
After a lifting appliance itself or the outside environmental condition has changed, inspections corre-
sponding to the change or damage degree should be done; after an accident, the inspection items should
be determined according to accident consequence; after a standstill for a long time, before reuse, the in-
spection items should be determined according to the characteristics of the specific lifting appliance.
Before reuse, load tests must be done to the crane after itself or the outside environmental condition has
changed, or it has gone through an overhaul or accident. Visual checks and no-load tests are required be-
fore the load test.
The said overhaul means removal or replacement of main load bearing structural members, or repair of
whole mechanism or control system, but the performance parameter and specifications are not altered.
Visual check, no-load test and load test should be performed according to the requirements in GB/T
6068. Tests should be performed by qualified personnel. After the test, the crane LMI must be calibrated
again and must meet requirements.
An inspection report is required for the special inspections.
3. Special inspection items

Refer to the following table for special inspection items.

Table 1-10 Special inspection items
1-52
No. Special inspection conditions Inspection items Inspection method and requirement Solution Remark
Changed type or
Check the changed safety protective See section “Regular
specifications of Safety protective
1 devices according to the requirements maintenance and service
safety protective devices
in the manual. items”.
devices
Strengthen the effected
Check all performances of the crane
Mechanism and mechanism and metal
2 Changed rated load by static load test and dynamic load
metal structure structure/reduce lifting
test.
load.
Changed cross- Check the changed metal structure See section “Regular

3 section features or according to the requirements in the maintenance and service
Equipment manual. items”.
material quality of Metal structure
changed
main load-bearing Check the effected metal structure by Strengthen the effected
4
members static load test and dynamic load test. metal structure.
Check the changed mechanism or See section “Regular
5 Changed type or parts of the winch system according maintenance and service
specifications of Winch system to the requirements in the manual. items”.
winch system Check all performances of the crane Replace the winch
6
by dynamic load test. system/reduce lifting load.
Changed type or Check the changed mechanism or See section “Regular
7 specifications of Control system parts of the control system according maintenance and service
control system to the requirements in the manual. items”.

Table 1-10 Special inspection items(continued)
See section “Regular
Check the control performance of the
8 maintenance and service
crane by function test.
items”.
Changed type or Check the changed power source or See section “Regular
9 specifications of Power source its parts according to the requirements maintenance and service
power source in the manual. items”.
Visually check the wire rope, drum See section “Regular
Changed wire rope
10 Wire rope: and sheave to make sure the relevant maintenance and service
performance
requirements in GB/T 5972 are met. items”.
Strengthen the effected
Check all performances of the crane
Mechanism and mechanism and metal
11 Changed fixed slings by static load test and dynamic load
metal structure structure/reduce lifting
test.
load.
Mechanical parts Check the effected mechanical parts See section “Regular
Subjected to waves
12 and electric control and electric control system according maintenance and service
Beyond the or flood
system to the requirements in the manual. items”.
normal
Check the anemometer and metal See section “Regular
working Wind speed beyond
13 Metal structure structure according to the maintenance and service
environment designed range
requirements in the manual. items”.
and
Earthquake intensity Yearly inspected Check the items for yearly inspection See section “Regular
conditions
beyond designed items specified in

14 specified in “Regular maintenance maintenance and service
range “Regular and service items”. items”.
1-53
1-54
maintenance and Check all performances of the crane See section “Regular
15 service items”. by function test, load test, static load maintenance and service
test and dynamic load test. items”.
Check the mechanism and metal See section “Regular
16 structure according to the maintenance and service
Mechanism and requirements in the manual. items”.
Overloading
metal structure Check all performances of the crane Repair the effected
17 by static load test and dynamic load mechanism and metal
test. structure.

Emergency stop that See section “Regular
Check the winch system and its parts
18 causing abnormal Winch system maintenance and service
by load test.
shock to mechanism items”.
Visually check the main load-bearing
Main load-bearing members, all mechanisms, and check See section “Regular
19 Impact accident members, all all performances of the crane by maintenance and service
mechanisms function test, load test, static load test items”.
and dynamic load test.
Main load-bearing
Visually check the affected items, and
members, all See section “Regular
carry out function test and load test to
20 General fire safety mechanisms, and maintenance and service
make sure the requirements in the
electric control items”.

manual are met.
system
Yearly inspected
The crane has been items specified in Check the items for yearly inspection See section “Regular
21 Others idle for a year or “Regular specified in “Regular maintenance maintenance and service
more, before reuse maintenance and and service items”. items”.
service items”.

1-55
Note: prior to static load test or dynamic load test, make sure that the test conditions are met.
Maintenance and service during storage of the crane
1. Before storage
If intend to suspend using the crane for a long time, the following measures should be taken:
• It’s better to park the crane in a storeroom. If lay it in the open air, rain-proof, lightning protection
and anti-freezing measures should be taken;
• Lock all doors and windows of operator’s cab and driver’s cab, position all control levers and
switches to Neutral or position OFF;
• Turn off main power source switch or disconnect the negative terminal of battery, or remove the bat-
tery and store it in a place where appropriate;
• Wipe off dust and oil dirt on the crane to keep it clean;
• Retract the piston rod of each oil cylinder (except jack cylinders) fully;
• Make tires clear off the ground by extending jack cylinders;
• Inflate tires to specified pressure, and lay wood plates under tires;
• Coat all finished surfaces exposed with grease to prevent corrosion;
• Remove dust on ropes, and coat them with grease;
• Keep the fuel tank filled to prevent water accumulation.
2. During storage of the crane
If rust prevention has to be done for a crane that is parked in a storeroom, the doors and
windows must be opened, in order to improve ventilation and prevent personnel from being
poisoned.
1) Checking battery
A maintenance free battery is used for the crane. Battery state indicator lamp is on the top surface of
the battery. The user can obtain the current battery status according to the indicator lamp and the cor-
responding instructions, and then carry out corresponding maintenance.
Cautions for battery inspection:
• Keep the battery clean and dry. Remove the terminals for cleaning if they are contaminated, and
then lubricate them with clean, acid-free and acid-proof grease;
• Do not rest tools on the battery;
• Do not remove the battery cable while the engine is running;
• Remove the battery cable at negative pole before that at positive one.

• The battery voltage can be known by observing the instrument. If the voltage is below 22 V after
the key is turned to the ON position, or the voltage is below 16 V after the key is turned to the
START position, the engine could not be started normally. If the engine is not started (i.e the gener-
ator is not working), it is not allowed to use high-power automotive electrical appliances for a long
time, such as air conditioning, radio, lighting, etc., to prevent the battery from deep discharging.
Failure to do so could result the fact that the engine could not be started, and battery will lack of
electricity or be damaged.
2) Battery maintenance
①When the vehicle is not in use, the power supply of the whole machine should be cut off. Sunlight
and rain should be avoided if possible.
②When the vehicle is out of service for more than one week, the starter switch and the main power
switch should be cut off, or the battery and the electric system should be disconnected, to avoid the
battery discharging too fast.
③If the crane is taken out of operation for more than one month, charge the battery until the voltage
of each unit is 12.6 V; afterwards, weekly check the battery. If the voltage of any single battery unit
is lower than 12.6 V or the charging indicator lamp illuminates, recharge the battery in time.
If charging the battery, charge it with DC power only. The charging power should not exceed 1/10 of
the battery capacity. For example: when charging a 180 Ah battery, the charging currency should not
exceed 18 A.
See the notice on the battery for the charging state of the battery.
3) Start engine every three-month, and let all mechanisms run without load for no less than one hour
each time.
4) For a crane stored more than one and half years, not only clean it, but also thoroughly check and
maintain it before reuse. Whether replace engine diesel filter element, air filter element, clean cooling
system, replace coolant, etc. or not, it should be determined according to actual situation.
5) Specially-designated person should be responsible for the integrity of the crane, so as to ensure the
crane is ready for operation.


Chapter 2 Oil and lubrication
2.1 Cleaning of the crane

Making the crane clean is not only the most important work and precondition for crane’s maintenance
and service, but also the basis to improve maintenance quality, relieve part abrasion and reduce oil and
grease consumption. If a machine is not clean, it is difficult to find the fault in each assembly or part,
which may result in problems such as unreliable tightening, imprecise adjustment, contaminated oil and
grease, etc.
Before inspections or maintenance, the crane should be cleaned to ensure a safe working environment.
Clean the crane after a period of operation. Remove greasy dirt on the outside surface of the crane with a
neutral and non-corrosive cleaning solvent. Remove greasy dirt in cabs with a rag and suitable cleaning
solvents if necessary.
The following should be ensured after cleaning:
1. The working platform and area allowing access to the crane are clean and dry, to prevent the operator
and/or service personnel from falling.
2. The glasses of door and window, and lamps are clean so as to ensure clear visibility for the operator.
Figure 2-1 Cleaning of the crane
• Wet working platform or passage can lead to slip and fall. Anti-skid shoes must be worn before
cleaning the crane.
• If warm water is used, the water temperature cannot exceed 60℃.
• After cleaning, lubricate all exposed moving parts.
Oil and lubrication 2-1

• When clean the crane with high pressure, do not point it directly at electric components and con-
nections. Do not allow water to enter into load moment indicator and instrument panel, other-
wise short circuit will occur.
• When cleaning the crane with a hydraulic monitor, do not point it directly at the breathers of
transmission and axles. Otherwise, the water entering into the lubricating oil of assembly parts
will result in corrosion of parts, reducing the service life of the equipment and even causing seri-
ous fault.
Figure 2-2 Cleaning of the crane
2.2 Lubrication
2.2.1 Lubrication working conditions
Regularly lubricate all moving parts of the crane according to the manual. Clean the crane prior to lubrica-
tion of the crane. Care should be taken to follow the manufacturer’s recommendations about the points
and frequency of lubrication, maintenance of lubricant levels, and types of lubricant to be used. Lubricat-
ing systems should be checked for proper delivery of lubricant.
Check, replace and refill oils (including grease) according to the requirements specified in the man-
ual. Use the oils in terms of type and quantity according to the requirements in the manual. Other-
wise, deterioration of product performance or reduction in service life of related parts or damage
to parts may be caused, even accidents.
2-2 Oil and lubrication

If operating the crane in a severe environment, such as high temperature, high humidity, extreme
cold, dusty conditions, etc, oil changes and lubrication may need to be done more frequently to
maintain the performance and safe operation of the crane.
Lubrication working conditions
Machinery shall be stationary while lubricants are being applied and protection provided such as setting
all controls in the off position and ensuring all operating features are secured from inadvertent motion by
brakes, pawls, or other means unless equipped for automatic or remote lubrication.
• Apply grease monthly to the exposed portion of the luffing cylinder piston rod with the boom placed on
the boom rest.
• When lubricating the sliding surfaces of slide blocks at the heads and tails of boom sections 2–5, all
counterweight slabs must be applied and the hook block of 515 kg may be attached. The maximum per-
missible boom length is 35.5m. First, extend the second boom section for coating. After retracting the
second boom section, extend the third, fourth and fifth boom sections for coating. Do not grease the
boom unless the crane is in maintenance configuration.
Do not grease the boom unless the crane is in maintenance configuration.
Apply grease according to the requirements of working conditions, or serious equipment damage
and casualties may be caused!
2.2.2 Lubrication guidelines
In order to better increase working efficiency and the service life of the crane, regularly lubricate the crane
according to the specified lubrication points. The points of lubrication are shown in the figure for “Lubri-
cation points ”.

• Do not mix different brands of grease. Otherwise, characteristics of grease will be changed and
equipment be damaged. When refilling grease, use the same brand of grease that was used
previously.
• The dirt in grease may result in premature abrasion of gliding surface and reduce the service life
of the crane. Before refilling grease, the oil cup and other surface must be cleaned.
• The figures of lubrication points are only for illustration.
• The sliding surfaces that are not listed in the tables below should be periodically coated with
grease according to the actual condition.
• The exposed portion of piston rod after the hydraulic cylinder (elevating cylinder and outrigger
jack cylinder, etc.) is fully retracted, and the connecting rod and gliding section that have been
greased before delivery should also be lubricated appropriately.
• Prior to grease wire rope, remove the dirt on the surface of the wire rope by using steel wire
brush, compressed air, etc.
• Do not Lubricate wire ropes with unqualified grease or oil. Otherwise the service life of wire
ropes will be shortened. Lubricate wire ropes with the specified grease.

Figure 2-3 Lubrication points
Table 2-1 Lubrication points and methods
No. Greasing points Interval Brand Greasing method
Hook block Weekly or before No.2 Lithium base

1 Grease pump
trunnion use grease
Sheaves of hook Weekly or before No.2 Lithium base

2 Grease pump
block use grease

Table 2-1 Lubrication points and methods(continued)
Sheaves at boom Weekly or before No.2 Lithium base

3 Grease pump
head use grease
No.2 Lithium base
4 Boom head sliders Weekly Coat
grease
Gliding surfaces
for the sliders of No.2 Lithium base
5 Weekly Coat
2nd ~ 5th boom grease
sections
No.2 Lithium base
6 Boom tail sliders Weekly Grease pump
grease
No.2 Lithium base Centralized
7 Boom rear pivot Weekly
grease lubrication
No. 2 Lithium base
8 Single top Before use Grease pump
grease
No. 2 Lithium base
9 Sheave of jib Before use Grease pump
grease
No. 2 Lithium base
10 Jib guide roller Before use Grease pump
grease
Upper and lower
No.2 Lithium base
11 pivots of luffing Weekly Grease pump
grease
cylinder
Bearing of slewing No.2 Lithium base
12 100 h Grease pump
ring grease
Tooth surface of No.2 Lithium base
12 Weekly Coat
slewing ring grease
Pinion surface of
No.2 Lithium base
13 slewing Weekly Coat
grease
mechanism
Wire rope (for No.2 Lithium base
14 Weekly Coat
hoisting) grease
Bearing seat of
No.2 Lithium base
15 main/auxiliary Weekly Grease pump
grease
winch
No.2 Lithium base
16 Cab door hinge 5000 km Grease pump
grease

Table 2-1 Lubrication points and methods(continued)

Accelerator and No.2 Lithium base
17 5000 km Grease pump
brake pedal shaft grease
Upper and lower
No. 2 Lithium base
18 surfaces of Monthly Coat
grease
outrigger guide rail
Adjusting block of No. 2 Lithium base
19 Monthly Coat
outrigger grease
Steering knuckle
No.2 Lithium base
20 kingpin and 5000 km Grease pump
grease
bearing
Ball head of No.2 Lithium base
steering pull rod grease
In winter: No.0
Lithium base
Universal joint of 5000 km or half
22 grease; in summer: Grease pump
the propeller shaft year
No.1 Lithium base
grease
In winter: No.0
Telescopic spline Lithium base
5000 km or half
23 of the propeller grease; in summer: Grease pump
year
shaft No.1 Lithium base
grease
Ball head of push No.2 Lithium base

rod grease
No.2 Lithium base
25 Wheel hub bearing 5000 km Grease pump
grease
Front and rear No.2 Lithium base

brake camshafts grease
2.3 Instruction for using oil

2.3.1 Oil brands, filling amount and interval
Refer to “hydraulic oil specification” for oil brands and filling amount. Refer to “Comparison between
oil brands abroad and domestic” for different oil brands abroad and domestic.

• Please use the grease, antifreeze coolant and hydraulic oil recommended by XCMG. Do not mix
different brands of oil.
• Use suitable oil depending on the atmospheric temperature.
• Frequently check the oil level, and refill if it is lower than the specified level.
• Do not refill oil until the temperature of equipment drops to ambient temperature. Otherwise,
there is a risk of burn due to oil spray.
• Release hydraulic oil pressure from related hydraulic circuits before refilling oil. Otherwise, the
pressure will cause dangerous movements of the crane or will result in the high-speed spray of
hot oil, resulting in casualties.
Table 2-2 Oil brands, filling amount and interval
Theo-
retical Brand
Model and operat-
No. Position Type filling recom-
ing temperature
amount/ mended
L
In summer: 0# diesel
Special
1 Fuel tank Diesel fuel; In winter: -10# 300
ized oil
diesel fuel
Shang
1. 15W/40 diesel en-
hai
gine oil (above
Diesel
-20℃); 2. 10W/40
Engine engine
2 Engine diesel engine oil CH-4
oil 40
(above -30℃); 3.
Hang-
5W/40 diesel engine
zhou en-
oil (above -40℃).
gine 31
1. FD-1 coolant
(above -25℃); 2. FD-
3 Radiator Coolant 60
2B coolant (above
-40℃)
AdBlue
AdBlue solution
4 AdBlue tank —— 35
solution special
for

Table 2-2 Oil brands, filling amount and interval(continued)
Theo-
retical Brand
Model and operat-
ing temperature
amount/ mended
L
motor
vehicles
5 Transmission 13
Axle
pack 1. 85W/90 Heavy du- 13.5
3rd axle age ty gear oil (above
Whee -12℃); 2. 80W/90
2×3.5
l rim Gear oil Heavy duty gear oil GL-5
6 Axle
Axle (above -26℃); 3.
pack 75W Heavy duty gear 12
4th axle age oil (above -40℃).
Whee
2×3.5
l rim
7 Main winch system 1. In winter: Mobil 2
8 Auxiliary winch SHC220 Gear oil; 2. 2
Gear oil In summer: L-
9 Slewing system CKD220~320 Gear 4.5
oil
Turbine
10 Steering system L-TSA32 Turbine oil 6.6
oil
1. AE46 hydraulic oil
Hy-
(-20℃~50℃); 2.
11 Hydraulic system draulic 600
HS22 hydraulic oil
oil
(-40℃~50℃)
1. HZY5 or DOT5
(below -20℃); 2.
Braking HZY4 or DOT4
12 Clutch slave cylinder reservoir 1
liquid (-20℃～15℃); 3.
HZY3 or DOT3
(above 15℃)
Extreme pressure Great-
13 Slewing ring Grease ——
type lithium grease Wall L-

