QUY50C Maintenance Manual

QUY50C
Hydraulic Crawler Crane
Maintenance manual
Fuwa Heavy Industry Co.,Ltd

Foreword
Detailed specification and instruction are being done for crane’s inspection,
maintenance and repair in this manual, spare parts would produce natural
abrasion, looseness and damage after crane is used for a long time. So regular
inspection, maintenance and repair need to be done for the crane in order to
ensure the crane to have good performance so that prolong use life.
It’s absolutely forbidden to dismantle or adjust hydraulic elements when
repairing the crane. Don’t amend them at random in case accident happened if
there are something wrong with spare parts or being damaged, please select
appointed parts and appointed site to purchase the parts if need to replace,
operational manual, parts manual and maintenance manual is recommended to
be used together.
With the improvement for our products, maybe it’s possible for crane
performance data and every part in this manual is different from this crane,
please contact Fuwa or appointed site if there are some problems, sorry for any
inconvenience.
Please contact Fuwa to order if this manual is damaged or lost.
Contents
Chapter 1 Performance and Parameter for Main Element ……………………...........…………………1/39
1.1 Mobile set……………………………………………………………………………………………1/39
1.2 Hydraulic element…………………………………………………………………………………2/39
1.2.1 Main pump………………………………………………………………………………………2/39
1.2.2 Main valve…………………………………………………………………………………………2/39
1.3 Main hoisting motor(with balance valve)…………………………………………………………2/39
1.3.1 Derricking motor（with balance valve）……………………………………………………………2/39
1.3.2 Swing motor…………………………………………...………………………...….......................2/39
1.3.3 Traveling motor.................................…………………………………...….……………………...2/39
1.3.4 Pilot pump................................……………………………...…...….…………………….............3/39
1.3.5 Main hoisting, derricking pilot valve...............................…………...…...….…………………….3/39
1.3.6 Traveling pilot valve............................……………………………...…...….……………………..3/39
1.4 Drive element..........................…………………...………...…...…..…………………….................3/39
1.4.1 Swing reduction gear.......................………………...……...…...….……………………...............3/39
1.4.2 Traveling reduction gear......................………………...….…...…...….……………………..........3/39
Chapter 2 Schematic Diagram……………………………………………………………………3/39
2.1 Strcture diagram…………………………………………………………………………………3/39
2.2 Power drive diagram………………………………………………………………………………4/39
2.3 Hydraulic schematic diagram……………………………………………………………………5/39
2.4 Electric system schematic diagram…………………………………….....…………………………6/39
Chapter 3 Inspection, Repair and Maintenance………………………….........…………………………7/39

3.1 Schedule for maintenance inspection……………………………………......………………………7/39
3.1.1 Items for daily inspection and maintenance……………………………….........…………………7/39
3.1.2 Items for monthly inspection, repairation and maintenance……........................................………8/39

3.1.3 Items for annual inspection and maintenance……………………..............………………………9/39
3.2 Requirements for inspection and maintenance………………………........…………………………9/39
3.2.1 Notes for inspection and maintenance………………………………………………......................9/39
I
3.2.2 Precautions for inspection and maintenance………………………………………………............9/39
3 Maintenance of greasing infusing………………………………………………....…………………10/39
3.1 Intervals for grease infusing…………………………………………………..……………………10/39
3.2 Precautions of grease infusing……………………………………………………………………10/39
4 Maintenance of mobile set…………………………………………………………………………11/39
4.1 Inspection and replacement schedule of engine parts……………………………………………11/39
4.2 Precautions………………………………………………………………………………………11/39
4.3 Contents of inspection and replacement……………………………………………………………13/39
4.4 Precautions…………………………………………………………………....................…………13/39
5 Maintenance of reduction gear…………………………………………….....………………………12/39
5.1 Oil filling diagram………………………………….......................…..……………………………12/39
5.2 Inspection diagram for hydraulic oil tank……………………….....................................................15/39
5.3 Contents of inspection and replacement……………………………....……………………………13/39
5.4 Precautions………………………………………………………………....………………………15/39
5.5 Replacement of filter element………..……………………………...………………..……………16/39
5.5.1 Clean and replacement……..……………………………......………………………...................16/39
5.5.2 Assemble…..………………………...…......……………………….............................................16/39
5.6 Hydraulic oil change.………………………...…......…..………………..…...................................16/39
5.7 Cleanliness of oil suction filter……………...…......….....………………........................................17/39
5.8 Replacement for filter element of vent device………...…......…....………...………......................17/39
5.9 Replacement of servo system filter……...…......…....……..………................................................17/39
5.10 Cleanliness and replacement of hydraulic pipeline…......…....……..….....……............................17/39
6.Inspection and tighten key parts of bolt specification...…....……..…....……..................18/39
6.1 Tighten moment of hydraulic tubing…...…......….....………………...............................................18/39
6.2 Bolts inspection tighten table…...…......…....……..……….............................................................19/39
6.3 Precautions...…......…....……..……….............................................................................................19/39
7 Maintenance of accumulator...…....……..………...............................................................................20/39
7.1 Maintenance during operating....……..……….................................................................................20/39

