SANY RSC45 Container Reach Stacker Maintenance Manual PDF

MAINTENANCE MANUAL

CONTAINER REACH STACKER
CONTENTS
1 . Preparing Work before Maintenance
2 . Maintenance Cycle Table of the Whole Machine
3. Maintenance of the Equipment
4 . Lubricating
5 . Functional Oil
6 . Checking of Key Bolts
7 . Safty Regulations during Maintenance Work
8 . Common Faults and Measures
9 . Maintenance of Equipment Tracking Sheet
Preface Reading Guidance
Preface Thanks for your trust to the SANY products. We Reading Guidance work of the equipment are listed. The whole
sincerely wish you realizing your ambitious dreams equipment lubricating cycle table which includes
in the future works and making great achievement. lubricating points and lubricating cycle is listed.
This manual mainly introduced specific 1.Information Clients must lubricate the equipment according to
maintenance method of container reach stacker The maintenance manual is a manual for you to this cycle table.
(here after refer to reach stacker) and other use and maintain the machine. It should be always
malfunction elimination methods. Concerning SANY Group put in the cab for your reference at any time. If it is
certain type of reach stacker, there will be more 6.Function Oils
damaged or lost, you should order another one
detailed information. Technical specification of hydraulic oil etc medium
from Hunan SANY Group. The Manual covers the
We sincerely appreciate your purchase of our and their standards, oil tank and volume are
information and instructions for safety, technology,
product SANY Container reach stacker. We will introduced in this part. Brand and type of
operation, transportation, lubrication and
provide you with high-quality products and high- recommended oil by the manufacturer are also
maintenance. Furthermore, some photos, drawing
class after-sales service. listed in this part.
details or optional components shown in the
Our Company has derived the technology Manual may differ from your machine. To make the
quintessence of the production of the container instructions easy, the cover sheet and hood may 7.Inspection of Key Bolts
reach stacker mobile in and out of China. With the have been dismounted. Inspection requirements of each key fastening
rich experience of designing and manufacturing of The Manual may exclude the modification due to bolts and torque are listed in this part.
engineering machinery, we develop the reach the improvement and updating of products. It is
stacker, which is completely new container recommended for you to read and research the 8.Safety during Maintenance Work
handling equipment. It is widely used at the Manual carefully and put it together with your Safety matters needing attention while
container terminal, railway transfer station, machine. maintenance, checking and lubrication: safety
highway terminate station and container freight For any question on the machine or the Manual, measure in the working place, safety measure of
yard, and mainly used for the stacking and portage please contact us for the latest information. product: introduction of personnel's safeguard
of containers.
measures.
The manual shows in details the specifications of
2.Preparing Work before Maintenance
performance parameter, technical characters,
Preparing work steps are introduced in the
operational principle, structural composition, safe 9.Guidebook of Identifying Common
Preparing Work before Maintenance part.
operation, transportation, lubrication and Malfunction
maintenance of SANY Container reach stacker. Common mechanical/hydraulic/electric system
In order to ensure a better operation of the reach
3.Maintenance Cycle of the Whole
malfunction are introduced in this part, which point
stacker, we strongly recommend you to read this Machine out direction for diagnosing common malfunction of
manual carefully before operation. It will: Maintenance cycle of key parts of the machine are the equipment.
□Help you understand the reach stacker; showed in this part which provide references to
□ Protect you from danger owning to improper maintain the machine in a regular time.
10.Track Record of Maintenance
operation; Taking track record provide convenience to the
□Enhance the reliability of the reach stacker; 4.Maintenance of the Equipment maintaining staff to keep track of the status of
□Enhance the service life of the reach stacker; Maintenance detailed specification of key parts maintenance and is easy to check the working
□Reduce the repair cost and the shutdown time. such as engine, transmission, driving axle and condition of the equipment.
Please put this manual at an easily reachable spreader etc. is showed in this part which indicate
position for your reference at any time. Only after the direction of maintenance work of the
fully understanding this manual, can you operate
11.Explanation of Signs
equipment.
the reach stacker skillfully and safely. Danger
5.Lubricating
The sign of “Danger” means the direct danger,
Necessary lubricating materials to enable normal
which may cause death or serious injury if no
preventive measure is taken.
Reading Guidance
Warning
It means the potential danger, which may cause

death or serious injury if no preventive measure is
taken.
Caution
It means the potential danger, which may cause

slight or moderate injury if no preventive measure
is taken.
Caution
There is no safety indication. If you ignore this

indication, there will be some potential danger to
induce loss of property.
Notice
It awarks people to take attention to the operation

and maintenance.
TABLE OF CONTENTS TABLE OF CONTENTS
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
1. Preparing Work before Maintenance 1-1 9. Maintenance of Equipment Tracking Sheet 9-1
2. Maintenance Cycle Table of the Whole Machine 2-1
3. Maintenance of the Equipment 3-1

3.1 Repairing and Maintenance of the Engine 3-1
3.2 Repairing and Maintenance of Transmission 3-5
3.3 Repairing and Maintenance of the Drive Axle 3-6
3.4 Repairing and Maintenance of the Steering Axle 3-7
3.5 Repairing and Maintenance of the Spreader 3-8
3.6 Repairing and Maintenance of the Jib System 3-10
3.7 Repairing and Maintenance of the Air Conditioner System 3-11
3.8 Repairing and Maintenance of Tyres 3-11
3.9 Repairing and Maintenance of Hydraulic System 3-13
3.10 Repairing and Maintenance of Electric System 3-14
Font -Arial Size:10pt

4. Lubricating 4-1
4.1 Lubrication 4-1
4.2 Lubricating Table 4-1
5. Functional Oil 5-1

5.1 Oil Specification 5-1
5.2 Oil Capacity 5-2
5.3 Check and Change of Hydraulic Oil 5-2
5.4 Using Principle of Oil 5-3
6. Checking of Key Bolts 6-1
7. Safty Regulations during Maintenance Work 7-1
8. Common Faults and Measures 7-1

8.1 General 7-1
8.2 Common Faults of Mechanical Systems and Measures 8-1
8.3 Common Faults of Hydraulic System and Measures
8-4
8.4 Common Faults of Electrical Control System and Measures 8-6
1 2
PREPARING WORK BEFORE MAINTENANCE MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE
In order to avoid unnecessary break down of reach

s t a c k e r, e n h a n c e t h e r e l i a b i l i t y a n d 2. Maintenance Cycle Table of the Whole Machine
maneuverability, reduce repair cost, client should
have a whole maintenance plan before operating. Plan Of Maintenance
In the run-in period, reach stacker can only stand
the medium or less load work. After working its first Maintenance Applicable plan
Serial No. Maintenance items
50 to 100 h work, reach stacker must take a parts
maneuverability maintenance. One should take the ★Walk one circle around the engine, check if there 1 Check air cleaning status indicator A B C D
fist maintenance according to C maintenance exists damage and leakage. 2 Replace air filter core A B C D
including adjustment of engine valve clearance. 3 Replace engine oil and engine oil filter core A B C D
★The function test should be conducted to.
4 Replace diesel filter core A B C D
Specification: We have already done the
maneuverability maintenance of the equipment for 5 Check cooling water quality and amount A B C D
you. 6 Clean foreign matters on the surface of the radiator A B C D
7 Check belt and belt wheel A B C D
8 Engine Check start, stop, and operation of engine A B C D
9 Check if oil, diesel, and water leakage exists A B C D
★Close the main switch, and take away the key. 10 Check if turbocharger and exhaust gas tube have leakage A B C D
11 Replace oil-water separator filter core B C D
12 Clean oil stain in the oil cleaner B C D
13 Replace cooling water filter core C D
14 Check if damping pad and fixed bolt are loose and D
15 brokenCheck and adjust clearance of intake valve and 50 D

Preventive Maintenance A-250hrs Preventive Maintenance A- 500 hrs exhaust valve
Preventive Maintenance A- 1000 hrs Preventive Maintenance A- 2000 hrs
★Set the limit stop in the front and back of the 16 Check and add transmission oil A B C D
tyre, so as to prevent accidental movement of
17 Check if fixed bolt of the transmission shaft is loose and A B C D
engine.
Gearbox and Broken
18 transmission Check rotary speed inductor A B C D
19 Replace transmission filter core C D

shaft
1.Preparing Work before 20 Replace transmission oil C D
21 Check if fixed bolt and fixed seat are loose and broken D
Maintenance
22 Check fixed bolt of drive axle tightness degree A B C D
Before repairing and maintenance of the Container ★Hang the warning brand of “stop, in repairing” on 23 Check if bolts of pressure plate of tyre are loose or broken A B C D
reach stacker, preparations should be well done the engine. 24 Check if drive axle and brake components have oil A B C D
Drive axle
strictly according to the following steps: (One is hung on the steering wheel and one is Leakage
hung at the end of engine) and brake
25 Check and add oil of drive axle differential and planet A B C D
★Ensure engine will be stopped in the safe system
26 Replace oil of drive axle differential and planet gear case C D
working site. If necessary, use the colored ribbon
to separate the safety isolated belt. 27 Clean venthole adaptor C D
28 Check hand brake sheet and hand brake function A B C D
1-1 2-1
MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE
Maintenance Applicable plan Maintenance Applicable plan