Table 2-2 Oil brands, filling amount and interval(continued)
Theo-
retical Brand
Model and operat-
ing temperature
amount/ mended
L
Inner gliding surfaces of the tel- XBCH-
14 ——
escoping sections B2 or
Mobil
grease
15 Sliding bearing ——
MP
NLGI2
Table 2-3 Table of comparison between oil brands abroad and domestic
Winch re-
Steering Transmission, transfer ducer,
Category Engine oil Hydraulic system
system gear, axle slewing
reducer
Medium
Heavy du-
Diesel Turbine duty ve- Industrial
Name ty vehicle Hydraulic oil
engine oil oil hicle gear gear oil
gear oil
oil
Sinopec L- AE46 ——
CKD220,
Petro CH-4 L-TSA32 GL-4 GL-5
L- —— XA130
China
CKD320
DE-
TEOIL. Mobilger
Delvac Mobilube Mobilube DTE10
MOBIL Name- 630, Mo- DTE25
super GX HD Excel 32
dseries. bilger 632
DTE
Oma-
Turbo T SPIRAX Tellus Tellus
SHELL Rimula D Spirax A la220,
oil 32 G S2MX46 S4VX32
Omala320
Meropa RANDO
RegaI R Thuban Thuban RANDO
CALTEX EDLA500 220, Mer- HDZ LT
＆O 32 GL-4 GL-5EP HD 46
opa 320 32

Table 2-3 Table of comparison between oil brands abroad and domestic(continued)
Winch re-
Steering Transmission, transfer ducer,
Category Engine oil Hydraulic system
system gear, axle slewing
reducer
Alpha
Castrol
CAS Perfecto SMX Multitrax Max 220, HYSPIN HYSPIN
15W/40,
TROL T32 80W/90 85W/140 Alpha HLP 46 AWV 32
RX Super
Max 320
Transmis-
Carter EP
BOLD sion AZOLLA equis
TOTAL Rubia XT PersIia 220, Car-
ORBV TM80W/ AW46 XV32
ter EP 320
90
Energol
GR-
Venellus TurbinoI Energol Hypogear XF220, HYSPIN HYSPIN
BP
C3 Extra 32 EP EP Energol HLP 46 AWV 32
GR-
XF320
10#, 0#, -10#, -20#, -35# light diesel fuel should be used. Apply EP Lithium base grease to the lubri-
cation points of bearing, slider, slewing ring, rope, boom pivot and elevating cylinder pivot, etc.
2.3.2 Replacement interval
Gear oil
1. The oil change period of each assembly in the chassis is as shown in the table below.
Table 2-4 Oil change period of each assembly
Category Engine Transmission Transfer box Drive axle Remark

1500 km of
First check ● ★ ★ ●
traveling
Routine check ●
1st class
● Every 20,000 Every 20,000 ●
maintenance
km km
2nd class
● ●
maintenance

Table 2-4 Oil change period of each assembly(continued)
Category Engine Transmission Transfer box Drive axle Remark

3rd class
● ●
maintenance
4th class
● ●
maintenance
• ★ Maintenance; ● Replace
• Change oil for each assembly at least one time per year.
2. The oil change period of each assembly in the superstructure is as follows:
Delivery Change Change

date 3 months later
oil Every 12 months
oil
• Clean the inner of each assembly in the chassis during first check, and replace gear oil with
new one.
• Whenever gear oil becomes excessively contaminated, replace the oil before scheduled
maintenance.
Hydraulic oil
The hydraulic oil change period is as follows:
Delivery Filtrate or Change

date
3 months later Every 12 months
change oil oil

• Hydraulic oil should not be used beyond 24 months even if it has been filtered.
2.3.3 Fuel
1. Checking the level of hydraulic oil

Check the level of fuel in chassis fuel tank from the indicator lamp shown in the figure followed after
the key switch is turned to “ON” position. If the pointer is within the red area after turning the key
switch on, it means the fuel is not sufficient. It is necessary to add fuel.
1/2
0 1
Figure 2-4 Fuel indicator lamp
2. Refill
The fuel tank is located below the left deck. Refer to the table for “Oil brands, filling amount and inter-
val” or Engine instruction for tank capacity and fuel type.
• After refueling is completed, tighten and lock the fuel tank cap to avoid the cap from coming off
or to avoid fuel from evaporating.
• If using a portable container in emergency, the container should have been approved by safety in-
spection and meet the fireproof requirements. The cap of the portable container should be able
to be locked automatically to prevent leakage of internal fuel.
• Manufacturer is not responsible for the trouble in the power system due to fuel quality.
• Never smoke while refueling the machine to prevent fire, which will cause significant loss of prop-
erty or personal injury.
• Before adding fluids, shut the engine. Otherwise, there is a risk of catching fire
• Fuel spills pose a hazard if not cleaned up immediately.
Figure 2-5 No fire!

2.3.4 Engine oil

Checking oil level from the instrument panel: observe the oil pressure on the chassis state screen, if it
displays the red scale and the oil pressure is lower than the prescribed value, it is needed to add the oil.
The real adding amount is shown by the oil dipstick.
The following method is recommended to check the level of engine oil:
1) Open the engine hood;
2) Remove the dipstick from the engine as shown in Figure 2-6;
3) Clean the dipstick, and reinsert it into the engine;
4) Take out the dipstick and observe to see if the soaked mark is in the marked area.
LOW FULL
Figure 2-6 Engine oil dipstick
Set the crane on firm and level supporting surface to check the engine oil level.
2. Refill
1) Clean the engine filler cap and the surface around it with a piece of clean rag to prevent dirt from en-
tering the oil tank;
2) Open the engine filler cap to refill oil. Refer to the Table “Oil brands, filling amount and interval”
for oil type;
3) Tighten the cap to prevent oil leakage.
3. Replace
Replace the oil according to engine maintenance interval. Replacement method is as follows:

1) Unscrew the drain plug;
2) Drain the used oil out into a container, and clean the drain plug. Dispose the used oil according to en-
vironmental requirements;
3) Before screwing in the drain plug, coat a little sealant beginning from the third thread of the plug;
4) Tighten the plug;
5) Replace the oil filter element according to section “Oil filter”;
6) Refill the oil of same brand according to the refilling procedure.
• Before checking the engine oil level, stop the engine and allow the engine to cool down to ambient
temperature.
• Do not mix different brands of oil. Different brands of oil have different kinematic viscosity and
operating temperature.
2.3.5 Antifreeze coolant

Observe the coolant level in the expansion tank. If the level is lower than min. mark, add coolant to the
max. mark. Add coolant only after the coolant cools.
Figure 2-7 Filler of expansion tank

• If it is necessary to check the antifreeze coolant level during normal operation, stop the engine
and allow the antifreeze coolant to cool below 40℃ (104℉) before checking the antifreeze cool-
ant level.
• The temperature of antifreeze coolant is very high while the engine is running under heavy
load. Never remove the expansion tank pressure cap with the engine running under heavy
load.
• Do not remove the expansion tank pressure cap while the engine is hot. Engine antifreeze cool-
ant is under pressure when hot and will spurt out.
2. Refill
Refill antifreeze coolant in time if it is not sufficient. Refilling method is as follows:
1) Only after coolant is below 40℃, open the cap of expansion tank and refill antifreeze coolant until it
is between Min. and Max. marks;
2) Recover the cap. Start the engine and observe the level when engine rotation speed is about 1,000 r/
min;
3) Stop the engine if the level drops below min. mark. Further refill antifreeze coolant until the level is
stable at the lower edge of the sight hole/ in the range of Min. and Max. marks after the engine runs
for over 20 minutes.
• When filling antifreeze coolant, take actions to prevent the air into the cooling system, otherwise
air bubbles will make damage to the engine;
• Replace antifreeze coolant after engine overhaul or every two years, or according to the actual
situation.
Do not refill antifreeze coolant with the temperature of antifreeze coolant over 40℃ (104℉). Other-
wise, explosion of engine may occur.
Use the specified antifreeze coolant. Replace antifreeze coolant according to the min. ambient temperature
at the place where the crane is working. Do not use the pure water, tap water or seawater as antifreeze
coolant, which will result in damage to engine, and corrosion and blockage of cooling system.

• Do not use the antifreeze coolant made of “alcohol-water”.

• Never use sea water to cool engine directly.
• Refill antifreeze coolant according to the requirements in engine instructions. When using anti-
freeze coolant, the freezing point of antifreeze coolant should be 5℃ lower than the lowest tem-
perature in the area.
2.3.6 AdBlue solution

The indicator lamp on the instrument panel in the driver's cab for low AdBlue solution level illuminates
when the AdBlue solution level is lower than 14%. When the AdBlue solution level is lower than 5%,
the indicator lamp flashes for warning. Refill AdBlue solution to the specified level.
MAX
Figure 2-8 When the AdBlue solution level is too low, this lamp illuminates.
• If the AdBlue solution could not be refilled in time, the engine will limit power and torque to
ensure the emission standard.
• Refill AdBlue solution in time so as to ensure normal operation.
2. Refill
Refill the AdBlue solution when refilling fuel each time.
2.3.7 Gear oil
1. Checking oil quality

The users should regularly check gear oil quality.
Pay attention to the following:
1) Oil sample should be taken when the machine is hot. Take oil sample of 150 ml from rear axle oil
hole by a sample syringe.

2) The sample syringe and oil sample container should be clean.
3) Do not add new oil before taking oil sample.
2. Usage of gear oil

Refer to specific sections for major parts gear oil inspection; refer to “Oil change period” for the us-
age of gear oil in major parts.
• Whenever gear oil becomes excessively contaminated, replace the oil before scheduled
maintenance.
• The gear oil for each assembly should be replaced at least once a year. If the gear oil is not re-
placed timely, it will lead to trouble in the crane, and reduce its service life, which would do more
harm than good.
2.3.8 Hydraulic oil
1. Checking oil quality

Hydraulic oil should be regularly tested to determine oil contamination level. Once per year is recom-
mended for the hydraulic oil of cranes used in general applications; once per quarter for the hydraulic
oil of cranes operated frequently and used in adverse environments. Whenever hydraulic oil becomes
excessively contaminated, filter or replace it even before the scheduled filtration or replacement time.
Replace hydraulic oil according to JB/T 9737-2013 Mobile cranes-Solid particle pollution grade, meas-
urement and selection of the hydraulic fluid.
• Different brands of hydraulic oil should not be mixed. Otherwise, the hydraulic oil character
will be changed, which will result in damage to equipment. Refill the oil tank with the same
brand of hydraulic oil as used before.
• Hydraulic oil should not be used beyond 24 months even if it has been filtered.
• Whenever oil becomes excessively contaminated, filter or replace it even before the scheduled
filtration or replacement time. At the same time, replace the filter element of return filter.
• Full hydraulic drive is used for the crane. The quality, viscosity and cleanliness of hydraulic
oil are critical to normal crane operation. If the hydraulic oil is not replaced timely, it will lead
to trouble in the crane, and reduce its service life. XCMG is not responsible for the adverse re-
sult due to nonobservance of the scheduled filtration or replacement time.

The limit of solid particle contamination: not more than 17/13 when the hydraulic oil is filled to hy-
draulic oil tank, and not more than 20/16 during operation. Refer to table 2-5 for visual observation of
oil contamination.
Table 2-5 Visual observation of oil contamination
Possible oil
Oil color Oil odor Treatment
contamination
Transparent Normal No contamination Continue to use
Further lab analysis
Transparent but darken Normal Mixed with other oil
needed or change oil
Transparent but Mixed with metal
Normal Filtrate or change oil
flashing particles
Transparent with
Normal Mixed with impurities Filtrate or change oil
darken spots
Black brown Smelly Oxidized Change oil
Mixed with air or Separate waste or

Cream white Normal
water change oil
If the hydraulic oil is seriously contaminated but not deteriorated, it should be filtered for reuse. If the
hydraulic oil is deteriorated, it should be replaced. Hydraulic oil tank should be cleaned before replace-
ment of hydraulic oil to prevent oil pollution. Always clean oil tank when needed.
Effective measures should be taken to prevent the dirt from entering into the hydraulic system
during assembly, installation, maintenance and repair.
2. Hydraulic oil temperature
1) Higher hydraulic oil temperature

The suitable temperature for hydraulic system working is about 60℃. If the hydraulic oil temperature
is higher than 60℃ for a long time, the deterioration of hydraulic oil will speed up, which will reduce
the service life of hydraulic parts and shorten filtration and replacement interval. When the tempera-
ture is over 80℃, the volumetric efficiency of the pumps and motors is reduced and is especially no-
ticeable at engine idle.
2) Lower hydraulic oil temperature

When the temperature is lower than -20℃, the hysteresis of hydraulic system will occur, which may
cause abnormal noise after the oil pump begins to rotate. In practical working, select open and close
of hydraulic oil radiator as well as viscosity according to the environmental temperature and working
conditions.

If the temperature is very low, hydraulic oil’s viscosity will increase and flow ability will decrease.
In cold weather, if operating the crane at high speed or under heavy load before the hydraulic oil
reaches the specified temperature, the hydraulic parts may be damaged. In this case, do not carry out
lifting operation. Let the crane engine run at idle until the temperature of hydraulic oil rises to 20℃.
3) Selection of hydraulic oil

In order to properly select hydraulic oil, the working temperature (the temperature of oil tank in start-
ing circuit) related to environmental temperature should be known. Selection principle: select the
higher viscosity grade in the optimum viscosity range ( as shown in the figure below). It is recom-
mended to select the higher viscosity grade.
For example, when the environmental temperature is X℃, the working temperature in the hydraulic
oil circuit is 60℃ (the temperature in the oil tank), and the optimum viscosity range is shaded in the
figure below. The corresponding viscosity grade is VG46 or VG68. Select VG68.
Figure 2-9 Hydraulic oil working temperature range
3. Usage of hydraulic oil
1) Checking the level of hydraulic oil

Check the level of oil in the hydraulic tank prior to starting the engine. The hydraulic oil tank of chas-
sis is located below the right deck. The sight glass can indicate the level and temperature of hydraulic
oil. When checking the hydraulic oil level, make sure that it is between the max. and min. marks. Re-
fill oil if it is below the min. mark.

When checking the oil level the crane must be in travel configuration. Make sure that the out-
rigger cylinders and boom are fully retracted.
Only when the crane is in non-working state, the hydraulic system is cooled down to ambient
temperature, can the level of hydraulic oil be checked. Otherwise, burn may be caused or the
hydraulic oil may be spill.
YWZ-16
0
C
100 20
90
80 18
70 16
60 14
50 12
II
40 10
30 80
20 60
10 40
0 20
10
20 0
Figure 2-10 Sight glass with thermometer
Table 2-6
No. Explanation No. Explanation

I Max. II Min.
2) Refill
Refill hydraulic oil when the level is below the min. mark. Prior to operation, make sure that the hy-
draulic oil level is not lower the min. mark. Filling method: remove the air filter cap and refill with
the same brand of hydraulic oil through the air filter screen. Refer to the Table about oils for selection
of hydraulic oil.

• Different brands of hydraulic oil should not be mixed. Otherwise, the hydraulic oil character
will be changed, which will result in damage to equipment. Refill the oil tank with the same
brand of hydraulic oil as used before.
• The disassembly of hydraulic piping must be done carefully. Otherwise, oil leakage or hy-
draulic element failure can be caused.
• Dust, foreign body and water entering into the hydraulic system will lead to failure of the
crane. During maintenance, do not allow dust, foreign body to enter into the hydraulic
system.
OIL A
OIL B
Figure 2-11 Different brands of hydraulic oil cannot be mixed
3) Replace
①First replace the hydraulic oil in the hydraulic oil tank, drain out the hydraulic oil and remove the
return circuit oil pipes. Clean the oil tank and filter carefully. Use the chemical cleaning solution,
whose pollution grade of solid grain is no more than 21/17/13. After it is cleaned and dried, wash
it again with hydraulic oil, whose pollution grade of solid grain is no more than 21/17/13. After
that, drain out the oil and add the new hydraulic oil again.
② Start the engine with low speed, and make the oil pump work. Operate each system separately, use
the new hydraulic oil to drain out the old oil. The old oil shall not enter the hydraulic oil tank. Stop
the oil pump until the main return oil pipe has new oil. During changing oil, add the new hydraulic
oil constantly to avoid the void suction.
③Connect the main return oil pipe to the oil tank. Return all the components to the initial state. Add
the hydraulic oil to the prescribed level.
2.4 Disposal of used oil and grease

Various greases, fuels and antifreeze fluids used in cranes will cause direct or indirect pollution to the en-
vironment. Antifreeze fluid and hydraulic oil are toxic. Dispose of them according to local and state laws.
Recycle used antifreeze fluid and grease with permissible disposal equipment (including disposal equip-
ment in service station and those supplied by automobile service station).

Contact local environmental protection agencies for assistance if needed.
• Never dump waste fluids into a sewer system, on the ground, or into waterways. Always drain
waste fluids from the machine into a proper storage container and dispose of them properly.
• Always recycle when possible. Failure to recycle may result in fines or penalties.
e oil
st油
Wa废
电池
电池
池电
Figure 2-12 It is forbidden to dump waste fluid at will.


Chapter 3 Maintenance and service of chassis
3.1 Power system

3.1.1 Power system
The power system consists of the parts shown in the figure below.
Ⅳ
Ⅰ Ⅱ
Ⅲ
Ⅵ Ⅴ
Ⅸ
Ⅷ
No. Name No. Name

Ⅰ Expansion tank Ⅱ Radiator
Ⅲ Engine Ⅳ AdBlue supply device
Ⅴ Air filter Ⅵ Transmission
Ⅶ Fuel tank Ⅷ Fuel filter
Ⅸ Silencer and after-treat-
ment device
3.1.2 Engine
1. Engine should be strictly maintained according to the instructions in Engine operation manual.
Maintenance and service of chassis 3-1

2. Contact local XCMG office or Engine service center or call 4000015678 for help about the troubles that
could not be removed.
#
*
3.1.3 Oil filter
The flow resistance becomes larger after a long time usage. Although there is bypass valve, the oil besides
the bypass valve hasn't been filtered, which will speed up the wear of the engine. So, regularly replace fil-
ter element. Refer to regular maintenance and service items for replacement interval. Replacement method
is as follows:
1. Clockwise turn the filter to be replaced with a special spanner. Dump the used fluid into a waste barrel
after the filter is removed.
Follow the guidelines of the EPA or other governmental agencies for proper disposal of waste
fluid.
3-2 Maintenance and service of chassis

2. Clean the base surface with a piece of clean rag.
3. Refill oil into the new filter until it is more than half of its capacity.
Pour it into the filter element through the oil filling holes, rather than the middle thread hole in
order to avoid unfiltered oil flowing into the engine.
4. Coat a little oil on the seal ring with a brush.
5. Put the filter onto the base. When the upper end face of filter seal ring contacts with the base fitting sur-
face, counterclockwise rotate the filter 3/4~4/5 turn. Check if there is oil leak.