7.2 Storage and maintenance wthout operating……..……….................................................................20/39
II
8 Inspection and adjustment of brake...……..……….............................................................................21/39
8.1 Make following preparations before adjustment……..……….........................................................21/39
8.2 Inspection……..………....................................................................………....................................22/39
8.3 Adjustment…..……….....................................................................………......................................22/39
8.4 Replacement of friction lining band.……….....................................................………....................22/39
8.5 Adjustment of lightening pedal force..……….....................................................................……….22/39
9 Inspection and adjustment of clutch.………......................................................................………......22/39
9.1 Inspection diagram.………....................................................................………...............................22/39
9.2 Adjustment………...................................................................………..............................................22/39
10 Inspection and adjustment of derricking brake..........................................................………............23/39
11 Adjustment of crawler tension……...................................................................……….....................23/39
11.1 Adjustment……...................................................................…..…..................................................23/39
12 Inspection and replacement of wire rope..................................................…….................................24/39
12.1 Inspection.............................................……..........................................…….................................24/39
12.2 Replacement............................................…….........................................……...............................24/39
13 Inspection and maintenance under special working environment...........................................……...24/39
13.1 Rain and snow operation......................................……..........................................…….................25/39
13.2 Seashore operation....................................…….........................................…….............................25/39
14 Notes for long term seal-up.................................……........................................…….......................26/39

Chapter 4 Failure Judgement Manual……………………..…………..…......………… ………….….27/39
1 Treatment for engine failure….…………………………..…………..………....……………….. ….27/39
2 Treatment of hydraulic system failure………………..…………..…..………… ......……………….30/39
3 Treatment of mechanism driving failure……..…………..………….…….....…………..……… ….33/39
4 Treatment of electric device failure………………..…………………......………....…………… ….34/39
Chapter 5 Grease Recommendation List……………………….….............………………………. ….32/39
1 Engine lubrication recommendation list………………….………...................…………………. ….35/39
2 Engine fuel oil recommendation list…………….……………………....………………………. ….35/39
3 Lubrication recommendation list………….……………………….....…. …………………………..36/39
4 Gear oil recommendation list………….…………………………….....……………..…………. ….36/39
5 Hydraulic oil recommendation list……………….…………….....…………..…………………. ….36/39
III
Chapter 6 Use and maintenance of slewing bearing……………..........…………..………………. ….33/39
1 Jugement of wind speed……….……………………………………....…..…………. ......................37/39
2 Screw thread connection tighten moment table….………...……………....……………..…..……...38/39
3 The relations between actual working pressure and using service life of hydraulic tube……............39/39
IV
QUY50C Hydraulic Crawler Crane Maintenance Manual
Chapter 1 Performance and Parameter for Main Element
1.1 Mobile set

Characteristic curve for engine (fig1-1)
Type：D6114G1A
Power：105KW/2150rpm
Max.output power：466N.m/1500rpm
1/39
1.２ Hydraulic element

1.2.1 Main pump
Type：Ａ８Ｖ１０７ＳＲ３
Max.cubic capacity：107ml/r Working pressure：25MPa
Max.rev：2150rpm
P—Q curve see fig 1-2
1.2.2 Main valve
Type：DL25-11 DL25-12
Diameter：φ25 Working pressure：25MPa
Control pressure：0.5-2.5Mpa
1.3 Main hoisting motor(with balance valve)
Motor type：M3X800ACM
Cubic capacity：800cm3 Relief valve pressure：24MPa
Balance valve type：KDC30MR
Fig 1-2
Fig 1-2
1.3.1 Derricking motor（with balance valve）

Motor type：M3X530ACN
Cubic capacity：530 cm3 Relief valve pressure：23MPa
Balance valve type：KDC30MR
1.3.2 Swing motor
Type：A2F80
Cubic capacity：80ml/r
1.3.3 Traveling motor
Type：A2F107
Cubic capacity：107ml/r
2/39
1.3.4 Pilot pump