Serial No. Maintenance items Serial No. Maintenance items
parts parts
29 Check if steering axial component has abnormal A B C D 53 Replace main hydraulic oil tank and brake oil tank D
clearance and damage ventilation filter core
30 Check anti-tilting inductor A B C D 54 Check if battery water is sufficient A B C D

Circuit
31 Check if bolts of tyre pressure plate are loose and broken A B C D 55 Check all working lights and indicator lights A B C D
Steering
32 axle Check if tyre is deflective A B C D 56 Check tyre pressure plate and nut tightness degree A B C D
33 Check if steering wheel bearing and fixed nut are loose C D 57 Check tyre status and air pressure A B C D
General
or broken 58 items Check horn, reversing buzzer, and alarm light A B C D
34 Check if spherical pin and fixed nut are loose and broken C D 59 Lubricate all slide blocks and lubrication points A B C D
35 Check twist-lock and relevant components A B C D 60 Test anti-tilting protective system A B C D
36 Check twist-lock inductor and indicator A B C D 61 Function Test twist-lock safety interlocking device system A B C D
37 Check and adjust 20 /40 chain and limit A B C D 62

test Test integrated function of hydraulic system A B C D
38 Check crane spreader rotary decelerator gear oil and B C D 63 Check and treat places with oil or water leakage A B C D
Crane
lubricating oil amount
spreader Replace crane spreader rotary decelerator gear oil C D
39
40 Check if fixed bolt of crane spreader rotary gear case C D

is loose and broken
41 Check if slide block on the crane spreader is abraded C D

to the limit
42 Check if crane spreader has cracks by general vision C D
43 Check if fixed seat and lock pin on the basic boom are A B C D
Contraction loose, broken, and worn

44 Check if fixed seat and lock pin on the pitch oil cylinder A B C D
and pitch
are loose, broken, and worn
system
45 Check if slide block on basic boom is abraded to the limit B C D
46 Check if basic boom has cracks by general vision D
47 Check oil amount in main hydraulic oil tank and brake oil A B C D
tank
48 Check accumulator pressure A B C D
49 Hydraulic Check if hydraulic pressure on the hydraulic nameplate C D
system is consistent
50 Replace all high-pressure filter cores C D
51 Replace brake oil and brake cooling oil filter core C D
52 Replace hydraulic oil and hydraulic system filter core C D
2-2 2-3
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
。 Take care of the filling-up amount of the engine oil Engine oil filter core
as charging. If the level is too high, the foam may
come out, lube ability may be decreased.
Otherwise, if too low of the oil level and there may
be not enough engine oil into the lube system.
The filter core of the engine oil plays a part of
filtering the engine oil. When the filter has been
Filter cover Dust collector Safety filter core
blocked, the engine oil may be blocked into the
system, the cooling and lube ability of the engine
★Change the diesel filter core
oil may be decreased. So that engine oil filter core
Filter indicator The diesel may be blocked into the injection
must be changed.
system by jammed and unclean filter, which make
As changing the filter core, something. Should be
the diesel deficient atomization, lowering the
taken out as follows:
working efficiency of engine.
Fresh engine oil and new filter should be used, the
Main filter core Attention while changing the diesel filter core:
seal rings of the filter should be infiltrated by the
The seal rings of the filter should be infiltrated by
fresh engine oil; tighten it by hand and then screw
the fresh fuel oil; tighten it by hand till touching and
★Change the engine oil and engine oil filter oil it three-fourths coil.
then screw it half coil.
Function of the engine oil: Oil drain plug
Diesel filter
― Cleaning: Wash away the wear scraps and
carbon in the system.
―Cool down: Take away the heat generated by the
engine and its components.
The performance and decontamination ability of
the engine oil may goes bad as the reason of
temperature and carbon, the reason is that the Before oil charging
viscosity of the water、diesel and engine oil has

Diesel oil filter core
been decreased. Besides, as the contamination of
the carbon, the acidity of the engine oil will be
increased, which may generate chemical reaction
with metals, so that the metal goes rusty. Because
of the reasons above, the engine oil should be
Filling the oil Fuel inlet Oil dipstick
changed after the usage of a period to ensure the
system normal.
We have to check the status of engine oil regularly.
Once abnormal situation is found, prompt
treatment should be taken. ★Change the oil-and-water trap filter core
Notice
No. Phenomenon Cause The main function of oil-and-water trap is to
1 Engine oil level arising The lube system is infiltrated with
Engine oil filter separate the impurity and water from the oil, and
water or coolant
so that it can provide clean fuel to the engine.
2 Engine oil with metal pellet Surface of the spool with is large area
Firstly detach the core from the top, then loose the
damaged
Piston ring damaged, the engine oil

bottom valve, clean the inner of the oil cup, replace
3 Quick reduction of the come into the combustion chamber, another new one (take care to change all the seal
engine oil engine oil leakage from the edge and O-rings), at last charging the fresh fuel oil.
joints
3-1 3-2
Notice Notice please change all the damaged seal rings、 buff when start-up of the engine.
As changing the filter core, it is necessary There may be bad influence to the connected pipe. Once the vent of crankcase is
to clean the bottom oil cup, so that it is obvious to coolant of the engine, normal working of the air blocked, the pressure will higher, the oil may
know whether the oil cup is clean. condition and generator if the belt loose. pressed into the gas handing system of booster
Bolt
Automatic tension pulley. and engine.
Check the tightness of the spring device. Notice
Shock pad
Check the inner shaft of the device. Never start the engine in the case of
disengaged of turbocharger and exhaust pipe. Framework
★Check the start-up、halt and operation of the

engine
Follow steps should be abide by before start-up: ★Check and adjust the gap of inlet and
★Inspect the quality and quantity of the
―Check all the oil level(engine、gearbox、 exhaust valve
cooling water
hydraulic oil、drive axle、planet gear、brake
Observe the cooling water on one's own eyes. It is
coolant);
necessary that the cooling water should be
―Exhaust the air of fuel system;
changed when it become worse. When the .cooling
―Turn the fire-key to start-up position, release it
water is not enough, you should recharge for fear
as the engine enable.
of overheat of the engine.
Do not let the engine work on the state of cold, Rule of thickness
Shell anti-freeze (ice point:-45℃) 50L
neither too the critical low speed, working for 2-3
minutes on the state of 1200-1500rpm till the
temperature gets normal is ok. ★change the filter core of cooling water
★Clean the contamination attached on the
surface of the radiator Notice Firstly close the stop valve, get out the old core,
It is important for the warm-up of the lube the o-rings with lubrication, then tighten the
In order to the cool the air thoroughly, periodical
engine, which may ensure the smooth run of the new one by hand, screw it by half coil. In the end,
clear away of the contamination is necessary.
engine oil before the high speed run of the turbine. open the stop valve.
Ways of clear away the contaminations:
―Take away the radiator cover; Notice
―Wipe out all the exotics on the radiator fins; The liquid level of the expansion tank The open and close time of gas gate may be
―Clean the radiator with abluent; should be checked, refill that in time. relevant to the gas gate cap.
―Inspect the damaged radiator fins and rubber It will be late if the cap big, and be earlier if narrow.
seal components. Way of adjusting the gap:
Cut-off valve Turn the crankshaft to the position that the inlet
Notice valve just open but the outlet valve incomplete
Do not wash the radiator with high
Filter open. Check the valve gap, adjust it if necessary.
★Check oil、diesel or water leakage
pressure water. Notice
Go around the machine, inspect the leakage of The check sequence of the air valve is 1-
oil、diesel or water. If any part leaking, marking 2-3-4-5-6, and the observe sequence of rotational
and cut off the power instantly. crankshaft is 6-5-4-3-2-1.
★Check belt and pulley
Belt checking mode: ★Check the damping pad and fixed bolt if they
Press down each section of the belt, the downward are loose See User's Guide of “VOLVO Engine”and
★Check the leakage of the turbocharger and It is essential to check if the damping pad “Cummins Engine” for more details of use and
distance should not exceed 10mm.
exhaust pipe damaged or the loose of the bolts before the start- maintenance.
If the belt loose, to tighten it.
You must check the leakage situation of the pipe of up of engine.
If still loose, replace that.
turbocharger as well as the connectors of each gas Function of damping pad:
If belt abrasion, change another one.
hose before the start-up of engine. If leaking, Fasten the engine onto the frame work,which can
3-3 3-4
3.2 Repairing and Maintenance of ★Change the gearbox filter Check items: fixed seating、damping pad、bolts Oil-immersed disc brake
Block of filter will reduce oil volume of gear shift