• When replacing the filter element, check the rubber washers of the filter element and base seal
ring, and replace if damaged or aged. Otherwise, oil will penetrate outside.
• Replace oil while replacing filter element.
3.1.4 Fuel pipeline and fuel filter
Check the fuel pipeline for tightness, leakage and deformation. Refer to “Regular maintenance and serv-
ice items-power system” for replacement interval of fuel pipeline.
In engine oil inlet pipeline, there is a fuel filter (see the figure below). It should be regularly maintained
for draining water and replaced.
Figure 3-1 Fuel pipeline and fuel filter
1. Method for draining water

Water has greater density compared with oil, so the water in the fuel oil will go down below the fuel oil.
Driver or maintenance worker should check the collector every day. If there is water emerged, drain it
in time. Daily check the water collector, and drain the water in the collector in time. Counterclockwise
turn the drain valve to drain the water. Clockwise turn and tighten the drain valve after the water is
drained completely.

No. Name No. Name

1 Manual fuel pump 2 Fuel filter housing
3 Water collector 4 Drain valve
5 Sensor connector
• Loosen the drain valve and do not remove it, otherwise the water will flow to your hand.
• Avoid the water to flow to the sensor connector as far as possible.
• If the crane is to be idle for a long time, do not store the crane until the water in the oil-water
collector has been drained out. Otherwise, the filter will be corroded by water and impurity.
2. Replacement of fuel rough filter element

The replacing frequency of filter element depends on the level of impurity in diesel oil. During use of
engine, the filter element will be gradually jammed with impurities and the flow resistance of the fuel
will gradually increase, the resulted consequence is significantly reduced power or difficult starting.
• It is recommended to replace the filter element every half-year or every 500 working hours or
when the engine power decreases, whichever expires earlier.
• A spare element should be taken on board.
The procedure for replacing filter element:

1) Disconnect the sensor connector. 2）
2) Clockwise turn the filter to be re-

placed with a special spanner. Dump
the used fluid into a waste barrel after
the filter is removed.
3) Clean the base surface with a piece of

3）
clean rag.
4) Remove the water collector and dry it

with a piece of clean rag after cleaning
with water. Properly install it on the
new oil-water separator and make sure
that the seal ring is intact. Ⅰ Ⅱ
4）
5) After installing the water collector, re-
fill new fuel into the oil-water separa-
tor until it is full of fuel.
6) Coat a little oil on the seal ring with a

brush.
7) Put the filter onto the base. When the

upper end face of filter seal ring con-
tacts with the base fitting surface,
counterclockwise rotate the filter 3/ No. Name
4~4/5 turn. Check if there is oil leak. Ⅰ Old filter element
Ⅱ New filter element
8) Bleed the air in the fuel pipeline by
the manual oil pump: loosen the air-
bleeding bolt on the oil pump, and
then press the button on the manual
oil pump until diesel oil without bub-
ble or foam emerges continuously.
9) Reconnect the sensor connector and

secure it with insulating tape.

Follow the guidelines of the EPA or other govern-

mental agencies for proper disposal of waste fluid.
Dump the fuel residual in the water collector into a

waste barrel and dispose of the waste oil-water sepa-
rator in the way that the environment will not be
polluted.
If the fuel is not new, pour it into the oil-water sepa-

rator through the oil filling holes, rather than the
middle thread hole in order to avoid the fuel unfil-
tered to flow into the engine.

5）
6）
7）
8）
3. Replacement of fuel fine filter element

Refer to the above items 2), 3), 4), 5) and 6) for replacing fuel fine filter element.
4. Cleaning of fuel tank
There will be sediment and water accumulated at the bottom of the fuel tank after use for a long time, or
unclean fuel has been filled. Regularly remove the sediment and water. Clean the fuel tank as far as pos-
sible when the fuel is about to run dry in order to avoid wasting fuel.

Ⅰ Ⅱ
Figure 3-2 Diagram of fuel tank
No. Name No. Name

Quick connector (con-
Ⅰ Fuel tank cap Ⅱ necting fuel pipeline
and sensor)
Ⅲ Drain plug
The method for cleaning the fuel tank is as follows:
1) Remove the fuel pipe and sensor from the fuel tank. Take care to avoid oil leakage.
2) Screw out the drain plug to drain out the fuel. And then screw in the drain plug.
3) Open the fuel tank cap to take out filter screen. Add proper clean fuel and clean the tank with com-
pressed air. Clean several minutes and drain out the fuel and then screw in the drain plug. Repeat the
said step one time.
4) Connect the fuel pipe and sensor and install a new filter screen. Refill fuel and close the fuel tank
cap.
• During cleaning the fuel should be drained into a barrel and dispose with environment protection
taken into consideration.
• The fuel for cleaning the tank may be used for next cleaning after being filtered by liner.
3.1.5 Air filter
Daily or when refilling fuel check the dust valve of the air filter, and remove the dust in it by following the
method shown in the figure below. If the dust valve is damaged, replace it in time so as to avoid dust re-
turning into the air filter.

Maintain the air filter every three months, or after 250 working hours or when the pressure differential in-
dicator warning lamp illuminates. The maintenance and replacement interval of filter element should be
shortened if it is used in dusty environment.
When the air filter is blocked or the air intake resistance is too high, the yellow piston in the pressure dif-
ferential indicator located in engine air intake pipeline will move toward red area. The piston displacement
is related to the degree of filter element blockage. The air filter must be maintained when the piston moves
into the red area.
Ⅱ
Ⅰ
%05 Ⅲ
Figure 3-3 Pressure difference indicator

Pressure differential
Ⅰ Ⅱ Yellow piston
indicator
Ⅲ Red area
It is not recommended to clean any filter elements. The air filter is easy to be damaged during filtering air
due to the shock of dust particles. Replace the filter element in time if abnormal phenomenon appears such
as excessive oil consumption, high exhaust pressure, more smoke, as well as power decrease.

1）
2）
3）
4）
5）
• The air filter is easy to be damaged during filtering

air due to the shock of dust particles. Replace the
filter element in time, otherwise, the engine may
be damaged, and the maintenance cost is much
greater than the expense of replacing the element.
• Do not change the filter frequently in the mainte-
nance period, unless the working environment is

1. Replacement procedure of main filter very harsh. With the accumulation of the dust, the
element is as shown in the figure: effect of the new filter will increase. Do not be mis-
guided by the dusty appearance. With the pres-
1) Open the latch on the air filter and re-
sure differential indicator on the air filter, the best
move the back cover.
filter efficiency can be ensured and the service life
2) Take out the main filter element care- of the filter element can be prolonged.
fully so as to avoid any dust to fall into
the filter housing.
3) Clean the inner of the air filter with a

piece of wet rag. Make sure there is no
dust left in it.
4) Install a new main filter element prop-

erly. Otherwise, it could not provide pro-
tection for the engine.
5) Assemble the back cover and close the

latch.
2. Replacement of safety element
The safety filter should be replaced when:

• The maintenance and replacement interval of filter
1) The main filter element has been re- element should be shortened if it is used in dusty
placed 2 times or the safety filter is environment. Daily empty and clean the dust cup.
damaged; • It is not recommended to clean the air filter ele-
ment except if a new element is not available.
2) Maintenance signal remains after a new
main filter element is mounted.
3. Cautions on cleaning the air filter

element:
1) Blow the element from its inside to out-

side with clean and dry compressed air
with pressure of not more than 500 kPa.
2) Let the compressed air blow along the

folded direction of the filter paper, and
lateral movement is not allowed.

3) Don’t directly point at the filter ele-

ment. Let the compressed air blow at
about 45° against the filter element.
4) Stop cleaning and replace the filter ele-

ment if any damage on the filter paper is
found during cleaning. It is forbidden to
use the damaged filter element.
5) The service life of the filter element

cleaned is shorter than that for a new
one. After cleaning the filter element
maintenance interval will be shortened
to about 60% of the new one.
6) The filter element could not be cleaned

more than 2 times. Otherwise, its role
will reduce close to zero. When instal-
ling the filter element and back cover,
make sure that they are tightened and
sealed with the opening of dust valve
downward.
7) It is not allowed to clean the safety

element.
Replace the filter element if damage is

found under light. If no damage is found, it
may be re-used after cleaning.

3-4 Filter element inspection method

No damage in lamp- Damaged in lamplight,
Ⅰ Ⅱ
light, continue to use replace it
3.1.6 Radiator
Visually check pipelines and hoses for leakage and damage. Repair or replace the radiator if damage or
trouble is found.
Make sure that all pipelines and hoses are not damaged or scratched. Verify pipelines and hoses
are properly installed.
1. Examine the outside of the radiator and clean when necessary

Clean the radiator after using it in dusty environments for long periods of time. Blow impurities (dust,
dead insects, and other debris) out of the radiator fins by using compressed air, or remove the foreign
bodies on the back of the radiator with water (in the opposite direction of the cooling air).
• Clean the radiator with proper pressure. Otherwise the radiator fins may be damaged.
• During cleaning, move the pressure washer continuously.

Never directly point at electric components and wire connectors. Otherwise, it will result in short
circuit, damage of electric components, even personal injury.
Never directly point at the following items in order to avoid damage to components:
• Electrical components
• Connectors
• Sealing parts
• Radiator core fins
2. Clean the radiator water line
Mix water and light alkaline cleaning compound to form a cleaning solution with 5% concentration and
then add the solution into the cooling system. Preheat the engine at proper speed to approximately 83℃
(anti-freeze coolant thermostat begins to open) and shut down the engine after running about 5 minutes.
When the engine cools to around 50℃, drain out the cleaning solution, and refill the system with clean
soft water. Start and preheat the engine, drain out the water after 5 minutes. And then repeat the opera-
tion again.
3.1.7 After-treatment device/SCR system (for China V)
1. Function and structure

The SCR system is a catalytic reduction device that is installed in the engine exhaust system and can re-
solve the NOX in the engine exhaust emissions into N2 and O2, also called after-treatment device. The
SCR system consists of AdBlue tank, AdBlue pump, Nozzle, Catalytic silencer, AdBlue piping and con-
trol unit, as shown in the figure followed.
In the SCR system, AdBlue solution is used as a reducing agent. It is injected into the exhaust pipe and
decomposed into CO2 and ammonia under the action of exhaust temperature and gasification. As a re-
ducing agent, the ammonia reduces NOX in the engine exhaust emissions into pollution-free N2 and
H2O.

Air filter
Supercharger
Intercooler
Engine
Catalytic Nozzle
silencer
AdBlue pump AdBlue pump
2. Regular check and maintenance

Check the AdBlue piping for tightness, leakage and torsion. Check the air pressure of the AdBlue pump
every half year, and regularly check the AdBlue tank for tightness and abrasion.
3.1.8 SCR system (for China VI)
1. The after-treatment system for China VI engine consists of DOC, DPF, SCR, DPM, AdBlue injection
system, etc. Engine exhaust will enter the DOC when it meets the homogeneity requirement under the
effect of the perforated plate at the air inlet after it passes the air inlet and enters the DOC-DPF-SCR as-
sembly. HC, CO and SOF will be effectively reduced in the exhaust processed by the DOC. Then the
exhaust will enter the DPF for filtration. After the PM and PN meet requirements of the regulations, the
exhaust will enter the AdBlue mixing pipe to fully mix with the AdBlue injected from the AdBlue noz-
zle and isolate NH3. The gas with the exhaust and NH3 mixed will enter the SCR. Under the effect of
the catalyst, NOx will be degraded, so NOx can be reduced. Finally, the exhaust processed by the DOC-
DPF-SCR assembly will enter the atmosphere. The after-treatment system for China VI engine is shown
in the figure below.

Differential
Fuel injection pressure AdBlue injection unit
unit
Temperature sensor Temperature
Temperature sensor sensor Temperature
sensor sensor
N2 and O2 N2 and O2
sensor sensor
1) Check and add AdBlue solution regularly.

AdBlue solution (in accordance with GB 29518 Diesel engine NOx reduction agent — Aqueous urea
solution AUS32) shall be purchased from an authorized dealer or a professional manufacturer. Pro-
fessional filling equipment shall be used to add the AdBlue solution to prevent splashing of the AdBl-
ue solution.
2) Check the AdBlue pump’s filter element.

During each time of maintenance, remove the AdBlue pump’s filter element, clean it with clean
water, and then install it. Do not knock the filter element with force.
3) Clean the AdBlue tank and system pipeline.

Clean the AdBlue tank regularly to prevent blockage and wear to the AdBlue pump caused by par-
ticles and impurities in the tank; the AdBlue tank sensor is an intelligent sensor and responsible for
measuring the liquid level and AdBlue concentration, corresponding to data in the engine ECU. OBD
fault can be caused if a mismatched AdBlue tank is used, which will lead to limiting engine torque. If
the AdBlue tank needs to be replaced, an AdBlue tank with the same model from the original manu-
facturer is required.
Maintenance in a designated service station is required after the machine has traveled 50,000 km or
been used for over 6 months. The maintenance includes: replacing the 3D filter screen of AdBlue lev-
el sensor & main filter element of the AdBlue pump, unchoking & cleaning the AdBlue pump, and
cleaning the AdBlue nozzle, the AdBlue tank, and the system pipeline.
After the engine stops, the SCR system will automatically enter the suck-back state, so the AdBl-
ue solution in the AdBlue pipeline will be sucked back to the AdBlue tank. This process will keep
for 2 minutes, during which, the vehicle’s main power switch cannot be turned off.
3. DPF system maintenance

The maintenance of the DPF system mainly refers to the process of removing ash from the DPF carrier.
If the DPF active regeneration function fails or the active regeneration is prohibited due to excessive
DPF carbon deposition, the vehicle must be driven to the service station for ash cleaning as soon as pos-
sible. Unpermitted dismantling and repair are prohibited.

3.1.9 Trouble indicator lamp
Fault indicator lamps are divided into the “MIL" lamp (indicating faults related to emission) and the
"TEST" lamp (indicating faults not related to emission). Schematic diagrams of the two indicators are as
follows:
Figure 3-5 MIL lamp
TEST
Figure 3-6 TEST lamp
ECU will store fault codes once faults are identified, and take corresponding measures according to types
and severity of the faults. ECU can store 10 fault codes at most.
Status and fault conditions of the “MIL" lamp and "TEST" lamps are as follows:
1. If both the “TEST” lamp and the “MIL” lamp are off although there is a fault, the fault is minor
and does not affect normal driving or exhaust emission. This fault may not be noticed by the driver.
2. If the “TEST” lamp turns on, the fault is serious but has nothing to do with the emission. Immediate
inspection is required. Some serious faults may cause limiting diesel engine torque, so the vehicle enters
the “limp home mode”. A few extremely serious faults will lead to engine stop due to oil injection
stoppage in the diesel engine. When these faults are eliminated, the "TEST" lamp turns off.
3. When the "MIL" lamp is on, the fault is serious and is related to emission. Immediate inspection is re-
quired. Some serious faults may cause limiting diesel engine torque, so the vehicle enters the “limp
home mode”. After all these faults are eliminated, the “MIL" lamp will not turn off immediately. It
will turn off only after no corresponding faults are identified during 3 consecutive working cycles.
3.1.10 Inspection of air intake and exhaust pipelines
Before daily work or when carrying out maintenance, check the air intake and exhaust pipelines and con-
nectors, including all hose connectors and the end cap of air filter housing.

OK
OK OK OK OK
Figure 3-7 Inspection of air intake and exhaust pipelines
1. Check the air intake hoses for twist and deformation, and clips for looseness.
2. Check the hoses for damage, and connection for tightness.
3. Check the pipe brackets for looseness, and connection for tightness.
Replace the deformed or damaged hoses and clips in time if any problems are found. Record mainte-
nance items in the maintenance log.
Keep the air intake pipeline clean. Any impurity entering into the engine cylinder will lead to seri-
ous wear of piston ring.
3.2 Drive system

3.2.1 Transmission system
The drive system consists of transmission, transfer box, PTO, propeller shafts and drive axles, etc. The ba-
sic function of the drive system is to reliably and stably transfer the power from the engine to the drive
wheels, so that the vehicle may travel.

Figure 3-8 Drive system
No. Name No. Name

1 Engine 2 PTO
3 Propeller shaft 4 Axle
5 Transmission
During traveling, the following items should be checked:

1. Check if the reverse gear can be locked or not, or if shift gear is normal, if there is abnormal sound.
2. Check propeller shafts for abnormal sound and tremble; check the main reducer and differential of
drive axle for abnormal sound.
• Transmission, transfer box and shift gear mechanism belong to precision parts, which should be
maintained and adjusted by professional. It is not recommended for user to remove them.
• Maintain the transmission according to the supplied Transmission Maintenance Manual.
• If there is any trouble in the hydraulic motor, please directly contact local XCMG office, or dial
hotline 4000015678 for maintenance.
3.2.2 Clutch
As an important part of drive system, the clutch is used to make sure the vehicle is stably moved, gear
shifting is smoothly carried out and to prevent the drive system from overloading.
Pull-type clutch is used for the chassis.
The clutch is controlled by braking liquid with the aid of air-assisted device. Depress clutch pedal to the
bottom of its stroke so that clutch friction disc can disengage from engine flywheel fully, to cut out
power.
Refer to the figure below for its control diagram.

Ⅵ Ⅴ
Ⅳ Ⅲ
Figure 3-9 Manipulation of clutch
No. Name No. Name

Ⅰ Foot pedal Ⅱ Oil cup
Ⅲ Clutch branch cylinder Ⅳ Clutch release fork
Ⅴ Clutch master cylinder Ⅵ Lock nut
pushrod

Lubrication of clutch control mechanism, inspection of clutch oil level, refilling oil and bleeding air,
check and adjustment of free stroke of clutch pedal, and inspection of clutch working condition are
included.
1) Lubrication of clutch control mechanism

For the coupled kinematic pair of clutch control mechanism, grease is used for lubrication for the
most parts of mechanism, timely lubrication can slow down the abrasion, especially for the release
bearing that takes a heavy load, has a high rotation speed and is susceptible to wear and damage.
Generally, the lubrication interval for traveling vehicles is every 4000-5000km and every 6000-
8000km for lubricating the space between clutch pedal shaft and clutch bracket depending on the
feeling of your feet .