Type CBk1016
Cubic capacity：16ml/r Working pressure：4Mpa
1.3.5 Main hoisting, derricking pilot valve
Type：XDF-15
Diameter：6mm, Working pressure：4Mpa
1.3.6 Traveling pilot valve
Type：XDF-4B
Diameter：6mm Working pressure：4Mpa
1.4 Drive element
1.4.1 Swing reduction gear
Type：GJB36AKB
Velocity ratio：79.2 Output torque：22000N.M
1.4.2 Traveling reduction gear
Type：GFT60T3
Velocity ratio：169.9 Output torque：60000N.M
Chapter 2 Schematic Diagram

2.1 Structure diagram
Fig 2-1
3/39
2.2 Power drive diagram
Fig 2-2
4/39
2.3 Hydraulic schematic diagram
Fig 2-3 Hydraulic schematic diagram
5/39
2.4 Electric system schematic diagram
Fig2-4 Electric schematic diagram
6/39
Chapter 3 Inspection, Repair and Maintenance
3.1 Schedule for maintenance inspection

Please implement maintenance inspection daily, monthly and annually. The replacement of fittings please follow
the service schedule
Daily inspection,maintenance Inspect before/after daily operation（5-10 hours on the service list）
Monthly
Once a month（150-250 hours on the service list）
inspection,maintenance
Heavy repair All parts disassembly maintenance （3000-4000 hours on the service list）
Notes:
The inspection and maintenance of engine please refer to Engine Operation Manual.
3.1.1 Items for daily inspection and maintenance（Inspect before/after daily operation）
Inspection items Remarks

Engine 1. Oil and radiator water sufficient or not
2. Strap tension of fan suitable or not.
3. Whether corlor of engine exhaust normal or not, cacophony and peculiar
smell or not.
4. Every gauge and electric system normal or not
Traveling Track tension suitable or not
Up/down guiding pulley, turning pulley, and reduction gear leakage or not,
bolts and nuts loosen or not.
Hydraulic components and tubings leakage, damage or not; pipe clip loosen or
not.
Beware of
1. Boom, pulley and hook damages and deformation or not
Working wire rope
2.Wire rope abrasion and deformation or not. button
Equipments
3.Operation of all working devices normal or not.
Safety device, alarm device and all parts wirings normal or not
Bolts and nuts loosen, fall down or not
Oiling sufficient or not
Others Whether there is fuel in the fuel tank
Oil volume suitable and leakage or not
All the actions of control lever, footpedal and positioned level normal or not
All the actions of clutches, braker and locking device normal or not
Tubings, tubes oil leakage and damage or not
All the gauges damage or not
7/39
3.1.2 Items for monthly inspection, repairation and maintenance（150-250 hours on the service list）
Inspection items Remarks
Whether the machine oil filter clean, plug or not

Whether the fuel oil filter clean, plug and damage or not
Whether the air filter core clean, plug and damage or not
Engine
Whether the radiator and pipelines plug or not, and replace the radiator coolant
The liquid level and proportation of accumulator normal or not, the end loosen,
corrosion or not.
Whether traveling device abonormal or not, traveling reduction gear oil suitable or
not
Traveling
If track shoe, track frame, base deformation, crack or not.
The operation of hydraulic device abnormal, rust or not
1.Boom. pulleys and hooks whether deformation, crack or not
2.Wire rope abnomity or not(span), abrasion, broken strands or not, and end Beware of
Working
treatment, connection reliable or not wire rope
equipments
3.Whether the working equipments of every mechanism normal or not button
4.The falling off prevention device of wire rope deformation, abrasion or not
1. Angle gauge indicating normal or not
2. Whether boom, hook overhoist prevention device and alarm device work normally
Safety or not.
Device 3.The backstop lever deformation, bend or not
4.All switches used by safety device in good order or not, whether all the
instruments indicating normal or not
5. Whether all indicating, safety labels dirt, damage or not
1.Oil volume suitable, leakage, dirt,etc. or not
2.Working oil dirt or not, filter plug, damage or not
3.All clutches,brakes cover and drum crack or not
4.All liner band of clutches and brakes abrasion or not, whether there is oil on them
5.Actions of hydraulic device normal or not, damage and rust or not
Others 6.Swing platform crack, deformation or not
7.The bolts of swing roller loosen or not
8.All brakes normal or not
9.All wirings loosen, circuit, damage or covered or not
10.All kinds of bolts and nuts loosen, fall off or not
11.Crane performance abnormity or not8/39