Transmission
and lubrication.
★Check and add the drive shaft oil
Change the filter core of gearbox:
Let the engine run slowly,then draw the dipstick to
Firstly detach the old core. Then the seal rings of
oil place of the gear-box.Add the oil as told when
the filter should be infiltrated by the fresh engine Fixed bolt
the place is lower than the lowest station.
oil; tighten it by hand and then screw it tow-thirds Damp pad
Differential
Framework
Notice
coil.
Select the right lubricating oil ,according
to the type of the gear-box. 3.3 Repairing and Maintenance of the
Drive Axle
★Check the tightness of the fixed bolts of
★Check the fixed bolts of the drive shaft driving axle
Driving axle
The loose bolts may be easily sheared in the Loose bolts may easily be cracked with load and
action of load and vibration. The fixed bolts should vibration.
★Change the gearbox oil
be inspected carefully for fear of any accident. Fracture of bolts may do a serious impact to our
Check if there is any prill in the old oil to see the
device, and may even cause injuries and deaths.
working condition of gearbox components. If it has
been polluted, open the fuel outlet, and give it off.
Parking brake system
As it is finished, first plug the outlet, then fill the oil
to the min position level. Start the engine, let the oil
reach the normal temperature, then check the oil
Fixed bolt Universal joint bearing dipstick, refill the oil to the max level position of oil
dipstick. Fastening bolt of driving axle
Check measures:
To see if the fixed bolts loose. Driving wheel
if the universal joint shaft damaged.

Relighted the loose shaft bolts with 200NM
moment.
★Check the speed sensor Fastening bolt of transmission shaft
Check the speed sensor and its support to see if Notice

★Clean the connector of vent hole
the speed signal can be transferred correctly into Tightness of bolts of drive axle: moment The purpose of cleaning the connector of vent hole
the control system by the inductor. For the 1200NM is to let the steam in the drive axle escape for fear
Oil drain plug Prefilter
protection of driving device, make sure that only
of high pressure in the drive axle. If not, may bring
when low speed can the gear position be shifted.
Notice about leakage of seal components.
★Check the leakage of driving axle and brake
Shell DonaxTD5W-30 shafting oil is
components
adopted for DANA Clark 36000.
Check items:
Oil dipped disk brake and its connecting tube、
Universal joint bearing parking brake system and its connecting tube、
★Check if the fixed bolts and fixed seating are
differential mechanism、drive wheel and drive
loose
axle.
Action of fixed seating and damp pad:
Transmission shaft Vent
Rotation speed sensor
It plays a part of damping the vibration as the
start-up, operation or halt of gearbox.
3-5 3-6
★Check the hand brake block and hand brake causes carriage tail to tilt, the clearance between ―Detach the lock cushion ring and lock nuts; 3.5 Repairing and Maintenance of the
function inductor and induce block will be enlarged, the ―Tighten the nuts with the moment of 350NM;
Spreader
Start up the engine; do not stop it until the induction will send no signal. With this mode, a rotate the wheel hub for 10 loops;
★Check the rotary-lock and its components
accumulator charging. Stop the engine, turn the kind of overload signal mill be formed, which make ―Tighten the nuts with the moment of 350NM
Check the rotary-lock components if damaged,
fire key to position 1.release the parking brake, the container retain to current state for fear of again; check the spacer ring of wheel hub if it lies
change it if necessary.
inspect that if the parking brake nipper can shift on accidents. on the wheel axle. If not, retighten it;
Check the position of rotary-lock link rod if correct
the bracket, as well as the cap of brake gasket and Before the machine lifting, please carefully inspect ―Mount on the lock nuts, tighten it with the
and firm, adjust that if necessary.
Brake disk if it satisfied to the requirement, adjust it the reliability of inductor. moment of 350NM;
Notice
if necessary. To find out if the sensor damaged as well as the ―Film the grease on the safety cover of shaft,
It is important to check the rotary-lock and
reliability of angle-bar of induce then fixed on.
its components because it plays a key role of lifting
block or bolts and if the space of inductor normal.
the containers correctly and safety.
Danger
There may be danger of crush if machine
Fixed nut Steering wheel shaft
shift freely, so in order to avoid accidents, make
Notice
sure that the truck may not move even if the brake
is released. Take care of the abrasion state of shaft,
change that immediately if damaged.
3.4 Repairing and Maintenance of the
★ Check if the knuckle-pin and fixed nut are

Steering Axle
loose
★Check if there exists the gap or damage of
Clear out and check the shaft bearing. Check the
components of steering axle
Check steering cylinder、joint shaft and joint ★Check the tyre if deviate knuckle-pin if it can roll smoothly, and the max
In normal cases, all the wheels should swing to the rotate distance is not allowed to exceed
bearing、steering link rod、damping pad、and ★ Check the status of rotary-lock inductor and
same direction, and be parallel of the back wheel. 0.25mm.Free stroke can be adjusted by the nuts.
counterweight, if any component loose or any indicator
abnormal cap and damage as well as the leakage If there is something serious, please check the
Check items:
of the steering axle. if one of the cases occurred, linking structure.
Each inductor and its connection status;
deal with it immediately. Each inductor if not firmed or damaged;
If the gap of inductor block normal;
If the indication lights are in the normal operation
state.
Knuckle pin Bearing
Notice
Find out the abrasion and loose
★Check if the steering wheel shaft and fixed components as early as possible and take some
bolts loose measures to give a precaution for fear of
Check measures: accelerate failure of some components.
★Check the anti-tipper inductor
Function of anti-tipper inductor: ―Detach the wheel hub cover; Indicator lamp
In normal condition, anti-tipper inductor is in ―Clean out the grease of wheel hub cover and
normally closed state.When hoisting overload steering wheel shaft;
3-7 3-8
3.6 Repairing and Maintenance of the

Jib System
★Check the fixed seating and pin roll of the
basic boom if loose or abrasion
The fixed seating and pin roll of the basic boom is
Inductor
the key components connected with frame and
spreader. And the stability of structure and welding
of fixed seating, pin roll, bearing of pin hole and
★Check abrasion status of the slide blocks in
fixed bolts should be checked periodically. Please
the spreader
color them if necessary.
There are two kinds of slide blocks on the
spreader: side-slide blocks and 20'-40' extension
Inductor blocks, which do an action of sustention and
guiding.
Firstly detach the bottom strap, shim and slide
Inductor block, then measure the thickness of slide blocks ★General observations of cracks
as well as the gap of slide block and slide The spreader is the direct container-lifting device
components, adjust and change the shim if of the machine, usually inspection of the important
necessary, at last reinstall the strap. components, to find out the cracks as early as
possible is necessary.
★Check if there exists the gap or damage of

components of steering axle ★Check the fixed seating and pin roll of the
Regularly inspection on the fixed bolts is pitch cylinder if loose or abrasion
necessary for fear of accidents caused by loose of Check if there is any crack around the fixed
bolts. seating; please color it for next inspection if
Rotary motor is composed of hydraulic motor, disk necessary.
brake, planetary gear set, who are connected by
fixed bolts.
The hydraulic motor lies on the upper of disk
brake, which provides rotary power. Disk brake is
something that avoids accidental rotation and
followed by the rotation of hydraulic motor, which
makes the brake released and spreader planetary
gear rotated, so that the output of motor and disk
brake will be enlarged.
★Check if the slide block of basic boom wears