• Before filling braking fluid for the clutch, clean the area around the clutch oil cup to prevent
dust or foreign matters from entering into the clutch mechanism.
• Braking fluid will corrode the painting surface of the crane, so if there is braking fluid
sprayed on the surface when replenishing braking fluid, flush it immediately with clean
water.
• Contact our customer service staff for support if there are impurities in the oil cup of clutch.
• If the braking fluid needs to be replaced, the residual fluid must be drained out completely.
The job to replace the braking fluid shall be done by customer service staff from XCMG.
2) Inspection of clutch oil level, refilling oil and bleeding air,
①Observe the level of braking fluid through the oil cup located inside the maintenance covering in
front of driver's cab. It should be between 3/4~4/5 of the cup height;
②If the level is out of the scope, check the pipelines for leakage. Refill or drain out oil according to
the actual condition. Refer to the table for “Oil brands, filling amount and interval”.
③Air shall be bled off from clutch hydraulic control system after refilling, the method is shown as
follows:
a. Remove the rubber cover on the branch cylinder bleeding cap.
b. Continuously depress the clutch pedal to maximum stroke until it is heavy to depress, and then
hold it down at the maximum stroke.
c. Loosen the bleeding cap on the clutch branch cylinder slightly, at this time there is air bubble
out of the bleeding cap. And then tighten the bleeding cap immediately, and release the clutch
pedal.
d. Repeat above procedures until there is no bubble in the brake oil spraying out of the bleeding
cap. During operation pay attention to the oil level in the oil cup and replenish oil according to
requirements.

No. Name
Ⅰ Clutch branch cylinder
At least two persons are needed to coordinate for bleeding the system.
3) Check and adjust the free stroke of clutch pedal

The clutch transfers the engine power via the friction. While the vehicle is traveling, the clutch is en-
gaged and disengaged frequently. As a result, the friction disc will become thinner due to friction,
which will further lead to decreased free stroke of clutch pedal. When the free stroke approaches
zero, the pressing force will also decrease, which will affect the normal transmission of engine power
and cause a series of faults. On the contrary, if the free stroke is too large, the effective stroke of
clutch pedal will be reduced during disengagement, and the clutch spider will continue to rotate, re-
sulting in incomplete disengagement.
It is necessary to check the free stroke of clutch pedal frequently and adjust it to the standard value.
The pedal clearance depends on the lever ratio of the operating mechanism and is normally 30-40
mm. Generally speaking, the free stroke of clutch pedal needs to be inspected and adjusted every
3000~5000 km. If the control parts are all right but the clutch slips, it’s necessary to check the
clutch friction lining and spiral spring for effectiveness.
①Adjustment of the clutch main cylinder pushrod:
a. Firstly, release the lock nut of clutch master cylinder pushrod;
b. secondly, screw in the master cylinder push rod till it contact the spherical surface of the master
cylinder, and then screw the push rod out 1/2 ~1 turn.
c. thirdly, keep the hexagonal nut on the master cylinder pushrod stationary, and then tighten the
lock nut with a wrench.
②Method for adjusting pushrod length of clutch branch cylinder
a. Loose the lock nut on the pushrod

and
b. rotate the pushrod to prolong or shorten its length according to actual requirement. A clearance
of 3±0.5mm between the bearing end face of clutch sleeve and the end face of declutching lever
should be ensured.
c. Tighten the lock nut after adjustment.
4) Checking the clutch

When the pressure in the pneumatic circuit exceeds 0.45MPa, if it is heavy to depress the clutch ped-
al, check the brake oil in the clutch operating mechanism, i.e. check if there is air in the pipeline be-
tween the main cylinder and branch cylinder, and check if there is any trouble in the branch cylinder.
If, after the clutch pedal is pressed the branch cylinder works slowly, or when the clutch pedal is not
pressed the branch cylinder begins to work, it means that the clearance between the pushrod of main
cylinder and the main cylinder is not proper, it needs to be readjusted.
Air may enter the pipe when checking or repairing the clutch hydraulic control system. The air may
also enter the hydraulic system when refilling the braking fluid. Bleed off the air in the clutch hy-
draulic control system after repairing and refilling. Otherwise, the pedal's working stroke will de-
crease, resulting in incomplete disengagement.
3.2.3 Transmission
1. Structure and function

The transmission consists of operating mechanism, variable speed drive mechanism and power take-off.
It takes the roles of shift gear, transferring and interrupting power. Meanwhile, the transmission is
matched with a PTO, transferring power for running of the hydraulic oil pump.
Select proper transmission lubricant. It not only may save fuel, but also improve the economical effi-
ciency of the vehicle. At the same time, this may prolong the service life of the parts to be lubricated.
The models and filling amount of gear oils are shown in Table 2-2. If the gear oil in the transmission
contains excessive impurity or is insufficient, it will result in damage to the moving parts. If the gear oil
is excessive, it will increase power loss and oil temperature rise. Regularly check the condition and level
of the gear oil according to maintenance requirements.
1) Checking the level of transmission oil and refilling oil

Park the crane on a level ground when checking the level of transmission oil and refill oil. The hot
oil's volume will expand. In order to get exact measurement, do not check the oil level as soon as the
crane stops. Check the oil level when the oil cools (below 40 ℃).

In the event that the driver is required to leave the crane while the engine is running, before
leaving the crane, the following must be done:
• Shift the transmission into N (Neutral position).

• Make sure that the engine runs at low idle speed (500 rpm-800 rpm).
• Apply parking brake and make sure it is engaged properly.
• Place wedges under the wheels or take other necessary measures to prevent the vehicle from
moving.
Checking procedure:
Remove the screw plug of sight hole to observe the transmission oil level as following figure shown.
The oil level should be the same level as the sight hole’s lower edge. If the coolant level is too low,
add oil.
Figure 3-10 Location of transmission oil filler
No. Name No. Name

1 Transmission oil filler 2 Transmission drain
plug
3 Sight hole

Ⅰ Ⅱ Ⅲ
Figure 3-11 Location of transmission oil filler
No. Name No. Name

Ⅰ Excessive oil Ⅱ Deficient oil
Appropriate oil
Ⅲ
quantity
• Park the crane on a level ground when checking the level of transmission oil. Otherwise, the
correct level of oil could not be determined.
• Too little oil causes lubricating problems of moving parts and reduces the service life of the
gear.
• Too much oil causes more displacement work and overheats the gear!
2) Replacing the oil
The procedure for replacing the transmission gear oil is as follows:
①Park the crane and make sure it is in horizontal position; Screw out the drain plug while the trans-
mission is warm;
②Drain the used oil into a container, and dispose it according to the environmental protection re-
quirements. Completely drain out the gear oil containing impurity, and remove the metal chips on
the drain plugs;
③Before screwing in the drain plug, coat a little sealant beginning from the third thread of the plug;
④Tighten the plug;
⑤Screw out the filler plug;
⑥Refill gear oil to the specified level;
⑦Before screwing in the filler plug, coat a little sealant beginning from the third thread of the plug;
⑧Tighten the filler plugs.

• Prior to reassembly, make sure that the seal rings of drain plug, filler plug and safety plug
are new.
• Too little oil causes lubricating problems of moving parts and reduces the service life of the
gear. Too much oil causes more displacement work and overheats the gear!
• Do not mix different brands of oil. Do not add additives and friction modifier in lubricating
oil.
• Replace oil according to the specified intervals.
• Shorten the interval if the crane is used in severe operating conditions and working environ-
ment, which mean that the crane is under heavy load and/or working in dusty
environments.
Always use caution when handling hot transmission oil and parts. Allow the oil and parts to
cool before servicing. To prevent possible fire, never allow transmission oil to contact hot
parts.
3. Towing
During work of transmission, transmission shaft and gear keep turning, which can provide adequate lu-
brication for the transmission. When the crane is towed with rear wheels on the ground and drive train
connected, the middle shaft gear and main shaft gear of main transmission do not rotate, while the main
shaft driven by the rear wheels is rotating at high speed, which will result in damage to the transmission
due to lack of lubrication.
When towing the vehicle is necessary, remove the half shaft or disconnect the drive shaft, or keep the
drive wheels off the ground.

Serious gearbox internal damage is likely to be the result of incorrect towing.
3.2.4 Propeller shaft

In general, the propeller shaft consists of universal joint, medium drive shaft and bearing assembly as
shown in the figure followed. It is used to transfer the engine power passed by the transmission to the
drive axles and so on. The PTO drive shaft will transfer torque for the hydraulic pump if it is available.
Ⅱ
Ⅲ
Figure 3-12 Propeller shaft diagram
No. Name No. Name

Ⅰ Bearing bowls Ⅱ Cross shaft
Ⅲ Spline
The bearing seat of intermediate support assembly is located in a rubber mat, which can absorb part of
the propeller shaft's vibration and reduce noise, and can accommodate to the error of shaft installation
angle, reducing the additional load on the bearing.

2. Regular maintenance and service

In the process of vehicle running, the propeller shaft is a rotating and vibrating part. During inspection
and maintenance, it is necessary to apply grease to the propeller shaft, and to check the connection of
the propeller shaft.
1) Lubricating the propeller shaft

The propeller shaft should be regularly lubricated. Refer to section for details.
Failure of propeller shaft is mainly caused by improper maintenance during use, i.e. no grease
is applied at regular intervals or non-compliant grease is applied, which lead to the damage to
the cross shaft and bearing bowls. Maintain the propeller shaft at regular intervals.
2) Tightening connections
Frequently check connecting nuts for looseness during use of the propeller shaft and tighten them ac-
cording to the specified tightening torque. See the tightening torque table for specific tightening
torque.
High-tension bolts should not be used again after removing. If there are no spare bolts avail-
able, the bolts removed can be used again only after they are approved by professional engi-
neer, and at most twice.
3) Checking the propeller shaft

Regularly check the propeller shaft to see if the connection between the cross shaft and bearing bowl
is loose or worn, the rubber mat of intermediate support for aging, damage or coming off. If repair is
necessary, please contact XCMG customer service center.

3.3 Travel system

3.3.1 Axle
The travel system mainly includes axles, wheels and suspensions. Its role is to accept the torque from
the engine that is transmitted by the transmission system and to ensure the vehicle driving normally
by the adhesive force between driving wheels and the road. While cooperating with the steering sys-
tem, the travel system ensures the vehicle moves according to the driver’s intention and handling
stability.
Axle is connected to frame by suspension and the wheels are installed on the axle. The function of axles is
to bear the vehicle load so as to keep the vehicle normally driving on roads. The axles can be divided into
drive axle and driven axle. The drive axle can be controlled by inter-axle differential and inter-wheel dif-
ferential to meet the need of different road conditions. The composition schematic diagram is shown
below.

No. Name No. Name

1 Hub 2 Steering tie rod
3 Steering knuckle 4 Rim reducer
5 Main reducer

Ⅰ Steering axle Ⅱ Drive axle

1. Lubrication and maintenance of the main

reducer and wheel reducer
Keeping proper level and quality of gear

oil in the axles may not only save fuel and
improve the vehicle economy, but also pro-
long the service life of driving axles. Refer Ⅰ
to Table “Oil brands, filling amount and
No. Name
interval” for selection of gear oil. The
Ⅰ Oil filler sight hole
procedure for replacing the oil is as
follows:
1) Position the vehicle on a flat ground and

have the drain plug of wheel assembly
face downward. Clean all filler ports and
drain ports, which are as shown on the
right. It’s better to clean them when the Ⅰ
vehicle in a warmer place or when the No. Name
machine is hot;
Ⅰ Drain port
2) Remove the drain plugs of the wheel re-

ducer, main reducer, inter-axle differen-
tial and axle package;
Ⅰ
Ⅱ
3) Drain the used oil into a container, and
Ⅲ
dispose it according to the environmental
Ⅳ
protection requirements. Completely
drain out the gear oil containing impur-
No. Name
ity, and remove the metal chips on the
Ⅰ Sight hole
drain plugs;
Ⅱ Oil filler
4) Clean the drain plug and replace the new Ⅲ Oil level
sealing gaskets and tighten them; Ⅳ Drain port
5) Remove the filler plugs of the wheel re-

ducer, main reducer, inter-axle differen-
tial and axle package;
6) Add new gear oil until it overflows from

the sight hole;

7) Repeat adding oil if the level drops, until

it stays at the specified level;
8) Before screwing in the filler plug, coat a

little sealant beginning from the third
thread of the plug;
9) Tighten the filler plugs.
If the vehicle is to be idle for a long time, it

is recommended to start the engine and run
the entire driveline every six months so as
to lubricate transmission parts and other re-
lated parts. Check the level of axle oil, take
measures to prevent water from entering
axle bodies and avoid rusting. If in a wet
environment, the brakes and related parts
should be protected doubly.
• Too little oil causes lubricating problems of moving parts and reduces the service life of the gear.
• Too much oil causes more displacement work and overheats the gear!
• When refilling oil, let the oil pass through the oil filter.
• The main reducer and wheel reducer of drive axle should be separately filled with oil.
• In a wet environment, brakes and related parts should be protected doubly. Regular operation
and maintenance of the braking system is essential.

2. Adjustment of toe-in
The procedure for toe-in adjustment is as

follows:
1) Preparation
①Park the crane on a firm and level S d1 S

road surface;
②Keep the front wheels in a location of

straight line driving and move forward Figure3-13 Checking the toe-in of front wheels
over 2 m.
2) Checking the toe-in of front wheels

Before checking, make sure the tire pressure con-
①Make a mark at the center of each forms to the specifications.
front wheel tire as shown in figure “
Checking the toe-in of front wheels”.
Ⅰ
②Measure the distance between the two Ⅱ
marks and record it as d1 (L1).
③Have the two tires move half turn by

moving them or driving the vehicle
forward, so that the marks come at the
rear of tires.
No. Name
④Measure the distance between the two
marks and record it as d2. Ⅰ Adjusting bolt
Ⅱ Steering tie rod

⑤The difference of two measured val-
ues is the toe-in value, which should
be in the range of 3mm~5mm.
3) Adjusting the toe-in of front wheels
①Loosen the bolt (one separately at the

left side and right side).
②Move the steering knuckle tie rod ac-

cording to the previous measured val-
ues. Move the rod forward to decrease

the toe-in value, move it backward to

increase the toe-in value.
③Repeat the checking steps of the toe-

in until the toe-in is in the permissible
range.
4) Use the same procedure to measure and

adjust the other toe-in.
3.3.2 Suspension
The suspension is used to connect axle to frame. Each suspension also plays the role of buffering, damping
and guiding. In general, a suspension consists of elastic elements, shock absorber, steering mechanism and
auxiliary components.
Leaf spring suspension is used as front suspension, and rubber suspension is used as rear suspension.
Suspensions also play the role of buffer, vibration reduction and guide.
• Check leaf springs and pivots for lubrication;
• Check U-bolts for tightness;
• Check leaf springs for corrosion and deformation;
• Check buffer block for abrasion;
• Keep rubber suspension appearance clean, check the rubber suspension for deformation, aging and
cracks.
No. Name
1 Buffer block

3.3.3 Wheel
The wheel consists of tire and rim as shown in the figure below. It bears the machine weight, ensures good
adhesiveness to road, transfers driving torque and brake torque, determines traveling direction, mitigates
impact from road and reduces vibration caused by such impact.
Ⅰ Ⅱ
No. Name No. Name

Ⅰ Rim Ⅱ Tire
1.
1) Rim rustiness;
2) Rim deflection and deformation;
3) Rim cracks;
4) Opening of the rim flange, mounting hole, and rim bolts and nuts.
After checking the rim, repair or replace the damaged or deformed parts at once. If paint is stripped,
repaint after rust is removed.
Do not weld the connections of bolts, and do not repair deformed rim bolts. Replace with new
ones.
2.
The following items should be regularly inspected:
1) If the type and specification of the two tires at an axle are identical.
2) The tread depth of the tire crown should not be less than 3.2mm;
3) The tire ply should not be exposed due to the partial wear of tire tread face.
4) There should not be crack and cut of more than 25 mm length and ply exposed depth on tire tread
face and side wall. There should not be defect, abnormal wear and deformation that will affect use.
5) The standard tire pressure should be 1.05±0.05MPa. The inflation pressure here means the cold tire
pressure that is measured before the vehicle travels or 3 hours after the vehicle stops. If measure the

pressure while the tires are hot, it will be 5%~10% higher than the cold tire pressure. Always check
the tire pressure when the tires are cold.
6) Check rim bolts and half shaft bolts for loss and tightness.
Regularly check the tires for damage, depth of tread and foreign particles, Frequently check the tire
pressure during long road trips. If the pressure decreases too quickly, check the reason for the air
leakage (for instance, check whether or not the tire has a puncture, a laceration or a leak in the valve
mouth).
3. Tire rotation
After 10,000 km of traveling, rotate the tires. Refer to the figure below.
Pay more attention to the following items during rotation:
1) Never scratch the bolt thread when replacing the wheels.
2) Never allow paint, grease or dirt on the touching surface between the brake drum and rim.
3) Keep the faces of the wheel nuts clean.
4) Coat the threads of wheel bolts and nuts with a little grease or oil.
5) Threads of all wheel nuts are right-handed. With the tires mounted and the wheels suspended, tighten
the nuts in the order of the diagonal rotation. Lower the wheels on the ground, and tighten the wheel
nuts with the tightening torque shown in “Tightening torque table”.
6) After tires get remounted, retighten wheel nuts once every 50 km of traveling according to
recommendations.
Figure 3-14 Tire rotation figure
No. Name
Ⅰ Forward direction

Pay more attention to the following items during replacement:
• The type and tread of the tires on an axle are the same.
• Radial tires should be installed on the axles at the same side.
• Never install used tires.
• After tire rotation, four-wheel positioning detection should be done by professional.
4. Abnormal abrasion of tires
1) Abrasion form and reason

If any one of the following problems is found, contact professional maintenance station for four-
wheel alignment.

