Professional Documents
Culture Documents
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
Caution
Caution
Notice
1. Preparing Work before Maintenance 1-1 9. Maintenance of Equipment Tracking Sheet 9-1
1 2
PREPARING WORK BEFORE MAINTENANCE MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
★Close the main switch, and take away the key. 10 Check if turbocharger and exhaust gas tube have leakage 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
1-1 2-1
MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE MAINTENANCE CYCLE TABLE OF THE WHOLE MACHINE
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
36 Check twist-lock inductor and indicator A B C D 61 Function Test twist-lock safety interlocking device 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
43 Check if fixed seat and lock pin on the basic boom are A B C D
47 Check oil amount in main hydraulic oil tank and brake oil A B C D
tank
system is consistent
2-2 2-3
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
。 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
3-1 3-2
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
―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
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
3.2 Repairing and Maintenance of ★Change the gearbox filter Check items: fixed seating、damping pad、bolts Oil-immersed disc brake
3-5 3-6
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
★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.
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
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
3-9 3-10
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
MAINTENANCE OF THE EQUIPMENT MAINTENANCE OF THE EQUIPMENT
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
4-1 4-2
FUNCTIONAL OIL FUNCTIONAL OIL
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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 whether the performance of the hydraulic liquid
Maypoles oil EP2
oil deteriorates. Please see the following table: 16/13 16,000 8,000
5-1 5-2
FUNCTIONAL OIL CHECKING OF KEY BOLTS
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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)
Hydraulic oil type: Before start, carefully check fastening status of key Recommended
The hydraulic system of this machine has the
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
temperature 35℃~-5℃) periodic check will avoid accidents. 200
Moisture: <0.1% 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
M24 360Fixed bolt of driving axle 1150
Rust preventing ability: disqualification Southern area of China(All year long) ―Checking of fixed bolt of torque-converter
Brake oil—Hydraulic oil No.46+AdditiveLZ9990A, M24 2 Fixed bolt of tyre platen 980
Ash content: 0.05% ―Checking of fixed bolt of transmission shaft
Variations of surface tension: 15 dyne/cm Proportion: 5.8%~6.5% M30 2
―Checking of fixed bolt of drive axle 475 1 0
Residue carbon: 0.05~0.10 Hydraulic oil—Shell hydraulic oil No.46 Fixed bolt of steering cylinder
―Checking of fixed bolt of crane spreader rotary
Variation of color (Union grade): above +2 gear case M30 1 40
1600 1 0
Guangdong province (China), Southeast Asia, Fixed bolt of up/down counter weight
Brazil, New Zealand etc, areas
―Checking of fixed bolt of tyre pressure plate
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 Torque(N.m) would generate following torque: 1m*120N
5m filter (filtering car) to the oil tank through the LZ9990A,Proportion: 5.8%~6.5%
12 3 M14 12 3 =120Nm
filter element until reaching the full scale of the oil Hydraulic oil—Shell hydraulic oil No.32T M6
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
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
aspects of mechanical system, hydraulic system, Engine speed up with difficulty EDC fuel control unit with problem Check the EDC fuel control unit
★Safety regulations of product:
―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
damage
Lubricating oil pressure is too Low-oil level; oil filter jammed; Add or replace lubricating oil;
Engine power is not enough meet the quality requirements; The Check whether the air intake is
7-1 8-1
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
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;
cannot break away in the condition Step on the clutch switch as brake,
available
shaft bearing
components
components of clutch is damaged
8-2 8-3
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
③Deficiency pressure of the system ③Increase the working pressure of ⑤low flow of cooler
①Overfall valve、relief pressure ①Change and clean the overfall ①Use the substandard quality
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
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
8-4 8-5
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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
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
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Category Faults Cause of faults Measures Category Faults Cause of faults Measures
①Find out the reason then deal with ①Circuit broken ①Check and recovery
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
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Category Faults Cause of faults Measures Category Faults Cause of faults Measures
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
8-10 8-11
COMMON FAULTS AND MEASURES COMMON FAULTS AND MEASURES
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Category Faults Cause of faults Measures Category Faults Cause of faults Measures
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
8-12 8-13
MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
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MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
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MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
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9-7 9-8
MAINTENANCE OF EQUIPMENT TRACKING SHEET MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual Container Reach Stacker Maintenance Manual
Maintenance Materials Materials Materials Maintenance Using Maintenance Materials Materials Materials Maintenance Using
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MAINTENANCE OF EQUIPMENT TRACKING SHEET
Container Reach Stacker Maintenance Manual
Maintenance Contents
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