to extreme
Firstly detach the strap, shim and slide block, then
3-9 3-10
measure the thickness of slide blocks as well as ―Check if the fixation of pipes is in good condition, ★The Dismantlement of Tyre
the gap of slide block and slide components, adjust pipes is over close to the heating component, ―Before dismantling tire, deflate the tire to reduce
and change the shim if necessary, at last reinstall rotary component and control rocker arm; the air pressure;
the strap. ―Check if the connector of circuit harness is in ―While dismantling tire, do not use sharp tools; do
good condition, harness fixation is solid. Pay not pry the tire bead forcibly; do not hit the tire with
special attention to the compressor clutch plug; a big hammer.;
―Check if the fixed bolt of compressor is ―While dismantling tire, replace the O-shape loop.
fastening; Before installing felly, check the O-shape loop to
―Check the fixed bolt of air conditioner is see whether there are any defects and apply
fastening; lubricant on it;
―Take off fresh air filter core, blow the dust off ―While dismantling tire, use the bead detacher or
from backside, and reinstall it. tire detacher. Forcible prying and smashing should
★General observations of cracks of basic Main checking items within 100 hours: be prohibited to avoid damage to the sealing layer
boom ―Recheck the above checking items; Notice in the tire and bead. To facilitate the installation,
Usual inspection of the usage of basic boom, to ―Blow the condenser with compressed air. Don't Don't over charge the tyre, keep the tyre neutral soap lye or special lubricant can be applied
find out the cracks as early as possible, then deal use the high-pressure squirt gun; pressure in a normal condition. to the bead bottom and ring support of the felly.
with that immediately for fear of deeper damage. ―Clean out of the dirt on the condenser. some lubricants, such as grease lubricant, which
Main checking items within 200 hours: affect the quality of the tire, should not be adopted.
―Recheck the above checking items; ★Check the tyre platen and nut tightness
―Change the fresh air filter core; Check the tyre nut tightness, Screw the rear axle
―Adjust the transmission strap tightness of nut with 350NM moment, front axle with 450NM ★Installation of Tyres
compressor. moment. ―Install the tire in the felly, which is installed in the
wheel hub. The direction mark on the side of the
Notice
Add proper amount of coolant. Too much tire should be in consistency with the forward
or too less would affect the cooling effect. Air direction of the front-handling crane. The locating
conditioner should be started for several minutes cone hole in the felly should match the outer cone
every week in order to lubricate each component of the hub to ensure the superposition of the felly
even in winder. center and the hub center;
―When the tire is pumped, the pumping pressure
★Attention when changing the tyres should be ensured at around 1Mpa;
3.8 Repairing and Maintenance of ―If the tire treads at the 1/4 breadth of the tire is ―Install the pressure plate on the threaded stud of
Tyres worn in 2~3mm, replace the tire; the hub and screw the hub nut. The hub nut should
★Check the tyre condition and pressure ―Old tyres can be replaced with retread tyres; be screwed down gradually with symmetrical force.
Before starting the equipment, check if there is any ―Must use tyres appointed by Sany Group. Using The moment of screwing down the hub nut is
cracks on the tyre surface, any corrosion and over- different type of tyres may cause early damage of 350~370Nm. When the nut is screwed down, make
wear. Change the over-wear tyre. Check and clean tyres or tyre explosion and endanger people and sure 2~3 circles of screw thread of the stud
dirt on the tyres, such as glasses, etc. Check tyre equipment; expose;
3.7 Repairing and Maintenance of the ―Changing dangers is companied with danger. ―Test the installed tire by spinning it. Make sure
pressure, add it when it's too low. Low tyre
Air Conditioner System pressure may have bad influence on stability and Trained workers must follow the operation steps the right-left amplitude of swing at the maximum
Main checking items within 50 hours: load capacity of the equipment. with proper tools. Any operation doesn't follow the outside diameter of the tire is less than 3mm.
―Check transmission strap tightness of standard schedule may cause explosion which has
compressor and adjust it promptly; enough power to hurt even kill someone;
―Check the leakage of each pipe connector. ―Anyone without formally training is strictly
There might be leakage when the refrigerant forbade to install or dismantle tyres.
connector has grease dirt;
3-11 3-12
3.9 Repairing and Maintenance of the measured value (the max charging pressure) such as dust, sand, liquid and gas, the pressure of
Accumulator of brake system
Hydraulic System as the accumulator has been charged completely, oil tank may be higher if the breather filter blocked,
then get another valve as the accumulator being so periodically change the breather filter.
★Check the oil volume of main hydraulic tank
recharged(initial charging pressure).
and brake tank
The accumulator measured pressure is composed
Check the oil volume of hydraulic tank and brake
Accumulator of control system of brake system and control system testing ★ Change the return oil filter
tank if it is sufficient by the window (the oil level
pressure, whose rated pressure are 10 0.5MPa The flow may be hampered if the filter blocked,
height should exceed the red line, at the position of
and 2.5 0.5Mpa individually. which bring about high pressure of outlet and burst
3/4 of the window), if deficient please fill in.
of oil tube.
★Check the if hydraulic pressure is consistent
with the hydraulic rating plate ―Spreader system pressure testing
―Test of the main system pressure The spreader system pressure is 14 0.5Mpa. 3.10 Repairing and Maintenance of
Electric System
★Check if there is enough battery water
Observation ★ Change the entire high pressure filter
Main hydraulic oil tank Brake oil tank window
Check the voltage of battery, which should be 23-
for oil volume Blocked filter may lower the flow of hydraulic oil,
25V as the engine halted 27-29V as the max
the movement speed of cylinder may be affected,
speed.
besides, it will bring about to greater oil pump
Notice As the engine powered off, turn off the main
pressure to make the tube easy to burst.
As checking the oil volume, all of the switch, tidy the battery, tie line and joints. Check all
The hydraulic system is sensitive to the impurity;
cylinder should retract to the original position. the connectors if they are tightened. Smear the
the tight damage of chromium piston rod may bring
grease on the binding post and connectors, put a
about the leakage of seal components.
rubber gasket under the battery for fear of drain,
★Check the pressure of accumulator Notice and check the height of electrolyte, which should
Replace all the seal O-rings; change a
There are two accumulators of hydraulic system: be 10-15mm higher than the battery, fill with the
new filter core with the moment of 140NM.
Brake system accumulator and control system plasma water when it is not enough.
Diagram of hydraulic rating plate
accumulator;
Start the engine, to keep it in idle speed; there are
Start the engine; let it rotate at idle speed for 5
two main pressure testing points, whose testing ★Change the hydraulic oil and brake oil
minutes (the accumulator may not be charged
pressure should be the same. The result will be The oil may be worsened gradually by the effect of
completely until the charging valve of brake system
displayed on the screen. pollution and heat; metamorphous oil may
accumulator shift to coolant loop). As the engine
accelerate the abrasion and erosion of
halted, turn over the start-up key to position 1,and
―Brake pressure testing components such as pump and valve, take Battery Add electrolyte
then step on the brake pedal iteratively with under
Brake pressure should be 14.5±0.5Mpa periodical examination, change the hydraulic oil Test voltage
square mode and to keep a small period of time at
Notice and brake oil.
stepping position each time. There can be at least
Please step on the brake pedal as testing Please adopt for the VG68G hydraulic oil at the
20 times brake before the warning light on, if not
the pressure of brake system. tropical zone or long-time use place.
there may be some problems in the system; you'd
better give a further inspection. There are also Notice
―Steering pressure testing Do not forget to fill in the oil for main
pressures testing joints, which can be measured
To keep the engine with medium speed, turn the pump case first before you have finished the whole
directly.
steering wheel to only one direction. the max renewing of the oil.
★Check all the work light and indication light
pressure you have got in this process is steering
Generally, the accumulator pressure of control Turn on all the work lights and indication lights, to
pressure. The valve is 1.75±0.5MPa.
system is satisfied to the requirement of control see if they are normal.
★Change the breather filter of main hydraulic
system.
―Accumulator pressure testing tank and brake tank
Start the engine, release the pressure, and get The hydraulic system is sensitive to the impurity
3-13 3-14
LUBRICATING LUBRICATING
★Test the overall function of hydraulic system