1. Problems caused by incorrect position-

ing data.
Sawtooth abrasion due to excessive large toe-in
Sawtooth abrasion due to too small toe-in
Ⅰ Ⅰ
No. Name
Ⅰ Inside
Too large camber angle will cause outside abrasion,

which is more smooth.
Too small camber angle will cause inside abrasion,
which is more smooth. The deformation of axle hous-
ing also results in inside wear of wheel.
Symbol Explanation
Tire slipping direction
Tire slipping direction
Driving direction

2. Problems caused by tire pressure
Too high tire pressure, which will result in

aggravation of abrasion in the middle of
the tire, as shown in the figure on the right.
Too low tire pressure, which will result in

aggravation of abrasion at two sides of the
tire crown, as shown in the figure on the
right.
3. Problems caused by dynamic balance
Dynamic balance is not compliant with

standard, which will result in wavy abra-
sion at tire surface as shown in the figure
below.
4. There are clearances in the steering sys-

tem, including those between the con-
nections of bearing and ball head, which
will lead to abnormal tire abrasion, as
shown in the figure below.
Maintenance and storage of tires

Do not exceed the max. speed limit for tires. Over-speeding for a long time will overheat tires, which will
reduce the service life of tires. During driving, the driver should pay close attention to avoid obstacles. If
there is an obstacle in front of the vehicle (for example, a pit), the driver should respond in advance to
avoid it. If the driver cannot avoid the obstacle, the driver should slow down as far as possible.
Tires are made of rubber, so when driving and stopping the vehicle or when storing tires, never let tires
contact chemicals such as oil, acid, hydrocarbon or other chemicals. Contact could cause corrosion, defor-
mation and softening of tires. While storing, transporting and mounting tires, avoid damaging the bead
toe. Otherwise, air tightness will diminish and the tire will not function.
3.4 Braking system

3.4.1 Braking system
The braking system consists of service brake (foot brake), parking brake (hand brake) and auxiliary brake
(engine exhaust brake and engine retarder brake). The service brake is foot pedal control with double-cir-
cuit air pressure brake. The parking brake is air-release spring brake, which gives effect by the spring-

loaded air chamber on each axle. The air pressure brake circuit consists of air compressor, dryer and air
reservoirs, valves, brake, brake air chambers and pipeline.
• If the crane is to be idle for a long time, especially in a wet environment, the brakes and related
parts should be protected doubly. Regular operation and maintenance of braking system is es-
sential. It is recommended to drive the crane at least one time per 6 months.
• The braking system is very important and should be serviced and maintained by trained and pro-
fessional personnel. Improper adjustment and maintenance will lead to brake failure, which may
further cause property damage, personal injuries and even fatalities.
3.4.2 Air dryer

When the air compressor sucks air into the pneumatic circuit, water vapor in the air may be changed in-
to liquid water once again. The liquid water gathered in the pneumatic circuit will corrode the valve and
its seal, and wash away the grease. In extreme cold weather, the water vapor may freeze, which will
block the pneumatic circuit and result in damage to parts.
The air dryer will dry the air from the air compressor according to the adsorption principle. When the
unloading pressure of the dryer is reached, the air will be blown backward (by the regeneration air reser-
voir), thus the water sucked by the cartridge will be blown away, and then the cartridge may be used
again to dry air.
Figure 3-15 Dryer structure diagram

Regularly check and maintain if there is water deposited in each air reservoir (especially when it is used
in areas where humidity is higher). If water is found in the air reservoir that farthest from the air dryer,
carefully check or replace the air dryer.

Regularly replace the air dryer cylinder, at least every two years.
If there is oil in the water discharged by air dryer, it means that air compressor may fail, or the
desiccant of the air dryer comes into oil. Please contact XCMG customer service center for in-
specting or replacing the air dryer.
Replacement method is as follows:
1) Remove the old dryer cylinder and clean the connecting bolt and valve, as shown in the figure below.
Figure 3-16
2) Evenly coat a layer of grease on the matching surface of the new dryer cylinder and valve body, and
coat a little thread sealant on the matching surface of the dryer cylinder and the connecting bolt, as
shown in the figure below.
Figure 3-17
3) Properly put the new dryer cylinder on the valve body and tighten it with tightening torque of max.
15 N.m.

• Do not reversely connect the inlet and outlet. Otherwise, it will lead to the assembly failure.
• Before replacing the air dryer, make sure that the compressed air in the related air reservoir
has been bled.
3.4.3 Air reservoir
Open the drain valves by pulling the pull rings shown in the figure below. If there is water discharged only
from individual air reservoir, drain the air reservoir completely. If there is water discharged from more
than one air reservoir, it is necessary to replace the desiccant in the air dryers.
Figure 3-18
• Air leakage from drain valve may appear due to aged sealing ring. If this is found, replace with
the same type of drain valve as used before in time.
• There is compressed air in the air reservoir. Prior to disconnecting related brake pipeline and
valve body, make sure that the compressed air in related air reservoir has been released, in order
to ensure safe maintenance.
3.5 Steering system

3.5.1 Steering system
The steering system consists of steering wheel, steering gear, steering drop arm, steering pull rod and
steering hydraulic system, etc.
Operational steering system can ensure the vehicle changes traveling direction according to the driver's
will.
Checking of the steering system should include the following:
1. Check the bolt of steering gear bracket for tightness;

2. Check the connection of steering arm shaft and steering arm and tightness;
3. Check the connection of steering straight link connectors and tightness;
4. Check the steering gear for leakage and remove trouble, check and tighten the steering gearbox tighten-
ing bolt;
5. Check the hydraulic system pipeline and connectors for leakage;
6. Regularly check or replace sealing rings and oil seals;
7. Check the steering gearbox for cracks and damage;
8. Check the connector of oil outlet hose and the thread of oil pipe connector for damage.
9. Monthly check the level of oil in steering oil tank, and oil quantity.
3.5.2 Steering oil tank
Monthly check the oil level and oil quality of the steering oil tank. Refill if the oil is insufficient. Replace
the oil if there is too many impurities in it. Refer the “Oil brands, filling amount and interval” for oil
brand and filling quantity.
The following should be observed:
1. Open the cover of the steering oil tank and screw out the hose connector at the oil outlet of steering
gear.
2. Drain the used oil in the oil pump and the steering oil tank, and turn the steering wheel to its left and
right limits several times until there is no oil flowing out. Screw in the hose connector.
3. Take out the filter element from the oil tank, thoroughly clean, and reinstall to original position.
4. Add clean oil to the oil tank. In sight of oil permeation from the oil outlet port of steering gear, connect
and tighten the hose connector.
5. Rotate the steering wheel to the left and right limits for two times. Then, idle the engine and rotate the
steering wheel to the left and right limits for several times to bleed the air, till the oil level in the oil tank
drops no further and there is no presence of air bubble.
6. Add oil, till the oil level in the oil tank reaches the marking position.
7. Tighten the cover of the steering oil tank.
• After the engine is running, pay attention to the oil level, refill in time if oil is insufficient to pre-
vent oil overflow due to air suction.
• Before replacing the oil, lift the front axle tires off the ground.
• While disassembling and checking the oil line of steering system, keep clean the system, place the
parts in clean containers, wrap and seal the disassembled hose connected by plastic bag, and do
not carry any impurity into the system. Do not reversely connect the inlet and outlet of the steer-
ing gear. Connect inlet pipe and outlet pipe according to the arrows on the front cover of the
steering gear. The inlet oil is high pressure oil from oil pump and the outlet oil is low pressure oil
returning to the steering oil tank.

3.5.3 Steering gear

The role of the steering gear is to provide the assistance, lower output speed, change force transferring
direction and weaken the impact transferred to the steering wheel caused by the forces acting on wheels.
The structure of the steering gear is as shown in the figure.
Figure 3-19 Steering gear
No. Name No. Name

Pressure oil port for
1 2 Input shaft
right steering
3 Inlet 4 Outlet
Pressure oil port for
5 Mounting port 6
left steering
7 Output shaft
2. Inspection and maintenance
1) Check the fixing bolt of the steering gear for looseness;
2) Check the oil port of the steering gear for leakage. If there is oil leakage, replace gasket or tighten in-
terface bolts.
Do not reversely connect the inlet and outlet of the steering gear. Connect inlet pipe and outlet
pipe according to the arrows on the front cover of the steering gear. The inlet oil is high pressure
oil from oil pump and the outlet oil is low pressure oil returning to the steering oil tank.

3.6 Hydraulic system

3.6.1 Hydraulic system
Notes on maintenance and service of hydraulic system:

1. Prior to disassemble the hydraulic system remove the dirt on the surface of each part.
2. Removal and Repair of hydraulic components should be done where dust-resistance requirement may
be met.
3. The following items should be prepared in the operation room: Plastic plates, plastic bags, plastic plugs,
clean papers, adhesive tape, cleaning equipment, air compressor or high pressure air pipes and clean oil
barrels.
4. Keep tools clean.
5. Store the components disassembled in specialized cabinets or on shelves rather than on the ground.
• Release the pressure in the hydraulic system before disassembling it. Prior to disassembly of the
hydraulic system with accumulators attached, release the energy stored in the accumulators.
• Take care to disassemble the hydraulic system. Never knock any component. Avoid collision be-
tween components.
• Protect the thread and sealing surface of the component disassembled with adhesive tape. Keep
small components in plastic bags to prevent losing.
• Mark the oil pipes disassembled for correct reassembly.
• Clean the inner of the oil pipes disassembled with the cleaning equipment and dry them with
compressed air. Cover both ends of each oil pipe with plastic plugs. If no plastic plugs available,
use plastic bags, and secure the plastic bags with adhesive tape.
• Never use the shredded paper or rags instead of plastic plugs.
• Blindly disassemble hydraulic system without knowing the residual pressure in the system, major
machinery accident or personal accident may occur.
• Take proper measures to protect hydraulic components while repairing a hydraulic transmission
machinery. Do not allow electric current passing through oil cylinder while welding.
3.6.2 Hydraulic oil tank
If the hydraulic oil is seriously contaminated but not deteriorated, it should be filtrated for using again; if
the hydraulic oil has been deteriorated and cannot be used, it must be replaced, refer to the table “Oil
brands, filling amount and interval” for selection of hydraulic oil. Clean the oil tank before replacing hy-
draulic oil.
The oil tank assembly is as shown in the figure below. Notes on disassembly and assembly of the oil tank
are as follows:
1. Stow the boom and retract outriggers. Prior to disassembly of the hydraulic system with accumulators
attached, release the energy stored in the accumulators;
2. Screw out the drain plug below the oil tank to drain out the hydraulic oil in the tank, and then screw in
the drain plug;
3. Add proper new hydraulic oil to the oil tank and extend the outriggers, and then extend and retract the
telescoping cylinder 3~5 times and let the motor run several revolutions. Screw out the drain plug again
to drain the oil; repeat the steps 1~2;
4. Remove the suction filter, return filter and air filter from the hydraulic oil tank;
Figure 3-20 Hydraulic oil tank
No. Name No. Name

1 Oil filler 2 Sight glass with
thermometer
3 Suction port 4 Drain port
5 Return port
• The figure of the oil tank is only for illustration.

• Always disassemble hydraulic pipes with care. Otherwise, oil leakage or hydraulic element in-
operative will be caused.
• When taking out the suction filter, return filter and air filter assembly from the oil tank, take
care not to damage the surface, mounting face and sealing ring of the suction filter and return
filter.

5. Screw in the drain plug again. Add a little cleaning solution to the oil tank and clean it with a piece of
silk cloth or PVC resin sponge;
• It's better to take hydraulic oil or test oil as cleaning solution. Never use kerosene, gasoline, or
alcohol.
• Never use cotton cloth or cotton yarn to clean oil tank.
6. Screw out the drain plug to drain out the cleaning solution. Repeat cleaning one time and dry the oil
tank with clean compressed air;
7. Clean or replace filter elements;
8. Mount the cleaned or new filter elements on the oil tank;
• Filter screen and sealing ring should be replaced with new parts in principle. Coat them with
hydraulic oil before reassembly, take care not to damage them when assembling.
• Smoothen the minor scratches on the mounting surfaces of the suction filter and return filter
with a fine oilstone.
• In order to assemble suction filter and return filter easily, separately align the centers of the fil-
ters with the holes on the oil tank for mounting them.
9. After the hydraulic oil is replaced, there may be air existing in the oil suction chamber of hydraulic
pump, so bleed the air in the hydraulic pump.
Do not operate the pump if air is not bled. Consult XCMG customer service center or local dis-
tributor for questions about air bleeding of hydraulic pump.
3.6.3 Oil filter
Hydraulic system is unavoidably subject to be contaminated. In order to ensure normal system working
and a clean hydraulic system a suction filter and a return filter are fitted on the hydraulic tank. The suction
filter and return filter are the places where dust is likely to accumulate. Excessive accumulation will influ-
ence the flow of filters and the normal working of the hydraulic system.
Regularly replace filter elements. Clean the oil filters by using gasoline and polyester cloth or silk cloth.
First cleaning for the oil filters of a new crane should be done after 100 working days. Afterwards, clean
one time every 300 working days. Suction filter is equipped with a pressure gauge and a filter plugged
alarm. Clean or replace filter element when the reading of pressure gauge reaches the specified value or
the alarm sounds.
1. Cleaning the suction filter and return filter

No. Name No. Name

1 Sight glass with 2 Air filter
thermometer
3 Oil tank body 4 Suction filter screen
5 Return filter
1) Prior to disassembly of the hydraulic system with a accumulator attached, release the energy stored
in the accumulator.
Some hydraulic parts are under high pressure even after the engine stops. Before maintaining
the hydraulic system, release the pressure, so as to prevent injury to personnel.
2) Remove the suction filter, return filter and air filter from the hydraulic oil tank;
• Always disassemble hydraulic pipes with care. Otherwise, oil leakage or hydraulic element
inoperative will be caused.
• When taking out the suction filter, return filter and air filter assembly from the oil tank, take
care not to damage the surface, mounting face and sealing ring of the suction filter and re-
turn filter.
3) Clean them with proper cleaning solution, it's better to take hydraulic oil or test oil as cleaning solu-
tion. Never use kerosene, gasoline, or alcohol.

4) Filter screen and sealing ring should be replaced with new parts in principle. Coat them with hydraul-
ic oil before reassembly, take care not to damage them when assembling.
Smoothen the minor scratches on the mounting surfaces of the suction filter and return filter
with a fine oilstone.
5) In order to assemble suction filter and return filter easily, separately align the centers of the filters
with the holes on the oil tank for mounting them.
2. Replacement of suction filter element
Select a proper container under the suction port to prevent the hydraulic oil from leaking on the
ground, polluting the environment.
1) Put a special spanner in the slot on the filter cap
• It's better to wrap the spanner with a piece of cloth in order to prevent paint being
scratched.
• Disassemble the filter element smoothly as far as possible, in order to avoid the pollutants
absorbed by the filter falling into the hydraulic oil.
2) Anti-clockwise turn the spanner. A connecting rod may be used if the cap is too tight to open.
Never knock it, otherwise the thread will be stuck or damaged.
3) Take out the filter element with care.
Take care to ensure that the filter element will not collide with filter housing, and the pollu-
tants absorbed by the filter will not fall into the hydraulic oil.

1）
2）
3）
No. Name
1 Filter element
4) Replace the old filter element with a new one.
Replace the O-ring with a new one if it is damaged.
5) Put the new filter element into the filter housing.

6) Tighten the cap with the spanner, and check to make sure no leakage.
4）
Ⅰ
5）
6）
No. Explanation
Ⅰ O-ring inside
3. Replacement of return filter element
If the return filter is located at the side of the hydraulic oil tank (return port is lower than the oil
level), prior to replacement of the filter element, drain out the hydraulic oil in the tank.
1) Put a special spanner in the slot on the filter cap

• It's better to wrap the spanner with a piece of cloth in order to prevent paint being
scratched.
• Disassemble the filter element smoothly as far as possible, in order to avoid the pollutants
absorbed by the filter falling into the hydraulic oil.
2) Anti-clockwise turn the spanner. A connecting rod may be used if the cap is too tight to open.
Never knock it, otherwise the thread will be stuck or damaged.
3) Take out the filter element with care.
Take care to ensure that the filter element will not collide with filter housing, and the pollu-
tants absorbed by the filter will not fall into the hydraulic oil.

1）
2）
3）
No. Name
1 End cover
4) Remove the distribution sleeve and bypass valve. Replace the old filter element with a new one. Re-
install the distribution sleeve and bypass valve.
5) Put the new filter element into the filter housing.