3.1.3 Items for annual inspection and maintenance
Inspection, maintenance and

Remarks
repair
Fuel oil filter core Replace
Air filter Replace
Working oil tank Clean，replace the hydraulic oil
Replace oil return filter element First replacement is 250 hours,
second is 1500 hours
Replace suction oil filter element 1500 hours replacement
Swing reduction gear Clean，replace the gear oil
Traveling reduction gear Clean，replace the gear oil
Wire rope Check, replace 2500 hours
Suspending rope Check、replace
Hydraulic tube Oil leakage、replace the damaged one
3.2 Requirements for inspection and maintenance
3.2.1 Notes for inspection and maintenance
The crane will abrasion and some connections will be loosen after long-time using. So right repair and adjustment
can prolong crane's use life, preventive maintenance should be done in order to ensure the crane to be in good
condition. Inspection, maintenance and service is very imperative job, especially work in bad weather, the
following notes must be taken
3.2.2 Precautions for inspection and maintenance
When the weather is fine, please inspect it on the firm and level ground. Try to avoid dust and dunghill into
system when maintaining hydraulic system.
Don’t inspect and adjust with load.The engine must be shut down and without load, please hang hang brand
"under maintenance" over the door of cab
3.2.3 The pump,valve, motor and other hydraulic components are not allowed to disassemble
9/39
3.3 Maintenance of greasing infusing

3.3.1 Intervals for grease infusing (No. in the table as shown in fig.3-1)
Intervals（hour）
No. Parts Locations Remarks
8 50 250 500 1000 1250 2000
1 Drum brake pawl 3
2 A-frame 2
3 Swing bearing 4
Swing roller tray inner
4 1
gear
5 Boom lower pin 2
6 Central swing joint 1
3.3.2 Precautions of grease infusing

The liner block of clutch , lining band of brake and electric device is forbidden to touch the grease
Fill small amount of grease on the clutch and brake, remove the redundant grease, the liner is forbidden to oil
The required grease should be the top quality mineral grease that can be availble in the oil gun, which is no
liquefaction under high temprature and no coagulation below freezing point
Please fill the oil after cleaning the oil mouth.Keep lubrication and oil gun clean
Please lubricate the control joystick and other places which are without installing the oil mouth in time.
Please use the same brand grease, don’t mix with other brands
Lubriate the wire rope to prevent rusting
The method of lubrication is as follow:
With brush With cotton yarn With cotton yarn
For hoisting drum, wire rope pulley blocks, driven pulley and up/down guiding pulley, and oil points that no need
oiling often, when fill the oil, please use special tools. Infuse the wasted oil to the track pins
10/39
3.4 Maintenance of mobile set

3.4.1 Inspection and replacement schedule of engine parts
Intervals （hour）
No. Parts location Remark
8 50 250 500 1000 1500 2000
1 Engine oil volume check 1 △
2 Engine oil change 1 △* △
3 Oil filter of engine change 1 △* △
Fuel moisture separator
4 1 △
release
5 Fuel tank drainage 1 △
6 Fuel filter change 1 △
7 Strainer of fuel tank clean 1 △
8 Air filter clearing 1 △

Resistance
9 Air filter parts change 1
over limit
Radiator cooling water
10 1 △
volume check
11 Fan belt tension check 2 △
12 Cooling water check 1 △
13 Outside radiator clean 1 △
14 Inside radiator clean 1 △

Oil inlet filter element
15 1 △** ○
replace
Oil suction filter element
16 replace 1 ○
Note △* is the initial replace

△** is after hydraulic oil change, and first replace the filter element
○ is the second replace and in the future
3.4.2 Precautions
(1) The cooling water should select soft water with impurity. Fill the oil tank, the oil volume is 180L after daily
work.
(2) Don’t remove off the water tank cover from high temperature engine, please wait until the temperature lowers
to below 50℃. It is not allowed to prevent leakage of cooling system by the seal-up additive.
(3) Clean out the lubrication after touching to avoid skin touches it long term and repeatly. Keep the lubrication
away from children.
(4) Give out the lubrication when it is hot and impurity suspending.
(5) The antifreezen is basic during all kinds of climates, which can reduce the freezing point of cooling fliquid and
increase its boiling point in order to widen working range. Replace the cooling fliquid while replace the cooling
fliquid filter.
(6) Open the water cover of radiator, observe water level whether between max.level of water complementary
11/39
tank and low level of water complementary. If the level lower than min.water level, and fill water to the tank until
it is between min. water level and max.water level
(7) When the engine change water, please let out all the water in the engine and radiator, then fill the cooling
water.
(8) When the antifreeze turns color due to rust, please change new anti-freeze after cleanout the cooling system
(9) When replace all the cooling water, fill the regulated water, and make engine idle running for 30s-1min.Open
the radiator cover to observe water level, if the water volume is insufficient, please make it up.
4 Maintenance of reduction gear
4.1 Oil filling diagram（Fig3-2）
Fig 3-2
4.2 Intervals for inspection and oil change (No.shown as fig 3-2）
Intervals （hours）
No. Parts Location Remarks
8 50 250 500 1000 1250 2000
Oil volume
Main hoisting check
1
reduction tank
Oil change 1
Oil volume
Swing
2 check
reduction gear
Oil change 1
Oil volume
Traveling check
3
reduction gear
Oil change 2
Oil volume
Derricking check
4
reduction gear
Oil change 1
12/39
4.3 Contents of inspection and replacement