Operate the electro-hydraulic control handler; test Lubricating Table of the Machine
all the hydraulic functions such as pitch and
contraction of jib, expansion, contraction and
sideshift of spreader. Find out parts that need Lubricating points Brand Amounts Cycle
adjustment. Steer axle 15
Front headlamp Rear headlamp
Boom lamp Pitching cylinder fulcrum 2
Lubricating pump 4
Jib extension and contraction
14
lubricating block
Extension and contraction surface of
6
spreader
★Check horn, reverse buzzer and rotary
Pivot of jib and spreader 2
warning light
4.Lubricating Damping cylinder lug of spreader 4 60 h or every
Turn on the horn, reverse buzzer and rotary
Mobil lubricating
warning light to check they are working. Sideshift cylinder lug of spreader 4 week
grease EP2
4.1 Lubrication Sideshift surface of spreader 4
Add lubricant coating in order to ensure the Extension-contraction cylinder lug of
★ROPS system test smooth rotation and sliding parts, not sufficient 4
spreader
Test if the ROPS system is working. Once the lubrication can cause issuing and excessive wear
controller get the front tilting signal, it would lock Rotary lock of spreader 8
parts. Lubricant is to guarantee the normal
the motion immediately (except contraction), give a operation of machine of lubricating necessary Turntable slewing bearing of spreader 4
warning and flash the red light. The signal would materials. Transmission axle 3
get through relay to control the front red acousto- Reach stacker use Mobil EP2 hanging type
Parking brake 1
optical alarm prompt. Once the controller gets the automobile universal lithium grease, banning the
signal, that red light would turned on, display Shell Diesel engine
use nonspecified lubricant by Sany Group. Diesel engine 1 250 h
screen will also have the malfunction warning CG-415W40
Lubricating (butter) method:
signal. Firstly clean the grease fitting, do not stop to inject Shell transmission oil 1000 h or one
Brake oil tank 1
the butter with the grease gun until the old grease DonaxTD5W-30 year
is forced out. Shell gear oil VG150 1000 h or one
Reducer of driving axle 2
（>0? ） year
Shell gear oil VG150 1000 h or one
Differential of driving axle 1
4.2 Lubricating Table （>0? ） year
Shell anti-wear 2000 h or one
Hydraulic oil tank 1
hydraulic oil VG46T year
Shell multi-function
★Test the Rotary-lock safe interlocking device 2000 h or one
Torque converter transmission oil Donax 1
system year
Before turning on the rotary lock, check if all the TD 5W-30
standby lights (green) is on; while the rotary Shell antifreeze
Engine radiator 1 one year
isworking , check if all the sensor light (yellow) is (freezing point-45°C)
on; check if clearance between sensor and
sensing block is normal, if there is any sign of
abnormal, treatment should be taken promptly.
4-1 4-2
FUNCTIONAL OIL FUNCTIONAL OIL
5.2 Oil Capacity The quality analysis refers to regular laboratory tests
made on various items, including the viscosity,
You must use the right Fuel、Hydraulic Liquid、
oxidization, water content, additives and cleanliness.
Cooling Liquid as SANY test says, and check the
They will be compared with the normal value to
quality and quantity of all the liquid often. Only all determine whether the hydraulic liquid needs to be
the liquid has good quality and enough quantity, replaced. Among the items, the cleanliness is the major
the engine is able to work. one which indicates the quantity and size of the solid
particles in the hydraulic liquid.
Capacity Table This system's requirement on the cleanliness of the
hydraulic liquid equals to level 8 or level 9 in NAS1638
Item Capacity (L) which is comparable to 17/14 level of ISO standard.
The Fuel Tank 470 Please see the two tables:
The Hydraulic Liquid 900
Type Brand Specification -30 -20 -10 0 10 20 30 The Engine Cooling Liquid 50 NAS1638 Standard
The Gear-box and Torque Converter 60
The Level Of The Size of Solid Particles (μm)
Fuel Diesel oil -20# The Driving Axle 49
Cleanliness
The Wheel Reductor 2 11 5～15 15～25 25～50 50～100 >150
Shell diesel engine API Classification SAE10 SAE30
Engine oil The Engine Oi 35 Level 7 32,000 5,700 1,012 180 32
CG-415W/40 CC or above SAE10W/30 SAE20W
The Brake Oil 150 Level 8 64,000 11,400 2,025 360 64
Shell gear oil
Driving axle Level 9 128,00 22,800 4,050 720 128
VG150(>0℃). GL5 SAE80W SAE90 Notice
oil
VG100(≤0℃) The capacities in the above table are for Notice
Transmission Shell transmission oil reference. The level 8 in the NAS1638 indicates that,
SAE10W/30 The oil level indicator is placed on the side of the in the 100ml oil sample, the number of the particles
torque DonaxTD5W-30
oil tank in order to check the oil level in the tank. with the size of 5~15m will not exceed 64,000; the
converter oil
number of those with the size of 15~25m will not
Shell anti-wear exceed 11,400, so on and so forth.
Hydraulic oil hydraulic oil SAE10～20W SAE30～40 5.3 Check and Change of Hydraulic Oil
VG46T（>0℃）Shell The Shell brand antiwar hydraulic liquid is adopted The ISO Standard
for this machine. The hydraulic liquid in the tank (DIS4406, SAEJ1165)
transmission oil
Transmission
SAE20W/40
should be checked every 6 months in the forms of
DonaxTD5W-30 SAE10W
cooling oil the appearance appraisal and quality analysis. Level of The Size of the Solid Particles（ μm）
The appearance appraisal refers to estimating Cleanliness
G eneral lithiumed oil >5 >15
Lubricatiing
Maypoles oil EP2
whether the performance of the hydraulic liquid
oil deteriorates. Please see the following table: 16/13 16,000 8,000
Shell antifreeze 17/14 125,000

Antifreeze -45℃
(freezing point-45 Appearance Appraisal of Hydraulic Liquid 18/15 250,000 32,000
19/16 500,000 64,000

Phenomenon Contaminant
Oil features are different from different manufacturer, so client should use recommended oil. Darkening Color Oxygen Notice
Milky White Water or Bubbles The cleanliness level 17/14 in ISO
Bubbles
standard indicates that, in the 100ml oil sample,
Air
Floating Impurities or Sediments
the number of the particles with the size above 5m
Solid Particles
should not exceed 130,000; the number of those
Separation of Oil and WaterSeparation Water
above 15m should not exceed 16,000.
of Oil and Water
5-1 5-2
FUNCTIONAL OIL CHECKING OF KEY BOLTS
During utilization, the particle contamination level Proportion: + 5.8%～6.5%（Suitable environment 6.Checking of Key Bolts Bolts' Fastening Torque of Main
in the hydraulic liquid in the tank should not exceed temperature ＞-5℃） Components (Undetermined)
18/15 (which is comparable to NAS10 level)
The hydraulic system of this machine has the Hydraulic oil type: Before start, carefully check fastening status of key Recommended
Bolt dimension
following items for oil change: Shell hydraulic oil No.68（Suitable environment bolts. Loose bolts will possibly cause acute fastening torque(Nm)
Variations of viscosity: 10 temperature≥35℃） shaking, damaged parts, weak function, broken M12 1 20Fixed bolt of engine 75 5
The increase of acid number: 0.1~0.25mgKOH/g Shell hydraulic oil No.46（Suitable environment bolts, and other dangerous phenomena, and, M16 70
Moisture: <0.1% temperature 35℃～-5℃） periodic check will avoid accidents. 200
Fixed bolt of torque converter
Mechanical Impurities: 5% Shell hydraulic oil No.32T（Suitable environment The following items of the bolt should be carefully
M12 130
Variations of density (15C/4C): 0.05 temperature≤-5℃） checked: 65
Fixed bolt of transmission axle
Copper sheet erosion: disqualification ―Checking of fixed bolt of engine
1150
Rust preventing ability: disqualification Southern area of China（All year long） ―Checking of fixed bolt of torque-converter
M24 360Fixed bolt of driving axle
Ash content: 0.05% Brake oil—Hydraulic oil No.46+AdditiveLZ9990A， ―Checking of fixed bolt of transmission shaft M24 2 Fixed bolt of tyre platen 980
Proportion: 5.8%～6.5% M30 2