6) Tighten the cap with the spanner, and check to make sure no leakage.
4）
5）
6）
No. Name No. Name

1 Distribution sleeve 2 Filter element
3 Bypass valve
4. Replacement of line filter (filter element)

Precautions for Operation
• Stow the boom.
• Stop the hydraulic pump.
Replace the filter element at the intervals shown below:

3.6.4 Hydraulic pump

Hydraulic pumps convert mechanical energy into hydraulic energy. They supply fluid to the compo-
nents in the hydraulic system. The hydraulic pump adopted by QY50KD truck crane is the gear pump.
Figure 3-21 Structural diagram of gear pump
No. Name No. Name

1 Driven gear 2 Inlet
3 Drive gear 4 Outlet
5 Cover 6 Driven shaft
7 Drive shaft 8 Shell
9 Key 10 Cover
1) Checking the hydraulic pump:
①Loose installation and damage
②Abnormal noise, vibration and heating
③Oil leakage
④Suction line condition (air entry)
⑤Delivery pressure

⑥Loose and leaking piping joints
2) Replace
If the pump needs replacement due to a flaw, be careful to minimize contamination of the system in
the process of dismounting and remounting it. Cover the oil ports with a plastic cloth.
After installation of a new oil pump is finished, refill the pump with hydraulic oil through two T ports
until it is full. Once the pipelines connect, the oil pump can operate after rotating for 15 minutes at an
idle speed.
• It is not recommended for customers to disassemble the hydraulic pump by themselves. If

there is any trouble in the hydraulic pump, please directly contact XCMG Customer service
center for maintenance.
• Be sure to remember the installation positions of each connector and part during
disassembling.
• It is not allowable to disassemble the hydraulic pump with hard tools such as hammer or
knock the hydraulic pump during disassembly.
• Keep all the parts clean before assembling into the pump. No impurities are allowed to enter
into the pump.
3.7 Battery
Battery may convert electric energy into chemical energy to store in the battery, it also may convert chemi-
cal energy into electric energy to supply power for electric appliances. The chassis battery mainly provides
power for the starter motor and radio, etc.
1. Checking battery
A maintenance free battery is used for the crane. Battery state indicator lamp is on the top surface of the
battery. The user can obtain the current battery status according to the indicator lamp and the corre-
sponding instructions, and then carry out corresponding maintenance.
1) Keep the battery clean and dry. Remove the terminals for cleaning if they are contaminated, and then
lubricate them with clean, acid-free and acid-proof grease;
2) Do not rest tools on the battery;
3) Do not remove the battery cable while the engine is running;
4) Remove the battery cable at the negative pole before that at the positive.
5) The battery voltage can be known by observing the instrument. If the voltage is below 22 V after the
key is turned to the ON position, or the voltage is below 16 V after the key is turned to the START
position, the engine could not be started normally. If the engine is not started (i.e the generator is not

working), it is not allowed to use high-power automotive electrical appliances for a long time, such
as air conditioning, radio, lighting, etc., to prevent the battery from deep discharging. Failure to do so
could result the fact that the engine could not be started, and battery will lack of electricity or be
damaged.
2. Maintenance of battery
1) When the vehicle is not in use, the power supply of the whole machine should be cut off. Sunlight
and rain should be avoided if possible.
2) When the vehicle is out of service for more than one week, the starter switch and the main power
switch should be cut off, or the battery and the electric system should be disconnected, to avoid the
battery discharging too fast.
3) If the crane is taken out of operation for more than one month, charge the battery until the voltage of
each unit is 12.6 V; afterwards, weekly check the battery. If the voltage of any single battery unit is
lower than 12.6 V or the charging indicator lamp illuminates, recharge the battery in time.
If charging the battery, charge it with DC power only. The charging power should not exceed 1/10 of the
battery capacity. For example: when charging a 180 Ah battery, the charging currency should not exceed
18 A.
See the notice on the battery for the charging state of the battery.
Figure 3-22 Battery
No. Explanation
Ⅰ Battery state indicator lamp

3.8 Driver’s cab

3.8.1 Air conditioner

The air conditioning system for engineering vehicles, such as cranes, mainly consists of evaporator,
condenser, compressor, accumulator and piping. The air conditioning system in the driver's cab works
through the compressor driven by the engine, as shown in the figure below.
Figure 3-23
No. Name No. Name

1 Compressor 2 Hose assembly
3 Condenser assembly 4 Hose assembly
5 Accumulator assembly 6 Hose assembly
7 Evaporator assembly 8 Hose assembly
2. Checking and refilling refrigerant

Check the refrigerant in the cooling system, that is observe the observation window on the top of the ac-
cumulator, which is located below the driver's cab. There is no air bubble appearing in normal state.
There are a little air bubbles appearing when the engine rotation speed changes.
Refrigerant should be refilled at qualified maintenance stations.

Figure 3-24
3. Check and maintenance
1) Daily checks
①Check and clean the condenser. Keep the heat sinks clean and there are no contaminants. Clean the
heat sinks with cool water or compressed air. Never use hot water or hot vapor.
②Check the drive belt of the compressor for tension.
③Check the hoses and their connection.
④Check the connection of the power supply for the cooling system in order to make sure that there
is no open circuit and short circuit.
2) Regular check and maintenance

Refer to Air conditioner instruction for details.
3.8.2 Other attachments
1. Windshield wipers: Check the windshield wipers weekly.
• Regularly check wiper blades, and remove the dust and foreign body.
• Add proper antifreeze to wiper cleaning liquid during winter.
• Never start the wipers without activating washer system.
2. Washer system inspection:
Check the level of cleaning liquid weekly.
Check whether the water jets are blocked.

If the crane is to be out of operation in humid areas such as the seaside, open the doors of
driver's cab at least once every week. Otherwise, the doors will be difficult to open due to
humidity.
3.9 Electrical system

3.9.1 Electrical system in the driver's cab
The main role of the electrical system in the driver's cab is to supply a platform for man-machine commu-
nication. The driver can know the vehicle information through the system and control the vehicle.
• Check the operation of instruments, and check the pointers of gauges for coming off;
• Check plug-in for looseness and wear;
• Check the switches and buttons for sensitivity and coming off;
• Check the display for proper indication, function of screen change and sensitivity of touch keys;
• Check the display for warning message or fault codes.
3.9.2 Lighting system
The chassis lighting system consists of all lamps on the chassis for illuminating, showing the vehicle
width, sending signals and so on.
Inspection and maintenance:
• Check the lamps for damage and brightness;
• Remove the dirt on the lamps;
• Check the illuminating range and angle of lamps.
3.9.3 Girder wiring harness assembly
The girder wiring harness assembly is the nerve system of chassis, which commands the movements of
chassis electric system.
• Check if lines are fixed firmly;
• Check the wiring harness for damage;
• Check the wiring harness connector for looseness;
• Check the wiring harness sealing for aging, looseness or damage;
• Check the wiring harness plug-in for looseness or damage;
• Check the wiring harness plug-in sealing;

• Check the wiring harness plug-in for water and oil dirt.
If blown fuse is used, replace it after it is damaged. It is not allowed to replace the blown fuse with
iron wire or copper wire, etc.
If resettable fuse is used, it can be reset by pressing the reset switch when the fuse is disconnected.
3.9.4 Battery
Battery may convert electric energy into chemical energy to store in the battery, it also may convert chemi-
cal energy into electric energy to supply power for electric appliances. The chassis battery mainly provides
power for the starter motor and radio, etc.
1. Checking battery
Maintenance free battery is used for the crane. Battery state indicator lamp is on the top surface of the
battery. The user can obtain the current battery status according to the indicator lamp and the corre-
sponding instructions, and then make the corresponding maintenance.
1) Keep the battery clean and dry. Remove the terminals for cleaning if they are contaminated, and then
lubricate them with clean, acid-free and acid-proof grease;
2) Do not rest tools on the battery;
3) Do not remove the battery cable while the engine is running;
4) Remove the battery cable at the negative pole before that at the positive.
5) The battery voltage can be known from the instrument. If the voltage is below 22 V after the key is
turned to the ON position, or the voltage is below 16 V after the key is turned to the START position,
the engine could not be started normally. If the engine is not started (i.e the generator is not working),
it is not allowed to use high-power automotive electrical appliances for a long time, such as air condi-
tioning, radio, lighting, etc., to prevent the battery from deep discharging. If fail to do so, the engine
will be unable to get started, and the battery be lack of electricity or damaged.
2. Maintenance of battery
1) If the crane is taken out of operation, turn off the main power switch, and park the crane at a place
where is free exposure of sunshine and rain as far as possible.
2) If the crane is taken out of operation for more than one week, turn off the starter switch and the main
power switch, and disconnect the electrical system from battery to prevent the battery from
discharging.

3) If the crane is taken out of operation for more than one month, charge the battery until the voltage of
each unit is above 12.6 V; afterwards, weekly check the battery. If the voltage of any single battery
unit is lower than 12.6 V or the charging indicator lamp illuminates, recharge the battery in time.
If charging the battery, charge it with DC power only. The charging power should not exceed 1/10 of the
battery capacity. For example: when charging a 180 Ah battery, the charging currency should not exceed
18 A.
Refer to the state of charge on the battery to view its charging state.
Figure 3-25 Battery


Chapter 4 Maintenance and service of systems for lifting

operations
4.1 Maintenance and service of systems for lifting operations

The crane has been tested and commissioned at the factory, but some deviation will occur during operation
due to wear, corrosion and environmental change, as well as damage due to external forces and service
condition changes. So after delivery the crane should be checked every year by experienced professional
technician. Refer to Chinese standards GB/T 3811 and GB/T 6067 for details. Products, which are in-
tended to be sold to other countries or regions, shall comply with local standards.
Experienced professional technician is a person who is trained on the machines to be serviced and has ex-
perience with the maintenance of cranes and is familiar with their unique standards and regulations.
A professional engineer is someone who engages in crane design, has a great deal of experience in manu-
facturing and maintaining cranes, is familiar with related standards and regulations, and can estimate if a
crane is in safe operating condition through inspection.
Re-inspection of the crane is a visual check of the crane and its parts and is conducted by a professional
engineer/ technician. Potential safety hazards may be found during inspections and repairs made in order
to keep the crane operating safely.
After overhaul of crane or maintenance of dynamic load-bearing members and before reuse, the
crane must be approved by professional technical personnel from our company, otherwise the re-
sulting responsibility for any accident will be borne by yourself.
Important items that should be checked by a professional engineer/ technician are shown below.
Be sure to perform pre-operational inspections of:
1. Outrigger structure;
2. Crane mechanisms: boom swinging, luffing and telescoping and rope winding;
3. Brake systems;
4. Electrical system;
5. Hydraulic system;
6. Safety devices.
4.2 Outrigger system

4.2.1 Outrigger system
The outrigger system is used to support the crane and level the vehicle. H-type outrigger system is adopted
for the crane. Outrigger composition is as shown in the figure below.
Maintenance and service of systems for lifting operations 4-1

Figure 4-1 Outrigger composition
No. Name No. Name

1 Outrigger float 2 Jack cylinder
3 Outrigger beam 4 Outrigger pin

5 Outrigger box
The locations of outrigger sliders should be adjusted as shown in the figure below if the sliders are seri-
ously worn.
4-2 Maintenance and service of systems for lifting operations

Figure 4-2 Adjusting bolts
No. Name
Ⅰ Adjusting bolt
4.3 Slewing system

4.3.1 Slewing system
The slewing system consists of slewing ring and slewing gear, contributing to the slewing movements of
the crane's superstructure.
The slewing ring is used to connect the superstructure and chassis of the crane. The inner circle of the
slewing ring connects with the turntable and the outer toothed circle connects with the frame. By the slew-
ing ring, the superstructure dead weight, the weight and tipping moment of load are transferred to the
chassis.
The slewing gear is the drive unit that controls the slewing movements of the crane's superstructure. The
slewing gear installed on the turntable consists of a slewing reducer and a hydraulic motor as shown in the
figure. The low-speed hydraulic motor drives planetary reducer to output power through the pinion, which
results in an external meshing action with the slewing ring fixed on the frame. The turntable's revolution
keeps the superstructure rotating.

Figure 4-3 Slewing system
No. Name No. Name

1 Slewing ring 2 Slewing reducer
3 Slewing motor
Slewing ring

The slewing support is the support device of the crane slewing unit. It can bear the superstructure dead
weight, the weight and moment of load. The slewing ring has a four-point contact ball structure. The in-
ner circle of the slewing ring connects with the turntable and the outer toothed circle connects with the
frame through high-tensile bolts. The steel ball sits between the inner and outer circles to make contact
with the circular arc sliding track at four points. It can bear axial force and radial force.
Figure 4-4 Slewing ring structure
No. Name No. Name

1 Bolt 1 2 Slewing ring
3 Bolt 2

• Check the bolts for looseness, missing or damage. Examine the pre-tightening force of the bolts after
the slewing ring operates for 100 hours. Thereafter, examine the bolts every 500 operating hours. Re-
fer to Appendix for the tightening torque.
• The bolts connecting with the slewing ring must be high-tensile bolts. Always use high-
tensile bolts when replacing the slewing ring bolts to ensure the security of the slewing ring.
• The bolts should be replaced by professional service personnel.
• Tighten the nuts in the order of diagonal rotation.
• In general, lubricate the slewing track every 100 operating hours. Refill grease until grease leaks from
the seal of the slewing track. If the optional automatic lubrication system is selected, the slewing ring
may be automatically lubricated at the pre-set interval.
• The tooth surfaces should be cleaned every ten days, and coated with new grease.
• Pay attention to the change of noise and slewing resistance. Carry out inspection and repair immedi-
ately if abnormal phenomenon occurs.
• Check the axial clearance and radial clearance of the slewing ring, as shown in the table followed.
Diameter of track center
Axial clearance Radial clearance
circle
1555 0.08~0.45 0.08~0.45
• During crane operation, pay attention to the operating condition of the slewing ring. If abnormal phe-
nomenon occurs, such as noise, shock or abrupt increased slewing speed, stop operation to check and
remove the trouble. Disassemble the slewing ring for checking if necessary.
• Never clean the slewing ring with a high pressure sprayer.

• Never allow harder foreign bodies to enter into the meshing tooth area of the slewing ring.
• Crush or shear hazard! During maintenance of the slewing ring, take care not to be caught by
the slewing pinion.
• During slewing and elevating operation, keep all personnel away from the dangerous areas, such
as the area between the boom/turntable and slewing ring, or the area between the frame and
slewing ring.
Slewing motor


Piston motor is used for the crane. It is one of actuators in the hydraulic system. The function of the hy-
draulic motor is to translate hydraulic energy into mechanical energy.
Figure 4-5 Hydraulic motor diagram
No. Name No. Name

Suction port and return
1 Outlet 2
port
1) Check
When there is no pressure in the hydraulic motor, examine the case drain line in the motor for leak-
age. The motor can still work without troubles if small leakage exists. Large oil leakage severely re-
duces pressure in the motor.
2) Replace
If the motor must be replaced due to a flaw, be careful to minimize contamination of the system in
the process of dismounting and remounting it. Cover the oil ports with plastic cloth in time.
• It is not recommended for customers to disassemble the hydraulic motor by themselves. If

there is any trouble in the hydraulic motor, please directly contact local XCMG office, or dial
hotline 4000015678 for maintenance.
• Be sure to remember the installation positions of each connector and part during
disassembling.
• It is not allowable to disassemble the hydraulic motor with hard tools such as hammer or
knock the hydraulic motor during disassembly. Keep all the parts clean before assembling into
the motor. No impurities are allowed to enter into the motor.
Slewing reducer

The slewing reducer should be periodically lubricated during use. Do not mix different brands of gear oil.
Otherwise, the character of each gear oil will be changed, which will cause damage to the equipment.
When refilling gear oil, use the same brand of oil that was used previously.
1. Refilling and replacing the gear oil
It is recommended to replace the oil by the following steps.
1) Remove the filler plug together with the dip stick;
2) Loosen the drain plug and drain the oil into a prepared container as shown in the figure below;
3) Before refilling with fresh oil, wash the gear system with diesel oil or kerosene;
4) Clean the drain plug and tighten it;
5) Fill with fresh oil to the marked level;
6) Tighten the oil plug and install the dipstick.
• Follow the guidelines of the EPA or other governmental agencies for proper disposal of used
oil.
• Prior to removing plugs, clean the dirt and foreign matter around the plugs so as to prevent oil
from being contaminated.
• Clean the plugs and sealing surfaces on the housing. Install the plugs with new seal washers
and tighten them.
Figure 4-6 Slewing reducer

No. Name No. Name

Suction port and return
1 Outlet 2
port
3 Slewing motor 4 Slewing reducer

• Examine the pinion every week. Inspect for oil leakage and abnormal sounds.
• Check the oil level of the slewing reducer every 100 operating hours, and regularly replace the oil.
Check the oil level only when the slewing system has stopped and the oil temperature is close
to the ambient temperature.
• Check the bolts of slewing gear for tightness, missing or damage. Examine the tightening torque of
the bolts every 500 operating hours. Refer to Appendix for the tightening torque.
• The brake installed on the slewing reducer is multi-disc wet brake, which is normally in a closed
state. When pressurized oil flows into the brake, the brake is in open state, and then the slewing gear
may freely rotate. When any one of the following occurs, the related parts should be replaced:
– Oil leaks out of the input end or the oil seal is damaged and needs to be replaced.
– Insufficient braking torque: serious friction or deformed friction lining will result in reduced brak-
ing torque. Replace the friction lining.
• Never allow the slewing gear to work or to be stored in a corrosive environment, in which it will be
subjected to acid or alkali gas. During operations, the rated load of the slewing gear shall not be
exceeded.
• When the fixed disc brake is failing, over-heating or having maintenance performed, replace
the following components: friction disc, spring, and seal.
• Slewing reducer has eccentricity regulating function. When slewing meshing clearance is not
proper, it may be regulated by rotating the installation position of the slewing reducer. Dur-
ing assembly of the slewing gear, pay attention to installation direction and make sure of the
slewing clearance. The slewing meshing clearance should be measured by professional main-
tenance personnel.

4.4 Boom telescoping system

4.4.1 Boom telescoping system
The boom is the main component to which force is applied; it bears the weight of load to be lifted, wind
load and other loads during operation besides its dead weight. The telescoping system activates changes in
the boom length, which mainly consists of telescoping cylinder and ropes.
The crane has a five-section boom. Two telescoping cylinders that telescope sequentially control the sec-
ond, third, fourth and fifth boom sections. The first-stage cylinder controls the second boom section, caus-
ing the third, fourth and fifth boom sections to extend. The second-stage cylinder and ropes then cause the
third, fourth and fifth boom sections to extend sequentially. During boom retraction, the second-stage cyl-
inder causes the third, fourth and fifth boom sections to retract sequentially; and then the first-stage cylin-
der controls the second boom section, causing the third, fourth and fifth boom sections to retract. The
pressure relief valve has been adjusted to 18 MPa in order to prevent the piston rod from bending due to
excessively high pressure during boom extension. A telescoping balance valve is installed to ensure
smooth telescoping operation and to allow the cylinder to self-lock.
Adjustment of ropes
The length of ropes will change due to the stress applied to the boom as repeated extending and retracting
of the boom. In order to ensure the normal use, monthly check and adjust the ropes.
Never operate the crane if the boom cannot been extended and retracted synchronously or if vibra-
tion is noticed. Do not operate until problems are corrected. Otherwise, wire ropes may fall out of
the groove or break.
To maintain normal operation, make periodic adjustments. The method for adjusting is as follows:
1. Set up the crane on firm and level ground.
2. Extend all sections out after elevating the boom to 60°, and retract them in fully; repeat several times.
3. Extend the 3rd, 4th and 5th boom sections until the ends of the thin rope I at the both side of the 4th
boom section are exposed.
4. Lower the boom to facilitate adjustment.
5. Adjust the adjusting nuts on the thin rope II of the 5th boom section and the thin rope I of the 4th boom
section, and then tighten the corresponding tightening nuts, as shown in the figure below.
6. Repeat steps 2~5, until the 3rd, 4th and 5th boom sections simultaneously move and there is no jitter
occurring.