(1) Inspect traveling reduction gear oil volume every other 250 hours, and oil change every other 1000 hours
Remove off the oil stuff first and then demount oil outlet stuff, oil drainage can be realized, as shown in fig 3-3
Install the oil outlet plug and fill 7.5L gear oil from the oil inlet mouth, at last mount the oil filling stuff.
Park the crane on the firm and level ground, demount the oil level stuff, if the oil surface can be seen,and the oil is
sufficient.
(2) Inspect derricking reduction tank oil volume once 250 hours, and oil change every 1000 hours. Demount the
oil outlet stuff which is under gear tank, and oil drainage can be realized. Install oil outlet stuff and demount
exhaust stuff, oiling seal-up cover, then fill the gear oil from oiling mouth.Check the oil mark on the tank, when
the oil reaches red point of oil mark, it means oil is sufficient
(3) Inspect swing reduction gear oil volume every other 250 hours, and oil change every other 1000 hours
Remove off the oil stuff first and then demount oil outlet stuff, oil drainage can be realized. Install the oil outlet
stuff and fill 7 L gear oil from the oil inlet mouth, at last mount the oil filling stuff and oil level stuff, as shown
(4) Inspect main(aux.) hoisting reduction tank oil volume once 250 hours, and oil change every 1000 hours.
Demount the oil outlet stuff which is under gear tank, and oil drainage can be realized Install oil outlet stuff and
fill the gear oil from upper oiling mouth of tank Check the oil mark on the tank, when the oil reaches red point of
oil mark, it means oil is sufficient
4.4 Precautions
When the oil change, the ejective oil should pass through clean cloth to filtrate and flow to container, observe
whether metal powder in it
Oil volume check, if it is insufficient, please make it up in time
When the oil change, the resid must be drained thoroughtly and fill the new gear oil.
Fig 3-3
13/39
Fig 3-4
5 Maintenance of hydraulic device
5.1 Intervals for inspection items,see fig 3-5
Inspection intervals （hour）
No. Items Remarks
8 50 250 500 1000 1250 1500
1 Hydraulic oil volume check 1 △
Deposits of hydraulic oil

2 1 △
tank check
Replace pipelines filter *
3 1 △ △
parts
Replace control system *
4 2 △ △
filter parts
5 Replace hydraulic oil △
6 Clean oil suction filter 1 △
7 Replace vent device parts 1 △
Note：△ is the initial replacement
14/39
5.2 Inspection diagram for hydraulic oil tank
Fig 3-5
5.3 Inspection contents and procedures
5.3.1 Check the hydraulic oil volume once every other 8 hours.
（1）Inspection before the engine startup
Before the engine starts, check the hydraulic oil volume, if the oil volume reduces too fast, it indicates that there is
leakage in pipelines or hydraulic components, this time find out the leakages and screw the pipelines connection
or replace hydraulic components.
5.4 Deposits exhaust of oil tank

The deposits in the hydraulic oil tank need exhaust once
every other 50 hours. The drainage is performed by
shut-off valve which is under the hydraulic oil tank.
When drain the wasted oil, firstly screw off the plug under
the shut-off valve, then open the valve, the oil can be drained.
Close up the valve after drainage.
Fig 3-6
15/39
5.5 Replacement of filter element
Replace the filter element of pipeline every other 500 hours, the inial replacement is 50 hour
Disassemble diagram 3-7, demount the stuff②

And screw the bolt③, then demount as the order
① ④⑤⑥⑦.
Note: when demount cover ①, the spring is

easy to bounce out, so press down the cover
①, and demout bolt ③
Fig 3-7
5.5.1 Clean and replacement
Take out outer casing⑧, and clean its inside, expecially the bottom, then replace⑦ filter element
5.5.2 Assemble
When assembly, don’t deflect the filter element⑦, the moment of bolt③ is 50N.M when install the bolt③
5.6 Hydraulic oil change.