Variations of surface tension: 15 dyne/cm ―Checking of fixed bolt of drive axle 475 1 0
Hydraulic oil—Shell hydraulic oil No.46
Residue carbon: 0.05~0.10 ―Checking of fixed bolt of crane spreader rotary Fixed bolt of steering cylinder
Variation of color (Union grade): above +2 gear case M30 1 40
1600 1 0
Guangdong province (China), Southeast Asia,
Brazil, New Zealand etc, areas
―Checking of fixed bolt of tyre pressure plate Fixed bolt of up/down counter weight
The hydraulic liquid, the checking results of which
are not up to the requirement, should be changed Brake oil—Hydraulic oil No.46+Additive Notice
Notice
in time. The change of oil should follow the LZ9990A，Proportion: 5.8%～6.5%
If the bolts are loose, please check it with torque
following steps: Hydraulic oil—Shell hydraulic oil NO.68
spanner and screw the bolts and nuts to torques ― Make sure thread on the bolts and nuts are
―Remove the plug on the bottom of the hydraulic
according to figures in the following table. If bolts clean before install them.
oil tank to drain the hydraulic oil in the tank and Northern area of China, Germany, Sweden,
or nuts are broke, they should be replaced with ―Lubricate the bolts and nuts to stablize their
pipe. America, Australia etc, areas
equal or higher standard bolts or nuts. friction coefficient.
―Open the hydraulic oil tank to clean the hole cap. Brake oil—Hydraulic oil No.32T + Additive
―If the bolts of counter-weight are loose, screw up
―Use the cleaning liquid (diesel, etc.) and paste to LZ9990A，Proportion: 5.8%～6.5%
Fastening Torque Standard immediately; please connect your nearest and
clean the oil tank. Hydraulic oil—Shell hydraulic oil NO.32T
Sany service engineer.
―If it is qualified after being checked and cleaned, Standard Nut and Bolt ―Standard measurement of torque is Nm:
the cleaned hole lip should be installed back. Severe cold region (temperature lower than-25
Screw Standard Screw Standard For example: Screw bolt or nut with a spanner(1m)
―Add oil to the tank: Open the air filter lip on the ℃）,Russian, Canada etc, area
Thread Fastening Thread Fastening with 120N force twisting the spanner end, which
top of the oil tank. Add the hydraulic oil filtered by Brake oil—Hydraulic oil No.32T + Additive
dimension Torque（N.m） dimension would generate following torque: 1m*120N
5m filter (filtering car) to the oil tank through the LZ9990A，Proportion: 5.8%～6.5% Torque（N.m）
=120Nm
filter element until reaching the full scale of the oil Hydraulic oil—Shell hydraulic oil No.32T M6 12 3 M14 12 3
Same torque by using a 0.25m spanner:
indicator. M8 28 7 M16 28 7
0.25m*y=120Nm
Changing period:
M10 55 10 M20 55 10 Needed force: y=120Nm\0.25m=480N
Hydraulic oil—Running-in of new equipment:
change it after 50 h ;second time: 500h ，following M12 100 20 M30 100 20
5.4 Using Principle of Oil
changing period: 1000h
Working temperature of brake oil and hydraulic oil
Hydraulic oil—Running-in of new equipment:
don't exceed 80℃,selecting principles are：
Change it after 50h; following changing period:
Brake oil:
2000h
Hydraulic oil No.46 + Additive LZ9990A，
Proportion: + 5.8%～6.5%（Suitable environment Notice
when the environment temperature is
temperature ＞-5℃）
under 0℃，equipment has to be warming-up for
Hydraulic oil No.32T +Additive LZ9990A,
one hour.
5-3 6-1
SAFTY REGULATIONS DURING MAINTENANCE WORK COMMON FAULTS AND MEASURES
7.Safty Regulations during 8.Common Faults and Measures 8.2 Common Faults of Mechanical Systems and Measures
Maintenance Work
8.1 General Table 8-1 Common Faults of Mechanical Systems and Measures
Safety regulation while maintenance, checking and The machine can finish the operations such as Category Faults Cause of faults Measures
lubricating. pile; fetch containers and operating with
containers. It must bring some certain impacts to Temperature is too low ; preheating
★Safety regulations in working place： users on the progress of work, economic and Difficult to start up time is short; Air filters or air intake
―Make sure equipment parked in a safe place； social benefits, etc. when the faults occur. With a jammed; Thermostat is failure;
―Segregate a safe area with a ribbon if timely diagnosis and elimination, the customers Starting voltage is insufficient
necessary; can restore the economic losses and keep our
―Arrange a signaler to assist the work if corporate image. This section will state the
Engine high-speed EDC fuel control unit has problem Engine high-speed
necessary. common faults of machine and give elaboration
corresponding to the measures in three major Bellows cracks with air-leakage Self-faults Replace
★Safety regulations of product: aspects of mechanical system, hydraulic system, Engine speed up with difficulty EDC fuel control unit with problem Check the EDC fuel control unit
―Use warning sign; and electrical control system. No oil in tank; oil-pipe plugs ; air Check whether the fuel is out;
―Cut off or lock the electric power switch to Engine parking by itself enters into oil-pipe Check whether oil line plugs or
prevent unauthorized reenergize; enters with air
―Release the electric power or discharge the Check whether coolant water is
storage energy liquid power, gas power or electric Engine Lack of water coolant; Thermostat enough;
power; is Engine temperature is too high failure; The fan belt is loose; The Check thermostat;
―Regarding to information of certain situations abnormal water pump is damaged Check whether the fan belt is loose;
and working conditions which haven't included in
Check water pump
this manual, please ask manufacturer for help.
The water with oil but oil without Engine Oil Cooler is damaged Check whether the oil cooler
★Safe protection of persionnel： water is damaged

―Must wear working clouth, helmet and safe Replace;
shoes while working; Cylinder head Cracks Self-faults / coolant is not enough Check whether the coolant is
―Safty belt must be weared while working in high enough
position;
Check whether cylinder head or
―Hang the warning brand of “stop, in repairing” on
Fuel level of oil sump tank (with Cylinder head or cylinder body cylinder body crack;
the equipement.
water) cracked; cylinder liner water Check whether cylinder circle
damage
Lubricating oil pressure is too Low-oil level; oil filter jammed; Add or replace lubricating oil;
Low lubricating oil is too thin Replace filter
Water leakage Water tank is damaged Replace
Oil radiator leakage(gearbox) Oil radiator is damaged Replace
Check whether the fuel oil circuit
Insufficient fuel; Diesel does not flows smoothly;
Engine power is not enough meet the quality requirements; The Check whether the air intake is
air intake jammed smooth;
Use the appointed fuel
7-1 8-1
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Category Faults Cause of faults Measures Category Faults Cause of faults Measures
Automatic deceleration of the Check whether the fuel circuit flows Check the signal of gearbox
Oil supply is not smooth
engine smoothly Gearbox control unit if it is normal、check
The diesel rough filter and Diesel is too dirty; the cleanliness of Use the clean diesel; is Gearbox cannot shift Gearbox control unit with problem the magnetic coil of gearbox
s e c o n d f i l t e r o f e n g i n e j a m m e d diesel box is not enough Clean the oil tank abnormal
magnetic valve if it is burn-out、
Engine exhaust pipe leakage Exhaust pipe is damaged; exhaust Check the leakage position and
the valve core if it is blocked
pipe joint is not sealed enough repair Low brake oil pressure、oil brake
Engine fan belt broken Self-faults; the belt is too tight Replace the belt; circuit with air、brake block Check weather brake oil leakage
Engine Adjust the belt tension Drive axle Foot brake force not enough abrasion and invalidation
is Wear intensity between air valve and Replace air valve or guide tube; is Check the fans of cooler system
abnormal E n g i n e w i t h b l u e - s m o g Replace oil scraper. abnormal
guide tube becomes larger; oil High temperature of brake oil change the flabellum if they were
scraper ring is damaged damaged

E n g i n e s p e e d u p w i t h d i f f i c u l t y EDC fuel control unit with problem Check the EDC fuel control unit Big noise Gear damaged、shaft bearing wear Replace the wear and damaged
Engine supercharger with oil Supercharger sealing component is Replace the sealing components components
or damaged
leakage damaged gear change Manual shift is incapable Inspect the contact
Contact Failure
Fuel meter shows wrongly Fuel meter or liquid level sensor is Check fuel meter and liquid level handle
sensor Work Handle Joystick failure Contact Failure Inspect the contact
damaged
Oil seal of engine front Replace Traversing Angle adjustment failure Retaining mechanism Failure Check the retaining mechanism
Self-faults
crankshaft with leakage machine
Cab mobile
Cab cannot move Brake cylinder cannot release Check the oil circuit of brake
Low oil pressure、low oil level、 Check the oil level；
mechanism
Clutch slipping cylinder
charging pump is damaged、 Check the charging pump；
Cab shock Cab vibration; big noise Tighten loose bolt
Change the clutch Tighten the loose bolt
Clutch abrasion and invalidation
damper
Check the charging pump；
Low oil level、charging pump is Check the oil level of luboil；
Gearbox damaged、high oil level、too much To avoid to make the torque
is working hours on fallback condition converter work on the condition of

High oil temperature
abnormal of torque converter、the clutch fall-back mode;
cannot break away in the condition Step on the clutch switch as brake,
of long period brake check the clutch switch if it is
available
Gear mesh with problem、shaft Check the gear mesh condition；

Big noise
bearing abrasion or damaged Change the damaged or abrasion
shaft bearing
Low oil level、charging pump is Check the charging pump；

Deficiency pressure of oil
damaged、pressure control valve of Check the pressure control valve；
pressure gauge
clutch is damaged，oil seal Change the damaged seal
components
components of clutch is damaged
8-2 8-3
8.3 Common Faults of Hydraulic System and Measures

Category Faults Cause of faults Measures
①Parking brake failure ①Clean the parking brake
Table 8-2 Common Faults of Hydraulic System and Measures
Brake Without the handbrake or ②Magnetic valve failure ②clean the magnetic valve or
Category Faults Cause of faults Measures System handbrake failure ③Feed pump Failure change
Libration phenomena as the Magnetic valve blocked Clean the magnetic valve ④Shuttle Valve Failure ③check the return line
boom retraction ④Clean or Replace
①Internal drain of telescoping ①Strip inspection and change the ①Insufficient fuel supply ①check the system pressure
Automatic retraction of the pitching cylinder seal components ②Hydraulic steering gear failure
Steering ②clean and replace
boom ②Self-lock function of logic valve ②Check the logic valve Poor or not to shift ③Serious leakage of steering
System ③change the seal components
invalidation cylinder ④clean
①Low oil pressure ①Check and adjust the pressure ④Prefill valve Failure
Boom ②Logic valve with problem valve of between pump and main ①cooler failed ①replace
System No pitch、telescoping of the ③Only one movement of differential valve ②Air-cooled hydraulic motor of ②change the hydraulic motor
boom magnetic valve ②Check the logic valve cooling circuit is damaged, made ③change the back pressure spring
③Check the electrify state of inadequate wind ④change the reversing valve
differential magnetic valve Cooling High oil temperature
③Oil supply of loop feed pump is ⑤clean the cooler
①Low oil tank level ①Add the hydraulic oil to the tank System not enough ⑥swash the out radiator
The boom can not reach its
②Cushion protection distance of ②Minish the cushion protective ④Inter drain of change valve is
position
telescoping cylinder is too large distance serious
③Deficiency pressure of the system ③Increase the working pressure of ⑤low flow of cooler
the system ⑥out radiator is too dirty
①Overfall valve、relief pressure ①Change and clean the overfall ①Use the substandard quality
valve damaged or valve core valve、relief pressure valve hydraulic oil