Figure 4-7 Telescoping system (boom head)
I Thick rope Ⅱ II Nuts on the thin rope I
III Thick rope Ⅰ IV Nuts on the thin rope II
Figure 4-8 Telescoping system (boom head)
No. Explanation
I Thin rope Ⅱ

• If the boom shakes during adjustments, coat the sliding surface of the slide block with grease.
• The crane setting must in accordance with lubrication conditions when applying grease. Prevent
the rope from rotating while the nut is tightened.
• If there is more than 1 – 2 mm of clearance between adjacent boom sections while the boom is
fully retracted, insert adjusting shims to compensate. Otherwise, the force applied to the hy-
draulic cylinder and rope will be affected.
Adjustment of sliders
The sliders have been adjusted in place before delivery. During use, the sliders will become thinner due to
wear. If the sliders are worn seriously or boom lateral bending, side loading and deflection increase are
caused by other reasons, it is necessary to adjust the clearance between the boom and sliders. See the fig-
ure below.
1. As to the upper sliders on the boom head, they may be adjusted by the adjusting bolts;
2. As to the lower sliders on the boom head, they may be adjusted by increasing or decreasing the shims
below the sliders;
3. As to the sliders on the boom tail, they must be adjusted by increasing or decreasing the shims below
the sliders.
• Before adjusting the slider on the boom head, fully retract the boom.
• For adjustment of the lower boom head sliders and boom tail sliders, it must be carried out by
trained professionals.
III
IV
II
Figure 4-9 Adjustment of boom sliders
No. Name No. Name

I Shim II Adjust the bolts
III Boom tail slider IV Shim

Lubrication of boom tail sliders
Lubricate the boom tail sliders through the sight holes at both sides of the boom.
There are sight holes on the left and right sides of basic boom and boom sections. Regularly refill grease
for the boom tail sliders. Extend the boom until the grease nipple of the boom tail slider to be lubricated
aligns with the sight hole.
• Make sure that the crane is properly supported and leveled when lubricating the boom tail
sliders.
• Make sure that counterweight is erected according to the rated load charts.
Ⅱ
Ⅲ
Ⅰ
Figure 4-10 Lubrication of boom tail sliders
No. Name No. Name

I Grease nipple II Boom tail slider
III Shim IV Sight holes
4.5 Winch system

4.5.1 Winch system
The winch system is used to control the raising or lowering movements of the load through winch rope.
The winch system consists of main and auxiliary winches as shown in the figure. The winch system con-
sists of hydraulic motor, winch reducer and drum, etc.

Figure 4-11 Winch system
No. Name No. Name

1 Auxiliary winch 2 Main winch
3 Winch motor 4 Reducer and brake
5 Drum
Winch motor
Function and structure

The winch motor is one of actuators in the winch system, its structure is as shown in the figure below. The
function of the winch motor is to translate hydraulic energy of fluid into energy of the machine, in which
the input parameters are flow and pressure of fluid, and the output parameters are rotation speed and
torque.
When the pressurized oil from hydraulic pump enters into the piston bores of cylinder through valve plate,
piston extend out under oil pressure against the swashplate, which then produces a normal reaction force
on pistons. This force can be further decomposed into axial branch force Fx and vertical branch force Fy.
Fx is balanced out with the pressure acting on the pistons, while Fy develops a torque with respect to the
cylinder center, which causes a counter clockwise rotation of motor shaft.
Figure 4-12 Winch motor diagram

Winch reducer

The winch reducer consists of the reducer, brake and drum. This reducer is a 2-stage planetary gear re-
ducer mechanism with oil-bath internal lubrication. The bearings used in the reducer are rolling bear-
ings with high load-bearing capacity. The output shaft of reducer is connected to winch drum through
bolts; wet brake is installed on the input shaft as shown in the following figure.
Figure 4-13 Diagram for winch reducer
No. Name No. Name

1 Reducer 2 Drum
3 Rope wedge 4 Bearing block
2. Checking and refilling oil
1) Checking the level of hydraulic oil
①Position the crane on a level ground.
②Loosen the oil level check plug to observe the oil level. If the oil level reaches the lower edge of
the oil level sight hole, or there is oil overflowing from the oil level sight hole, it means that the oil
is sufficient. Otherwise, refill gear oil according to the requirements. The location of the oil level
check plug is as shown in the figure below.

Figure 4-14 Oil level check plug of winch reducer
No. Name No. Name

1 Inlet of braking fluid 2 Oil level check plug
3 Drain port
The winch and motor will become too hot to touch during normal operation. Let the winch
and motor cool before doing maintenance.
2) Replace
• Prior to removing the plugs, clean the dirt and foreign matter around the plug so as to pre-
vent oil from being contaminated.
• Clean the plugs and sealing surfaces on the housing. Install the blanking plugs with new seal
washers and tighten them.
• Do not mix different brands of gear oil. Otherwise, the character of each gear oil will be
changed, which will cause damage to the equipment. When refilling gear oil, use the same
brand of oil that was used previously.
It is recommended to replace the oil by the following steps:
①Position a container to catch the used oil;
②Loosen the oil level check plug;
③Remove the oil drain plug;
④Drain the used oil into the container;

Follow the guidelines of the EPA or other governmental agencies for proper disposal of used
oil.
⑤Screw in the drain plug after it is cleaned;
⑥Remove the filler plug;
⑦Refill with fresh oil using a flexible funnel until the oil flows from the oil level check hole;
⑧Tighten the oil level check plug;
⑨Remove the funnel;
⑩Screw in the filler plug.

• Regularly observe the matching surface of winch and motor for oil leakage, as well as bolts and
screws for tightness, missing or damage. Examine the tightening torque of the bolts every 500 operat-
ing hours. Refer to Appendix for the tightening torque.
• Replace oil once a new machine has operated for 100 hours, and then replace oil for the second time
once the vehicle has been operated for 500 hours. Hereafter replace lubrication oil every 1000 hours
or every year (replace oil every year even if the vehicle works less than 1000 hours in one year).
Operate the crane for 15 minutes before replacing oil in order to warm the oil for complete
draining.
• A brake is installed on the winch reducer. When any one of the following occurs, the related parts
should be replaced:
– Oil leaks out of the input end or the oil seal is damaged and needs to be replaced.
– Insufficient braking torque: serious friction or deformed friction lining will result in reduced brak-
ing torque. Replace the friction lining.
When fault or brake overheated occurs, or fixed disc brake is maintained, parts should be
replaced are as follows: disc, spring and seal.
• The drum should be discarded if any one of the following occurs:

– Surface defects that affect performance, such as cracks, etc.

– When the drum flange thickness reaches less than 80% of the original wall thickness. (20% of
flange is warn away)
Wire rope
Unless an alternative rope has been approved of by the crane manufacturer, rope manufacturer or other
competent person, only one of the correct length, diameter, construction, type and direction of lay and
strength (i.e. minimum breaking force), as specified by the crane manufacturer, shall be installed on the
crane.
Unless an alternative rope termination has been approved of by the crane manufacturer, rope manufacturer
or other competent person, only one of a type, as specified by the crane manufacturer in his manual, shall
be used to attach a rope to a drum, hook block or anchor point on the machinery structure.
The inspection frequency shall be determined by a qualified person and shall be based on such factors as
expected rope life as determined by experience on the particular installation or similar installations, se-
verity of environment, percentage of capacity lifts, frequency rates of operation, and exposure to shock
loads. Inspections need not be at equal calendar intervals and should be more frequent as the rope ap-
proaches the end of its useful life. This inspection shall be performed at least weekly.
1. Visual inspection
Daily checks
All running ropes in service should be visually inspected once each working day. A visual inspection
shall consist of observation of the section of rope that can reasonably be expected to be in use during
the day's operations. These visual observations should include the following:
• Rope winding around sheave and drum.
• Distortion of the rope such as kinking, crushing, unstranding, birdcaging, main strand displacement,
or core protrusion as shown in the table below.
Table 4-1 Distortion of the rope
No. Illustrations Explanation

Local reduction in rope diame-
1
ter (sunken strand)
2 Bird-caging
Core protrusion, basket

3
deformation

Table 4-1 Distortion of the rope(continued)
No. Illustrations Explanation
4 Wire protrusion from a strand
5 Looped wires
6 Severe kinking
Local increase in rope diame-

7
ter, basket deformation
8 Crushing, broken wires
Flattening of the
9
circumference
10 Un-stranding
Fatigue is the main reason of rope damage besides of the said distortion. There may be broken wires in
the inner of the rope even no defect is found on its surface. Therefore, replace the rope after 2000 work-
ing hours or when it's time to replace.
• Protective gloves should be worn when inspecting the rope.

• Care shall be taken when inspecting sections of rapid deterioration such as flange points, cross-
over points, and repetitive pickup points on drums.
• Make sure that the inspection for rusting covers entire length of wire rope before use every
time, especially for the casting parts of wire rope head and the parts of wire rope that contact
with winch drum. If the wire rope is rusty, stop using it immediately!
Periodic inspections

The ropes used in the lifting appliances that handling molten metal or hot metal, the acid solution, in-
flammable, explosive and toxic substances, should be inspected at least two times per week; for the gen-
eral purpose ropes, they should be inspected at least once per week; the ropes that are expected to be
able to work for a long time, should be inspected at least once per month.
Periodic inspection shall be performed by a qualified person. This inspection shall cover the entire
length of the rope. Only the surface wires of the rope need be inspected. No attempt should be made to
open the rope. Any deterioration resulting in an appreciable loss of original strength, such as the condi-
tions described below, shall be noted and determination made as to whether further use of the rope
would constitute a hazard.
• Points listed in the visual inspection
• Reduction of rope diameter below nominal diameter due to loss of core support, internal or external
corrosion, or wear of outside wires
• Severely corroded or broken wires at end connections
• Severely corroded, cracked, bent, worn, or improperly applied end connections
• Care shall be taken when inspecting sections of rapid deterioration, such as the following: (1) sections
in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited; (2) sections
of the rope at or near terminal ends where corroded or broken wires may protrude.
The inspection frequency shall be determined by a qualified person and shall be based on the
service life of wire rope.
Special inspection
Special inspection should be done for a crane that has encountered natural disaster (such as earthquake,
hurricane) or accident, or stands idle for more than a month before being put into service.
2. Discard criteria
• Broken wires;
In running ropes, six randomly distributed broken wires in one lay or three broken wires in one strand
in one lay, refer to the figure below; In rotation-resistant ropes, two randomly distributed broken
wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.
Note: lay length is the distance measured along rope in which one strand makes one complete revolu-
tion around core.

II
Figure 4-15 Rope structure diagram
Symbol Notes Symbol Notes

A Lay length I One wire
II One strand
• Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure;
• Apparent damage from any heat source, including, but not limited to, welding, power line strikes, or
lightening;
• Reduction from nominal diameter of more than 3%, refer to the figure below for measuring method;
Figure 4-16 Measuring method for nominal diameter of wire rope
• Severe corrosion as evidenced by pitting.

No precise rules can be given for determination of the exact time for rope replacement since many vari-
able factors are involved. Once a rope reaches any one of the specified removal criteria, it may be al-
lowed to operate to the end of the work shift, based on the judgment of a qualified person. The rope
shall be replaced after that work shift, at the end of the day, or at the latest time prior to the equipment
being used by the next work shift.
Broken wire removal criteria cited in this manual applies to wire rope operating on steel sheaves and
drums. The user shall contact the sheave, drum, or XCMG, or a qualified person, for broken wire re-
moval criteria for wire ropes operating sheaves and drums made of material other than steel.

Replacement rope shall have the same or higher minimum breaking force as the original rope furnished
or recommended by the rope manufacturer or XCMG. Any deviation from the original size, grade, or
construction shall be specified by a rope manufacturer, XCMG, or a qualified person.
Ropes not in regular use. All rope that has been idle for a period of a month or more due to shutdown or
storage of a crane on which it is installed shall be given an inspection before it is placed in service. This
inspection shall be for all types of deterioration and shall be performed by an appointed or authorized
person.
3. Rope maintenance
Effective protective measures should be taken to prevent any part of the crane to contact wire
rope during installation.
Follow the items, methods and requirements of initial, daily and regular inspections in section
“Regular maintenance and service items” for maintenance and service of wire rope. Regular
lubrication shall be done for the entire length of the rope, including the casting parts of rope
head and the parts of wire rope that contact with winch drum.
• Rope should be maintained in a well-lubricated condition. It is important that lubricant applied as part
of a maintenance program shall be compatible with the original lubricant, and to this end, XCMG or
the rope manufacturer should be consulted. Lubricant applied shall be of the type that does not hinder
visual inspection. Those sections of rope that are located over sheaves or otherwise hidden during in-
spection and maintenance procedures require special attention when lubricating rope. The object of
rope lubrication is to reduce internal friction and to prevent corrosion.
• Rope should be stored to prevent damage or deterioration.
• Unreeling or uncoiling of rope shall be done as recommended by XCMG or the rope manufacturer
and with care to avoid kinking or inducing a twist.
• During installation, care should be exercised to avoid dragging of the rope in dirt or around objects
that will scrape, nick, crush, or induce sharp bends in it.
• When an operating rope shows greater wear at well-defined localized areas than on the remainder of
the rope, rope life can be extended (in cases where a reduced rope length is adequate) by cutting off a
section at the worn end, and thus shifting the wear to different areas of the rope.
• Prior to cutting a wire rope, seizings shall be placed on each side of the point to be cut. The minimum
length of each seizing shall be equal to or exceed the nominal diameter of the wire rope to which it is
being applied. The required number of seizings is one seizing on each side of the point to be cut on
preformed wire rope; at least three seizings on each side of the point to be cut on non-preformed wire
rope.

4. Rope replacement
• Wire ropes should be replaced by professionals.

• Protective gloves should be worn during replacement.
Table 4-2 Rope replacement
No. Procedure Illustrations Note Tools

Place the main Avoid disorderly
1 hook block on the winding the rope
ground. on the drum.
Disconnect the
Be careful to
rope socket from
2 avoid losing Wrench
the boom head or
parts.
main hook block.
Remove the rope

Be careful to Bar, hammer,
3 from the rope
avoid losing parts wrench
socket.
Let out the rope

by turning the
4 Pull the rope.
winch under
power.
Remove the rope

5 end from the Keep the wedge Bar, hammer
winch drum.
Reeve the new Properly bind the

6 rope over all the rope end with Wire or vinyl tape
sheaves. wire or vinyl tape.

Table 4-2 Rope replacement(continued)

1. Put the wedge
in the correct
orientation. 2.
Install the rope
The rope end
7 end to the winch
must not protrude
drum.
from the outer
surface of the
drum.
1. Avoid
disorderly
winding the rope
Wind the rope on
8 on the drum. 2. Wire or vinyl tape
the drum.
Bind the rope end
with a wire or
vinyl tape
Reeve the rope

over the sheaves Exercise care to
9 at the boom head route the rope
and the hook correctly.
block.
Attach the rope Put the wedge in

10 socket and rope the correct Hammer, wrench
clamp to the rope. orientation.
Attach the rope

socket to the
boom head or the
11 hook block Wrench
depending on the
number of parts
of line.
Raise and extend Never lower the
the boom, then hook block
12 ——
lower the hook excessively.
block until no Otherwise the

Table 4-2 Rope replacement(continued)

turn of the rope rope may be
remains on the damaged.
winch drum.
Wind the rope on
the drum while
hoisting a weight
which applies
Never exceed the
13 approx. 30 % of ——
total rated load.
the “maximum
permissible load
for winch rope”
to the rope.
Remove the
14 weight from the ——
hook.
Newly replaced wire rope must be run in to ensure that all devices involved with the wire rope (such as
the winch drum and sheaves) function properly. In order to regulate new wire rope and its accessory to
actual service condition, let lifting mechanism run at lower speed and with 10% of rated load, and then
perform several lifting operations with partial loading, or alternate loading, or unloading.
5. Inspection and replacement records
To establish data as a basis for judging the proper time for replacement, a dated report of rope condition
at each periodic inspection shall be kept on file. This report shall cover points of deterioration listed in
periodic inspections. If the rope is replaced, only that part need be recorded. A long-range inspection
program should be established and should include records on the examination of ropes removed from
service so that a relationship can be established between visual observation and actual condition of the
internal structure.
Adjustment of lowering limiter
When only 3 turns of rope left on the winch drum while winch rope is letting out, the lowering limiter in-
stalled at the tail of winch automatically activates to stop hook lowering, at the same time, the buzzer
sounds and rope over-release warning lamp comes on. Raising the hook by spooling in the rope may re-
lease the limitation.

Figure 4-17 Rope-end limiter location
No. Name No. Name

1 Lowering limiter 2 Main winch
3 Auxiliary winch
Adjustment of accuracy for the lowering limiter is as follows:

1. Let out the winch rope until only 3 turns of rope left on the winch drum;
2. Screw out the fixed bolt of housing of the lowering limiter and remove the housing;
3. Loosen the fixed bolt of drive shaft and clockwise turn the cam until the roller of proximity switch is
pressed down by the cam. At this time, two leads of the proximity switch are connected;
Figure 4-18 Lowering limiter structure
No. Name No. Name

1 Sealing ring 2 Propeller shaft
Fixing bolt of propeller
3 4 Cam
shaft
Installation bolt of the
5 Limit switch 6
cover
4. Tighten the fixed bolt of drive shaft;

5. Reinstall the housing of the lowering limiter.
Pulley

There are hook sheave, boom head sheave, jib head sheave and jib guide sheave on the crane.
The structure of sheave assembly is as shown in the figure below.
Figure 4-19 Pulley assembly diagram

• Check
– Check the sheaves for cracks, dents or other damage. Replace the sheave if damage is found.
– Check the sheaves for wear. Replace the sheave if it is worn excessively.
• Lubricating the bearings of sheaves

Lubricate the bearing of each sheave with a grease pump through the oil cup mouth.
• Discard criteria
Discard the pulley if:
– Cracks or damage or permanent deformation;
– Damaged sheave edge;
– Wear of sheave groove wall reaches 20% of the original wall thickness.
– Reduction in diameter at the bottom of sheave groove exceeds 50% of wire rope diameter.
– Defects that damage wire rope or impair performance.