As the fig3-8, change the hydraulic oil every other
1500 hours, and use the same brand hydraulic oil
Remove off bolt①,demount upper cover② of

air filter, and fill new hydraulic oil to standard
level by the strainer
If the hydraulic oil is found abnormity,

However long it is running, the hydraulic oil
must be changed. If it is stained or deterioration
is too short, please check it before replace
with new oil
Fig 3-8
16/39
Precautions for hydraulic oil change

Please use the regulated hydraulic oil, to prevent dust and sand entering
into the oil tank. Clean the oil tank and filter. If the brand of replaced hydraulic oil is not same as the original ones,
and the oil tank must be cleaned thoroughly, replace all the hydraulic oil of pipelines and hydraulic components.
Precautions for hydraulic oil complementary

If find the hydraulic oil is insufficient during maintenance, the brand of complementary oil must be same with
original oil tank’s, and reaches the regulated oil volume.
5.7 Cleanliness of oil suction filter(fig 3-9)

Clean the oil suction filter once 1500 hours, it is mounted in the hydraulic oil tank. Remove off the vent device,
the oil suction filter can be seen. Take it out from the vent hole. The oil suction filter is made of metal, it can be
used after cleaning. Whose handle is mounted with magnet, when clean the filter element, clear up the metal
powdal attached on the magnet.
5.8 Replacement for filter element of vent device

As shown in fig 3-9, the filter element of vent device should be replaced every other 1500 hours.
The method is:
Loosen bolt①, remove off cover ②, during filter element replace and strainer clean, keep the surroundings clean
and prevent from water, dust entering into the oil tank
Fig 3-9
5.9 Replacement of servo system filter(fig3-10)
The filter element of servo system should replace every other 500 hours, when initial replacement 50 hours, screw
six squarehead with ⑦, one side screw, and the other demount, altogether remove off the filter element ③ with
outer casing. When replace filter element③, please replace O-seal-up ring④ and protective ring ⑤, clean insdie
shell body⑥
5.10 Cleanliness and replacement of hydraulic pipeline
Check the hydraulic pipeline for leakage, damage every day, and check hydraulic tube for crack, and replace with
17/39
new one in time to avoid dangers due to tube is overdue. As the O-seal-up ring used in pipeline, and avoid
scuffing during assemble. The hydraulic components must be cleanout before installing.
6.Inspection and tighten key parts of bolt specification
Check the bolts, nuts and hydraulic tubing for loosen and falling off during daily, monthly inspection. Tighen the
loosen ones and make up the falling ones
Fig 3-10
6.1 Tighten moment of hydraulic tubing
Nominal diameter 1/8″ 1/4″ 3/8″ 1/2″ 3/4″ 1″ 1¼″ 1½″

screw thread
used by pipe
－ 50 70 95 180 210 350 550
connection
Tighten
(high pressure）
moment
N·M crew thread
used by pipe
15 20 30 50 70 110 160 200
connection（low
pressure）
18/39
6.2 Bolts inspection tighten table
Tighten Intervals （hour）

Bolt Distance to
No Bolt parts moment Remark
diameter bolt 8 50 500
N·M
1 Erection bolt of slewing ring 27 41 1200 △ ○* ○
2 Erection bolt of engine 14 21 △ ○
3 Erection bolt of engine 16 24 △ ○
Erection bolt of upper guiding

4 12 18 90 △ ○
pulley
Lower guide pulley of lower
5 20 30 400 △ ○
guiding pulley
6 Erection bolt of main hoisting 30 46 1200 △ ○
7 Erection bolt of aux.hoisting 30 46 1200 △ ○
8 Swing device installed bolt 16 24 500 △ ○
9 Erection bolt of derricking 30 46 1200 △ ○
10 Erection bolt of traveling 20 30 950 △ ○
11 Erection bolt of cab 16 24 210 △ ○

Erection bolt of Main
12 20 30 400 △ ○
(aux.)hoisting motor
13 Erection bolt of slewing motor 12 18 210 △ ○
14 Erection bolt of slewing motor 20 30 210 △ ○