No pressure in the system
blocked ②Check the oil pump feedback ②Use the substandard viscosity
Spreader
System ②No output of oil pump oilcircuit hydraulic oil
①Electrical Fault ①Change the circuit ③Long-term use of hydraulic oil Check the mass of hydraulic oil;
Without movement
②Magnetic valve is damaged or the ②Clean or change the magnetic without filter or change Periodic filteration
Hydraulic oil pollutes and goes
Hydraulic ④The constant input of dust, sand Change the filter core periodically
spool is locked valve
Oil bad
and other debris Change the hydraulic oil
①Adjust the distance of brake
⑤High temperature; oxidation
①Brake valve failure valve
metamorphism
②Brake Failure ②Check the clearance of brake
Brake Without foot brake valve the ⑥Enter with water and air, as a
③Pressure Relay Fault block
System brake function failure result of cavitation erosion etc.
④Accumulator Failure ③Clean or Replace
⑤Gear pump Fault ④Replace

⑦Filter plug
⑤Replace the gear pump ①seal components damaged or ①change the seal components
⑥Brake valve block fault Leakage of hydraulic oil
⑥Clean or Replace the valves distorted ②tighten the loose parts
②joints、pipelines are free
8-4 8-5
8.4 Common Faults of Electrical Control System and Measures

Category Faults Cause of faults Measures
Big error of movements of ①Adjusting valve of pressure switch ①Reset
Due to the complexity of malfunction of electric-control system, careful observation and
pressure switch inaccuracy ②Change
research and rich experience are needed to determine the real cause of malfunctions.
②Invalidation of pressure switch
After determine the cause of malfunctions, eliminate them from the easy ones to hard
①Broken circuit ①Check and recovery
ones. No signal of pressure sensor ②Reverse of power line and signal ②Check and correct
line
Table 8-3 Common faults of electrical control system and measures Electricity
①Line abrasion, there is contact
component
Category Faults Cause of faults Measures Big Error of pressure sensor resistance between signal line and ①Check and recovery
①Broken circuit or short circuit power line ②Change
②Rust-eaten of magnet ①Change loop ②Invalidation of sensor

Non-operation of Magnetic ③Spool abrasion or invalidation of ②Scrubbing magnet Wrong signal of accelerator
valve seal-ring aging ③Change spool or seal ring pedal, start-up the engine, Reverse of pedal power wire and
④Severe oil carbon pollution in the which reaches the max speed, ground wire Check and recovery
④Scrubbing magnet
valve ⑤Change the spring when step on the pedal, the
⑤Invalidation of deflection spring speed reduces

Air Ejection from Magnetic valve Change the magnetic valve
Invalidation of magnetic valve
①Check and recovery Non-operation of wane switch ①Wane switch failed ①Change
①Short circuit
Water level alarm as full water ②Change ②Lead wire is off ②Check and recovery
②Fault of structure of water level
tank ③Full install，make sure that the ①Bulb broken ①Change the bulb
switch
switch close if there is water in the Indicator light failed ②Something wrong with electricity ②Find out the reason then deal with
③Reverse of water level switch
water tank wire it
Electricity
①Broken circuit ①Check and recovery ①Too soft of contact spring
component No indication of fuel level ②Check and correct ②Ragged and protrude bottom ①Adjust the elastic force
②Reverse of power line and signal
Contactor armature cannot fall board ②Remove of the protrude part
line
when electricity failure
①Line abrasion，there is contact ③Tightly seized of armature and ③Refit that to make it more flexible
resistance between signal line and ①Check and recovery mechanical parts ④Change the contacts
Inaccuracy of fuel oil level Electricity
power line ②Change ④Contacts are fusion welded
component
②Invalidation of sensor together
Contactor cannot fully close Adjust the elastic force of the
Too soft of contact spring
Non-operation of Temperature ①Fault of circuit
①Check and recovery when power on spring
switch ②Switch damaged
②Change ①Find out the reasons then deal
①Load exceeds the rated capacity
①Inaccuracy of temperature switch
①Readjust with it
②Large range of contacts
Big error of temperature switch adjusting valve Contact of relay generates heat
②Change ②Change the contacts
③Severe burning loss of contact
②Invalidation of temperature switch
③Change the contacts
④deficient pressure of contacts
Non-operation of pressure ①Fault of circuit
①Change ④Change the contacts
switch ②Switch damaged
②Check and recovery
8-6 8-7
①Find out the reason then deal with ①Circuit broken ①Check and recovery
①There is dust、dirt or burnout it ②Burn-out of power fuse ②Change the fuse

Pool contact of relay
②Too soft of contact spring ②Inspection on spring force, ③The fuse of enter point power is ③Change the fuse
Electricity
Change that if necessary No response of screen when the burn-out ④Check and recovery
component
system is electrified ④Input-output circuit failure
①Contact is not qualified ①Change the contacts ⑤Check and recovery，refresh the
There is sparkle on the contact
②Too soft of contact spring ②Change the spring ⑤Endless loop of program program
of relay when it is closed
③Burning loss of contact, poor ③Change ⑥The controller is damaged ⑥Change the controller
contact ①Retighten the contactors
①Pool connection of armature and ①Clean out the joint surface ①Loose of the lead wire contact ②Find out the reason then deal with
Exception noise of direct current
iron core ②Change the contact spring and ②Burn-out of fuse of control circuit it
contactor
②Large pressure of contact contactors if necessary ③Position handle not at neutral ③Put the position handle to neutral
The engine cannot setup when
pressure position position
rotate the key switch
①Contacts are welded together ①Change the contacts or switch ④Setup relay damaged ④Inspect on the relay，change
Cannot break away the
②Tightly seized of mechanical ②Repair it to make it flexible ⑤Failure of setup key switch that after confirmation
accumulator switch
structure ⑤Check on the key switch and
Electricity
①Circuit broken ①Inspection and maintenance change that as confirmed
Non-operation of preheating
component
heater ②Heater damaged ②Change ①Pool contact of startup key switch ①Find out the reason then deal with
①Loose of conductor connector ①Retighten the connector ②Burn-out of the body of control it of that
②Burn-out of control circuit fuse ②Find out the reason then clear of Electricity Rotate the start-up key switch,
circuit fuse ②Change the fuse body after
③No zero line in the control circuit, that component no movement of start-up relay ③Pool contact of lead wire or Inspection
Press down the set-up button， which cannot constitute control ③Re-connect the zero line or start-up contractors contactors ③Find out the reason then deal with
the wiper has no response circuit ④Inspection on relay，change that ④Loose of the lugs of relay or it of that
④Relay damaged as being conformed to be damaged contactors or something wrong with ④Find out the reason then deal with
⑤Priming button failure ⑤Inspection on button ,change that the wire ring it
as being conformed to be damaged ①Footplate locked，enable to step ①Make the footplate elastic
①Short circuit of horn power wire Engine speed cannot reach to to the end ②Ensure the output signal of
The horn chirping ceaselessly and control power line ①Check and recovery the rated speed ②Output signal of gun with mistake gun1.6V~3.8V
when being electrified ②Fusion welding of contact of horn ②Change the relay ③Connectors loose or drop ③Check connector and wire
controller After starting the engine, and ①Braking system has some mal ①Inspection and exclusion
engaging a gear, the crane can function, with a braking signal ②Open the parking button
①Lead wire break off or circuit ①Inspection and recovery
Acousto-optic alarm failure not move with the lights lighting. ②Still with signal as parking
broken ②Change
②Warner damaged ①Earth connection of power line ①Check and repair
No indication of the whole car
with problem ②Change
speed，and can only run at gear
②Velocity sensor is damaged ③Change the gate，and change
one
③Breadboard is damaged the frequency divider is necessary
8-8 8-9
Some of the one-to-four gears ①Gear handle is not flexible ①Check and repair gear handle ①The power supply fuse of hanger ①Change the fuse
cannot be put up ②Connectors loose or drop ②Check connector and wire control device is burned out ②Inspection and recovery
Duct pilot is short, for example, ②The lines of general oil supplying ③Check and resume it, change the
conducting wire insulation is short to No movement of the spreader valve have some malfunction general oil supplying valve if
Power supply being on, the main Find the causations and exclude
ground, electric coil is burnout, ③General oil supplying valve necessary
cut-out switch of duct pilot trip them
magnet coil is short, wire is wrongly maybe has some malfunction ④Change
jointed, etc ④Spreader controller damaged
①The cut-out switch of its power ①Induction distance of location ①Adjust the distance of the four
supply trip The yellow indication light
①Inspect the fault, and then close sensor with problem location sensor
②The on-off of freezing pressure blinking or bright all the time as
the cut-out switch after you confirm ②Location sensor is damaged ②Change the sensor
Something wrong with Air has some malfunction the spreader has not location
it ③The yellow indication light is ③Change the yellow indication
conditioner
③Loose or off connection of the ②Check and Change damaged light
lines on air conditioning control ③Inspection and recovery The spreader has released but ①Wrong induction distance of ①Adjust the two induction distance
panel, condenser maybe has some
no red indication light or unlock sensor of unlock sensor
malfunction
twinkling ②Location sensor is damaged ②Change the sensor
①The fuse of power supply is The spreader has unlocked, but
Electricity
component burned out ①Change the fused body Electricity no red indication light or Red indication light is damaged Change the red indication light
②Temperature switch is damaged ②Change
component twinkling
Hydraulic cooling system
③Movement controlling relay ③Change contacts The spreader has locked in, but ①The induction distance of lock in ①Adjust the two induction distance
cannot refrigerate automatically
contact is sweated no red indication light or sensor with problem of tighten sensor
④Confirmed and recovery
④Cooler electromagnetic valve twinkling ②Tighten sensor is damaged ②Change the sensor
⑤Confirmed and change
maybe has some malfunction The spreader has locked in, but
⑤Radiator motor failure no white indication light or White indication light damaged Change the white indication light
①Malfunction of lines, conducting twinkling
wire is abraded ①Inspection and recovery ①Burn-out of power fuse of boom