Y Y
Figure 4-20 Pulley
1) X: is the difference between the new bottom surface and the actual bottom surface.
2) Y: is the clearance between the wire rope and sheave wall.
Hook blocks
1. Checking the hook block

The hook block system is shown below. Inspection of hook blocks should be done by professionals. Ac-
cidents may be avoided if problems are found as early as possible through inspection. Solve problems
promptly after they are found.
Regularly check the safety latch of the hook to make sure that it is functional.
Figure 4-21 Hook block system
The checklist is as follows:

• Surface defects
Inspect the hook for surface defects. If the hook surface has cracks, replace the hook.
• Deformation
– Measure the y value. If it exceeds 10% of the nominal dimension, replace the hook.
– Measure the twisting deformation α. If it exceeds 10°, replace the hook.
– If plastic deformation on the hook shank is found, replace the hook.
• Wear
Check the wear of the hook, ∆s. It should not exceed 5% of the original dimension. If it exceeds 5%
of the original dimension, replace the hook.
• Corrosion
– The diameter d1 of the corroded hook shank should not be less than 95% of the original dimension.
If it is less than 95% of the original dimension, replace the hook.
– Corrosion on the thread is not allowed.
• Do not weld the hook block to repair it.
II
V
III
y
I
a2
IV
Figure 4-22 Hook


I Excessive opening II Hook neck
Corrosion or plastic
III deformation on hook IV Wear
shank
V Twisting deformation
2. Discard criteria of hook block

The hook must be discarded when one of the following occurs:
• Cracks on the hook surface are found through a 20 times magnifying glass;
• Opening a2 (see the nameplates of main and auxiliary hook blocks) of hook blocks with number of
006~5 is more than 15% of the original dimension;
• Measure the y value. If it exceeds 10% of the nominal dimension, replace the hook.
• Critical section wore reaches 5% of the original dimension;
• Twisting deformation of hook exceeds 10°;
• The hook is warn down to 95% of the ordinal thickness;
• Plastic deformation on the critical section or on hook neck.
3. Inspection and replacement records
To establish data as a basis for judging the proper time for replacement, a dated report of rope condition
at each periodic inspection shall be kept on file. This report shall cover points of deterioration listed in
periodic inspections. If the hook block is replaced, only that part need be recorded. A long-range inspec-
tion program should be established and should include records on the examination of hooks removed
from service so that a relationship can be established between visual observation and actual condition
of the internal structure.
4.6 Superstructure hydraulic system

4.6.1 Hydraulic system
Superstructure hydraulic valve

The main valve (shown in Figure 5-23) controls the hydraulic circuit of crane's superstructure. It also
activates the telescoping system, elevating system, main winch, and auxiliary winch. The combined
valve also offers proportional hydraulic control of direction, flow and pressure. It proportionally gov-
erns the speed of several actuators simultaneously while supplies pilot oil source for elevating or slew-
ing brake.
1) Function check

• Check the lifting pressure of main winch. If the pressure is not sufficient, clockwise turn the main
relief valve for the main winch. Test the pressure once after turning the valve a quarter circle to see
if the pressure becomes normal level.
• If there is no movement after the main winch is actuated, check the spool of valve for the main
winch to see if it has changed direction, or check damping to see if it is clogged or pilot solenoid
valve is energized.
Hydraulic valves belong to precision components, which should be maintained and adjusted
by professionals. It is not recommended to disassemble hydraulic cylinder by users.
2) Disassembly and check

• Check sealing ring and retainer ring for damage.
• Check the valve spool to see if it is blocked by dirt.
• Examine the sliding surface of valve spool for scratches. If any small scratches appear on the slid-
ing surface, use a fine emery cloth or oilstone to polish them.
When pulling a spool out of the valve body, take care to prevent the valve spool surface and
sealing ring from being scratched.
3) Assembly
①Packing, backup ring and sealing ring: in principle, replace them with new ones, apply hydraulic
oil or grease when assembling, and take care not to damage them.
②When inserting spools into the body, coat with hydraulic oil and take care to avoid forcing them in
misaligned.
③After inserting the spool and piston in the body, check them for smooth movement.
④After assembly of the hydraulic valve is completed, tighten bolts with specified tightening torque.
After assembly of the hydraulic valve is completed, tighten bolts with specified tightening
torque.
Pressure hose
1. Check
Visually check:

• Oil port for leakage;

• Line for blockage;
• Hose clip, protective sleeve, shield for tightness;
• Defects;
– Fittings sliding along the hose;
– Damaged, cut or worn outer rubber layer;
– Hardened, cracked or burned hose;
– Cracked, damaged or seriously corroded fittings;
– Fittings or hose leaked;
– Kinked, broken, crushed, or distorted hose;
– Blistered, or softened outer layer of hose.
• Immediately replace the lines and fittings connected with the engine if they are damaged due
to mechanical effect or thermal effect.
• Keep sufficient safe distance from all lines and fittings to the overheating engine components
(such as exhaust system).
2. Replace
Visually check all pressure hose in hydraulic system once a month. Replace the hose if damage is
found.
Replace hydraulic hoses according to the recommended interval, even if they are not damaged.
Recommended use duration of hose for the mobile cranes is:

• About one year for the hose used in a crane used for difficult lifting and unloading operations;
• About three years for the hose used in a crane used for applications in high ambient temperature and
frequent operations;
• About six years for the hose used in a crane used for general lifting and unloading operations;
• About ten years for the hose used in a crane used for installation operations, and max. output power
is not frequently used.
Hydraulic rubber hose types are as follows:
• 1SN: Hydraulic rubber hose with a layer of steel wire webbed
• 2SN: Hydraulic rubber hose with two layers of steel wire webbed

• 4SP: Hydraulic rubber hose with four layers of steel wire webbed (for medium pressure)
• 4SH: Hydraulic rubber hose with four layers of steel wire webbed (for ultra-high pressure)
Figure 4-23 Hydraulic rubber hose types
4.7 Electrical system

4.7.1 Electrical system
Electrical system of operator's cab
The main role of the electrical system in the operator's cab is to supply a platform for man-machine com-
munication. The operator can know the vehicle information through the system and control the vehicle.
• Check the operation of instruments, and check the pointers of gauges for coming off;
• Check the switches and buttons for sensitivity and coming off;
• Check the display for proper indication, function of screen change and sensitivity of touch keys;
• Check the display for warning message or fault codes.
Lighting system
The chassis lighting system consists of all lamps on the chassis for illuminating, showing the vehicle width
and sending signals, and so on.
• Check the lamps for damage and brightness;
• Remove the dirt on the lamps;
• Check the illuminating range and angle of lamps.
Electric wiring harness
The electrical wiring harness assembly is the nerve system of electrical control system, which transmit the
electrical signals for controlling the movements of operation mechanism.

• Check if lines are fixed firmly;

• Check the wiring harness for damage;
• Check the wiring harness connector for looseness;
• Check the wiring harness sealing for aging, looseness or damage;
• Check the wiring harness plug-in for looseness or damage;
• Check the wiring harness plug-in sealing;
• Check the wiring harness plug-in for water and oil dirt.
It is not allowed to replace the blown fuse with iron wire or copper wire, etc.
4.8 Operator’s cab assembly

4.8.1 Operator’s cab assembly
1. Windshield wipers: Check the windshield wipers weekly.
• Regularly check wiper blades, and remove the dust and foreign body.
• Add proper antifreeze to wiper cleaning liquid during winter.
• Never start the wipers without activating washer system.
2. Washer system:
• Check the level of cleaning liquid weekly.
• Check whether the water jets are blocked.
If the crane is to be out of operation in humid areas such as seaside, open the door of operator's
cab at least once every week, to avoid that it is difficult to open the doors due to being affected
by damp.


Chapter 5 Appendix
5.1 Maintenance and check record form

Routine inspection record, regular check record and report, and special check report are required.
1. The check record should include at least the following items:
Content
No. Item Signature Date Remark
maintained
1
2
3
...
2. The regular check report and special check report should at least include:
• The name and address of employer who asks for regular check or special check;
• The basis for the regular check or special check;
• Identification items of crane, including crane type, manufacturer information, manufacture date, and
so on;
• The date of previous regular check or special check;
• The safe working load of the crane or the safe working load related to the previous regular check or
special check;
• The first regular check after assembly or reassembly at a new job site or new environment:
– Crane's erection and operation;
– Inspection results
• Regular check of lifting appliances:

– Check interval;
– Identification and description of the defects;
– Repaired, replaced or modified items for removing the defects;
– Defects, which do not pose danger for the time being but potentially pose danger to personnel:
♦ The time that danger comes due to the defects;
♦ Repaired, replaced or modified items for removing the defects;
♦ The date for next regular check.
• Special check
Appendix 5-1
– The problems found and conclusion;
– Repaired items;
– Suggestions about overhaul;
– The date for next regular check.
• Items of regular check or special check;

• The signature and address of check and approval personnel, check date and report date.
5.2 Tightening torque table
Only the bolts and nuts at main positions are listed in the table below, but not limited to these for
maintenance.
The tightening torque values of main bolts and nuts are shown in the table below.
Table 5-1 Tightening torque of main bolts and nuts
Tightening torque (N.

No. Name Remark
m)
1 Slewing ring and frame 1150～1350
2 Slewing ring and turntable 1150～1350
3 Slewing reducer fixture 78～104
Fixing of slewing reducer and its
4 78～104
protective covering
Bearing seat fixture of main
5 78～104
winch reducer
6 Main winch motor fixture 193～257
7 Main winch reducer fixture 193～257
Bearing seat fixture of auxiliary
8 78～104
winch reducer
9 Auxiliary winch motor fixture 193～257
10 Auxiliary winch reducer fixture 193～257
11 Wheel nuts 600～660
Tightening bolts of suspension
12 380～450
push rod
Connecting bolts and nuts of
13 210～260
propeller shaft flange
5-2 Appendix
Table 5-1 Tightening torque of main bolts and nuts(continued)
Tightening torque (N.

No. Name Remark
m)
14 Steering gear tightening bolts 333～450
15 U-type bolt of front suspension 300～400 Full-loaded leaf spring
Connecting nut of rear
16 suspension V-type pushrod and 850～950
axle
Suspension pushrod clamping
17 265～324
bolt
Tightening bolt of rear
18 suspension V-type pushrod and 350～400
frame
Notes about the tightening torque of bolts and nuts:

• The casing of engine flywheel and transmission casing are cast aluminum parts, the tightening torque of
the bolts and nuts used for them should comply with the requirements in their instructions. For those
have not been listed in the table above, please consult related suppliers.
• For the bolts connecting suspensions, and other bolts and nuts having no special connection require-
ments, after repairing, their threads need to be coated with thread sealant before remounting.
• High-tension bolts should not be used again after removing. If there are no spare bolts available, the
bolts removed can be used again only after they are approved by professional engineer, and at most
twice.
• Tighten the U-bolts of leaf spring with the crane in full load.
5.3 Main parts list
Table 5-2 Main parts list of QY50KD Truck Crane
No. Name Manufacturer Mark certified Remark

China National Heavy Duty Truck
1 Engine Group Co., Ltd.
Shanghai Diesel Engine Co., Ltd.
2 Transmission Shaanxi Fast Gear Co., Ltd.
Nantong Huanqiu Steering Gear
Co., Ltd.
3 Steering gear
Jiangmen Xingjiang Steering Gear
Co., Ltd.
4 Axle Shaanxi Hande Axle Co., Ltd.
Appendix 5-3
Table 5-2 Main parts list of QY50KD Truck Crane(continued)

5 Tire Shanghai Double Coin Holding Ltd.
Chassis
6 Xuzhou Keyuan Hydraulic Co., Ltd.
hydraulic pump
Xuzhou Rothe Erde Slewing Bear-
7 Slewing ring ing Co., Ltd.
Maanshan FY Slewing Ring
Zhonghang Liyuan Hydraulic Co.,
Ltd.
Main/Auxiliary
8 Beijing Huade Hydraulic Industry
winch motor
Group Co., Ltd. Huade Hydraulic
Pump Branch Company
Xuzhou Sunbun Machinery Co.,
Main/Auxiliary
9 Ltd.
winch reducer
Xuzhou Keyuan Hydraulic Co., Ltd.
Wire rope for Jiangsu Langshan Wire Rope Co.,
10 main winch and Ltd.
auxiliary winch China Juli Sling
Zhonghang Liyuan Hydraulic Co.,
Ltd.
11 Slewing motor
Beijing Huade Hydraulic Industry
Group Co., Ltd.
Xuzhou Sunbun Machinery Co.,
Ltd.
12 Slewing reducer Bosch Rexroth (Beijing) Hydraulic
Co., Ltd.
Xuzhou Keyuan Hydraulic Co., Ltd.
Xuzhou Hydraulic Parts Co., Ltd.
XCMG
13 Luffing cylinder
Chengdu Chenggang Hydraulic
Equipment Manufacturing Co., Ltd.
Telescoping XCMG
14
cylinder Chengdu Chenggang Hydraulic
Equipment Manufacturing Co., Ltd.
15 Jack cylinder
XCMG
5-4 Appendix
Table 5-2 Main parts list of QY50KD Truck Crane(continued)

Zhangjiakou Changyu
Extension
16 XCMG
cylinder
Zhangjiakou Changyu
Load moment
17 WIKA Mobile Control
limiter
Appendix 5-5
5-6 Appendix
Index
A
AdBlue solution................................................................................................................ 2-17
Adjustment of lowering limiter ........................................................................................... 4-24
Adjustment of sliders......................................................................................................... 4-11
After-treatment device/SCR system ..................................................................................... 3-15
Air conditioner ................................................................................................................. 3-59
Air dryer .......................................................................................................................... 3-41
Air filter.............................................................................................................................3-9
Air reservoir ..................................................................................................................... 3-43
Antifreeze coolant ............................................................................................................. 2-15
Axle ................................................................................................................................ 3-30
B
Battery..................................................................................................................... 3-57, 3-62
Boom telescoping system .....................................................................................................4-9
Braking system ................................................................................................................. 3-40
C
Cleaning of the crane ...........................................................................................................2-1
D
Daily maintenance and service......................................................................................1-5–1-8
Disposal of used oil and grease ........................................................................................... 2-22
E
Electric system in operator’s cab ....................................................................................... 4-32
Electrical system ............................................................................................................... 4-32
Electrical system in the driver's cab ..................................................................................... 3-61
Engine ...............................................................................................................................3-1
Engine oil ........................................................................................................................ 2-14
F
Fuel................................................................................................................................. 2-12
G
Gear oil............................................................................................................................ 2-17
Girder wiring harness assembly .......................................................................................... 3-61
H
Hook blocks ..................................................................................................................... 4-27
Hydraulic oil .................................................................................................................... 2-18
I Index
Hydraulic oil tank ............................................................................................................. 3-46

Hydraulic pump ................................................................................................................ 3-56
Hydraulic system .............................................................................................................. 3-46
I
Inspection of air intake pipeline .......................................................................................... 3-18
L
Lighting system ........................................................................................................ 3-61, 4-32
Lubrication.........................................................................................................................2-2
Lubrication guidelines .........................................................................................................2-3
Lubrication of boom tail sliders........................................................................................... 4-12
M
Main parts list.....................................................................................................................5-3
Maintenance and check record form ......................................................................................5-1
Maintenance and service during storage of the crane.............................................................. 1-56
Maintenance and service instructions .....................................................................................1-1
Maintenance and service items..............................................................................................1-3
Maintenance and service of systems for lifting operations.........................................................4-1
O
Oil brands, filling amount and interval ...................................................................................2-7
Oil filter.....................................................................................................................3-2, 3-48
Operator’s cab assembly .................................................................................................. 4-33
Outrigger system.................................................................................................................4-1
P
Power system .....................................................................................................................3-1
Pressure hose.................................................................................................................... 4-30
Propeller shaft .................................................................................................................. 3-28
Pulley .............................................................................................................................. 4-26
R
Radiator........................................................................................................................... 3-14
Regular maintenance and service...........................................................................................1-8
Rim inspection.................................................................................................................. 3-36
S
Slewing motor ....................................................................................................................4-6
Slewing reducer ..................................................................................................................4-7
Slewing ring .......................................................................................................................4-4
Slewing system...................................................................................................................4-3
Special inspection ............................................................................................................. 1-50
Steering gear .................................................................................................................... 3-45
II Index
Steering oil tank................................................................................................................ 3-44

Steering system................................................................................................................. 3-43
Superstructure hydraulic valve ............................................................................................ 4-29
Suspension ....................................................................................................................... 3-35
Systems that need to be maintained and serviced .....................................................................1-2
T
Tightening torque table ........................................................................................................5-2
Tires inspection................................................................................................................. 3-36
Transmission .................................................................................................................... 3-24
Transmission system.......................................................................................................... 3-19
trouble indicator lamp........................................................................................................ 3-18
W
Washer system.................................................................................................................. 3-60
Winch motor .................................................................................................................... 4-13
Winch reducer .................................................................................................................. 4-14
Winch system ................................................................................................................... 4-12
Windshield wiper .............................................................................................................. 3-60
Wire rope ......................................................................................................................... 4-17
III Index

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QY50KD

QY50KD Truck Crane

Maintenance and Service Manual

First edition, July 2020

All rights reserved

3.2.1 Transmission system.................................................................................. 3-19

4.4.1 Boom telescoping system ............................................................................ 4-9

III Table of Contents

Chapter 1 Maintenance and service instructions

1.1 Maintenance and service instructions

Maintenance and service instructions 1-1

• Installation of safety device

1.2 Systems that need to be maintained and serviced

1-2 Maintenance and service instructions

Figure 1-1 Systems that need to be maintained and serviced

No. Name No. Name

5 Operator’s cab 6 Luffing cylinder

7 Turntable 8 Slewing system

9 Counterweight 10 Winch system

11 Rear outrigger beam 12 Front outrigger beam

13 Transmission system 14 Traveling system

15 Steering system 16 Braking system

1.3 Maintenance and service items

Maintenance and service instructions 1-3

Daily maintenance and service

1-4 Maintenance and service instructions

No. Inspection items Example Remark

Visually check safety

Check fire extinguisher

and warning decals to

发动机型号 额定功率 千瓦/(转/ 分)

make sure that they are

legible and not missing.

Maintenance and service instructions 1-5

No. Inspection items Example Remark

Visually check the levels

Clean the dust cup of the

Check the pneumatic

Check braking system to

1-6 Maintenance and service instructions

No. Inspection items Example Remark

Check angle sensor and

With the crane set up on

Maintenance and service instructions 1-7

No. Inspection items Example Remark

Observe the display

Check tires to make sure

Regular maintenance and service

1-8 Maintenance and service instructions

Check the inspection Take

Check the maintenance Take

Maintenance and service instructions

Maintenance and service instructions

Maintenance and service instructions

Maintenance and service instructions

structural members and

nisms, and the requirement of

Maintenance and service instructions

Maintenance and service instructions

Maintenance and service instructions

发动机型号额定功率千瓦/(转/ 分)