Erection bolt of traveling
15 20 30 △ ○
motor
Erection bolt of A-frame
16 16 24 210 △ ○
support
Erection bolt of
17 30 46 750 △ ○
counterweight
18 Joint bolt of pump and engine 10 16 50 △ ○
19 Hydraulic pipeline △ ○
Note：△check ○* initial tighten ○ tighten
6.3 Precautions
(1) For the tightness moment is too great, the attacnment tools and wrenches are required, this wrench will
augment the torque 4 times.
(2) Strictly obey the daily inspection and inspect, tighten as the regualted time of daily and yearly inspection.
(3) If the parts is not tightness, please remove off the surrounding parts and tighten them all.
(4) Please according to the tighten moment of hydraulic tubing. When it exceeds torque tighten listed in above
19/39
table, there will be deformation in seal connection of pipe connection, especially when the casting tighten, it is
easy to appear cracks.
(5) Don’t have scars on the joint surface of hydraulic components, clean them carefully and prevent dust entering .
7 Maintenance of accumulator
The accumulator is as the power supply to startup the engine,electric control system, lighting and assist electric
equipments, whose technology is accord with PRC<<Lead acid accumulator used by crane GB5008-91>>
standards.So maintain and keep it in good condition.
7.1 Maintenance during operating
(1) Have inspection every 50 hours
(2) Check the connection whether fastness or not, prevent it from lossen strike fire
(3) Keep the surface of accumulator clean, and wipe the dry oil or vaseline on the connection to prevent corrosion
(4) Keep the liquid stuff in tension, to prevent the acid liquid spill out
(5) Check the electrolyte, control the electrolyte level within the regulation, the level should be higher than
clapboard between 15mm-20mm, it is not allowed to add the electrolyte due to add the distilled water when the
liquid level lower caused by electrolyte vaporized
(6) Check the charge status daily, and observe the current gauge whether normal or not.
(7) The following condition should be charged generally
○
A Electrolyte density reduces to below １.17g/cm3(25℃)
○
B The lighting is gray, the voltage is not enough, the pressure is less than 1.8v when releasing the electricity.
7.2 Storage and maintenance wthout operating
The accumulator should be kept in clean, dry and the ventilation storeroom, the temprature is ５℃－４０℃
when not using. It is should be stored without electrolyte. Under special suitations or after the accumulator
discharges, it should versatility once a month, and every three month have entire charge/discharge circle.
Don’t confect the electrolyte with the water, well water and impurity water.
When not use the accumulator on the crane, remove the joint of one side, and check it once a month, charge it in
time, and use it after charging.
The electrolyte contains vitiriol, which is corrosive for one’s skin, eyes, and clothes, so prevent it from spilling out.
Take the following measures when accidents happen.
A. Wash immediately after touching exterior.
B. Gargle after it enters mouth, and drink some water or milk, then seek for medical treatment .
There is some flammable gas in the accumulator, so keep the exhaust hole ventilation, protect it away from fire
when use or storage, to prevent it from explosive.
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8 Inspection and adjustment of brake
8.1 Make following preparations before adjustment,as shown in fig3-11
Pedal force
Fig 3-11
After diesel engine startup, the control system pressure on the pressure gauge① is 4Mpa. The slings should be put
on the ground. Drum locking② and brake pedal ③should be on braking status(ON). Clutch joystick leaves the
21/39
position to check B
8.2 Inspection
When the brake pedal is in (OFF) position(footpedal link rod⑦ bumps positioned bolt⑤), and check the
following dimensions:
A：230mm B：190mm D：174～176mm
E：0.8～1.0mm M：79mm N：40～41mm
When the engine shuts down D：203～210mm, all dimensions are suitable to above data, and it is no need to
adjust
8.3 Adjustment
When the dimension cannot reach above data, please take the following method to adjust
Put the brake pedal to OFF position, loosen tighten bolt⑥ and screw positioned bolt⑤, adjust A
○ to regulated
dimension, and screw nut⑥ Adjust M ○ 、○N to regulated dimension with bolts⑧、⑨ Adjust○ D to regulated
dimension with bolt⑩ Loosen nut○ 11 and bolt○12, adjustment bolt○13, hook bolts○14、○ 15, positioned bolt○
16, make
E reach the regulated value,the bolt ○
○ 12should touch with each other after adjusting, and put footpedal○ Z to ON
position, then screw nut○ 11.After the engine shut down○ D , it should be within. If it is below 203mm, and the ○ E
dimension is great; if it is above 210mm, and ○ Edimension is small, which needs to adjust
8.4 Replacement of friction lining band
The thickness of new friction lining band is 12mm, when it abrasion to 7mm, please replace it
8.5 Adjustment of lightening pedal force
Ajust link rod, reduce value, increase drive force of pedal to lighten pedal force
9 Inspection and adjustment of clutch