②Corresponding electromagnetic ②Tidy the magnetic valve control ①Change the fusing body
valve is locked ②Circuit failure, no handle signal ②Change and recovery
③Change the ring
③The ring of magnetic valve No operation of the boom
Only part movements of ④Change input of the screen or with ③Check according to the safety
spreader damaged proportion valve output signal, protective table

⑤Check and maintain it, change
④Spreader controller damaged circuit failure
the button or handle if necessary
⑤The button of operating handle ③With or without safeguards
has some malfunction has some ①Big interfer signal ①Make the handle earth-touching
malfunction ②Handle signal wire scored reliable
The operation of the boom Lose
③Handle damaged ②Repair the handle
of control
④Electric proportional valve ③Change the handle
damaged ④Change the proportional valve
8-10 8-11
①Without key switch ①Turn on the key switch Communication fault of the The engine works but no speed Check whether the wire broken or
Nutation emergency is failed ②Magnetic valve of Nutation ②Overhaul the magnetic valve engine and the controller information on the screen with water
emergency failure ③Check connector and wire There is length and angle indication
③Connectors loose or drop Controller and I/O extended on the screen but without gear Check whether the wire broken or
①Reverse plug of rod and rodless ①Joint the wire correctly block information, and the red light of the with water
Inaccuracy of weight- pressure sensor ②Change the pressure sensor I/O extended block always on
measuring ②Pressure sensor damaged ①Check whether the wire is broken
③Check connector and wire
③Connector lug loose of drop Communi or water intake;
cation wire Controller and screen The screen is ok but no content on it ②Check whether terminal
①Rough road surface ①Smooth the road surface
②Distance of Proximity switch ②Adjust the distance of Proximity resistance burn out or bad
ROPS give an alarm connects, The terminal resistance
improper switch
locates on its plugs.
③Proximity switch damaged ③Change the Proximity switch
①Check whether the wire is broken
④Connector lug loose of drop ④Check connector and wire
or water intake;
①Too much redundancy data ①Refresh the page
Abnormal show of the screen， Controller and length and angle The indication of the length and ②Check whether terminal
②The screen is disturbed by ②Eliminate the interference source
figures distorted sensor angle of the boom is abnormal the
resistance burn out or bad connect
Electricity magnetism ③Change the screen
others are ok
component .As the terminal resistance locates
③The screen damaged
in the length angle sensor ,the
①Bus failure ①Check the wire and recovery
the page data of the screen is
abnormal ②Bus terminal resistance damaged ②Change the resistance and

or lead fell off check the wire and recovery
①Power fuse burn out
②Power fuse burn-out on the enter ①Change the fuse
point ②Change the fuse
③Power fuse burn-out on the enter ③Check and recovery

No operation of controller point ④Check、recovery and refresh the
④To judge the state of the program program
according to the instruction book ⑤Change the controller

⑤Controller damaged
①Power fuse burn-out ①Change the fuse
②No blinking of communication ②Check and recovery

No operation of extended block
indication light communication wire
③There is light on the input、output ③Change the extended block

points but no operation
①No key switch ①Check the switch

Cab can not move
②Magnetic valve damaged ②Check and repair magnetic valve
③Connector lug loose or drop ③Check connector and wire
8-12 8-13
MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
9.Maintenance of Equipment Tracking Sheet

Maintenance of equipment tracking sheet 2
Equipment Manufacture Using Start Equipment Manufacture Using Start

Working Place Working Place
Name No. Date Name No. Date
Maintenance Contents Maintenance Contents
Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
No. Materials Operator No. Materials Operator
Part type quantity Source date time Part type quantity Source date time
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
9-1 9-2
Maintenance of equipment tracking sheet 3 Maintenance of equipment tracking sheet 4

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
9-3 9-4

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
9-5 3-4

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
9-7 9-8

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
9-9 9-10
MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual
Equipment Manufacture Using Start

Working Place
Name No. Date
Maintenance Contents
Maintenance Materials Materials Materials Maintenance Using

No. Materials Operator
Part type quantity Source date time
10
11
12
13
14
15
16
17
18
9-11

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MAINTENANCE MANUAL

CONTAINER REACH STACKER

It means the potential danger, which may cause

It means the potential danger, which may cause

There is no safety indication. If you ignore this

It awarks people to take attention to the operation

2. Maintenance Cycle Table of the Whole Machine 2-1

3. Maintenance of the Equipment 3-1

Font -Arial Size:10pt

5. Functional Oil 5-1

6. Checking of Key Bolts 6-1

7. Safty Regulations during Maintenance Work 7-1

8. Common Faults and Measures 7-1

In order to avoid unnecessary break down of reach

you. 6 Clean foreign matters on the surface of the radiator A B C D

7 Check belt and belt wheel A B C D

8 Engine Check start, stop, and operation of engine A B C D

9 Check if oil, diesel, and water leakage exists A B C D

11 Replace oil-water separator filter core B C D

12 Clean oil stain in the oil cleaner B C D

13 Replace cooling water filter core C D

14 Check if damping pad and fixed bolt are loose and D

15 brokenCheck and adjust clearance of intake valve and 50 D

19 Replace transmission filter core C D

28 Check hand brake sheet and hand brake function A B C D

Maintenance Applicable plan Maintenance Applicable plan

30 Check anti-tilting inductor A B C D 54 Check if battery water is sufficient A B C D

35 Check twist-lock and relevant components A B C D 60 Test anti-tilting protective system A B C D

37 Check and adjust 20 /40 chain and limit A B C D 62

40 Check if fixed bolt of crane spreader rotary gear case C D

41 Check if slide block on the crane spreader is abraded C D

42 Check if crane spreader has cracks by general vision C D

Contraction loose, broken, and worn

46 Check if basic boom has cracks by general vision D

48 Check accumulator pressure A B C D

49 Hydraulic Check if hydraulic pressure on the hydraulic nameplate C D

50 Replace all high-pressure filter cores C D

51 Replace brake oil and brake cooling oil filter core C D

52 Replace hydraulic oil and hydraulic system filter core C D

viscosity of the water、diesel and engine oil has

Piston ring damaged, the engine oil

★Check the start-up、halt and operation of the

Block of filter will reduce oil volume of gear shift

if the universal joint shaft damaged.

★Check the speed sensor Fastening bolt of transmission shaft

Check the speed sensor and its support to see if Notice

3.4 Repairing and Maintenance of the 

★ Check if the knuckle-pin and fixed nut are

3.6 Repairing and Maintenance of the

★Check if there exists the gap or damage of

★Check if the slide block of basic boom wears

★Test the overall function of hydraulic system

Shell antifreeze 17/14 125,000

19/16 500,000 64,000

Proportion: 5.8%～6.5% M30 2

★Safe protection of persionnel： water is damaged

Low lubricating oil is too thin Replace filter

Water leakage Water tank is damaged Replace

Oil radiator leakage(gearbox) Oil radiator is damaged Replace

Check whether the fuel oil circuit

Insufficient fuel; Diesel does not flows smoothly;

air intake jammed smooth;

Use the appointed fuel

3.4 Repairing and Maintenance of the