9.1 Inspection diagram Fig 3-12
The clutch joystick should be on 【come away】position
Screw loosen the locking nut②（5 parts） and fixed bolt③（3 parts）until the hexagonal posotion divorced from
A of⑥divorced from lining band
lining band① Screw loosen nut④, rotate cylinder handspike⑤, make part○
9.2 Adjustment
Adjust fixed bolt③, and space between lining band① and wheel drum, make all surrounding has 0.5mm space
Rotate handspike⑤, make ○ A part of ⑥ just touch the end of lining band, and fix it.
Fig 3-12
22/39
Rotate spring to adjust nut⑦ and make ⑦ length is 129mm.Screw locking nuts②、④
Operate clutch joystick 2,3 times, make it in come away position, and check the space between lining band and
wheel drum. If the space is not uniformity, and adjust the fixed bolt
The thickness of new lining band is 12mm, when lining band abrasion to 7mm, please replace with new one
10 Inspection and adjustment of derricking brake, fig 3-13
Put derricking joystick to neutral position, and derricking brake by spring C
○
When derricking joydtick perform hoisting, lowering operations, the brake will come away by cylinder ⑤
Fig 3-13
When the brake is adjusting, the drum should be locked by pawls, and take following order to adjust. Put
C length
derricking joystick to neutral position. Adjust nut③ ,make④ level. a=1.9mm. Adjust nut②, make spring○
is 153mm, lock nut① after adjusting
11 Adjustment of crawler tension, fig3-14

The adjustment of crawler tension should be on soft ground, crawler can be loosened a little while on rocky
ground, tightened.
11.1 Adjustment:
Dismount the cover ①and bearing board② on the left and right. Fill dry butter from oil nozzle③ with dry oil gun
Confirm the space between bearing④ and gasketA,and select suitable gasket from B, insert it to gasket A
Loosen valve⑤, the flowed dry butter make the space between cylinder⑦ and middle lever reach 5mm
Note: the installed moment of tighten valve is 150N.m. If it is too tighten, and the dry butter will leak. After
adjusting, confirm the center of bearing④whether it aims to the marker. If it is in marker, and reduce one
A should reach 20mm

gasket to suit crawler tension, whose deflection○
23/39
Fig 3-14
12 Inspection and replacement of wire rope

The service life of wire rope is much more different due to separate working conditions. Whatever hoisting or
derricking that wire rope be inspected at regular intervals. Using defective rope is not allowed. Once damages
found, please replace them at once.
12.1 Inspection
12.1.1 Daily inspection
Check the visible parts of the wire rope as often as possible, in order to find damages or distortions, expecially the
fixed part to the crane, if any evident change found, pleae report and deal with at once.
12.1.2 Inspection parts
A The span of wire rope；
B Begin/end parts of wire rope moving and fixing；
CThe rope through the pulley blocks
D Repeat operation under the mechanism should notice the parts that pulley rounding during hoisting load
E The rope located in the balance pulley, will cause tear and wear due to exterior factors. Inner inspection for
corrosive and tidy
12.2 Replacement
The replacement of wire rope should follow the breaking lines, wear and tear, corrosive ,if one of the below
conditions found, replace it at once.
Contusion
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More than 10% number of strands (except filler type) within one length of lay broken.
End contusion
When the end rope or surroudings appear the contusion, indicates that the stress is higher in this part. If the length
is permitted, cut off the contusion and install again.
Part collection of contusion
If the contusion get together is less than 6d rope length (wire rope diameter) within the range or centralize in one
rope strand, though the contusion is too little.
Increase of contusion
The contusion will appear after using for a period, the more the contusion is, the shorter the interval is
Wear and tear
Wear and tear makes the area of wire rope reduces, and lower the intension. When the outer wear and tear reaches
40% of its diameter or diameter relatives to nominal diameter reduces to 7%.
Strand cracks
The minish of rope diamter caused by rope core damages
Elasticity minish
The diameter minishes, the distance extension, all parts press out. Lack of space between wire rope and rope
distance called strand minishes
At this time no contusion appears,and the wire rope is hard to bend, which will cause suddenly crack, should
discard at once.
Corrosion
When the inner and outer of the wire rope appear seriously corrosion.
Distortion
When the wire rope lose normal shape, appear wave shape, cage aberration, strand extrusion and rope extrusion,
part of rope diameter increases or reduces, parts are staved,distorted,loosen and bend.
In addition, such as the pendant ropes are subjected to shock and heavy loads, care must be paid for failure due to
fatigue of materials. The replacement of a rope can be considered according to above conditions but inside
conditions can not be estimated due to different working conditions. All in all, ropes should be replaced every
2500 servicing hours

13 Inspection and maintenance under special working environment
13.1 Rain and snow operation
Before operation:Check kinds of stuffs,bolts for loosen; make sure actions of clutch and brake
After operation：cleaning crane, check bolts and nuts for loosen, falling off. And fill oil, lubrication.
13.2 Seashore operation
Before operation:Check kinds of stuffs,bolts for loosen，add the grease to the rusted ones,expecially the control
lever and link rod.
After operation: clean up the salt on the crane thoroughly, and add grease to the rusted parts.Maintain the electric
components carefully to prevent it rust.
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13.3 Dusty environment
Air filter：Clean the filter element and dust collector in advance
Fuel device：Clean the spare parts of filter ahead of time
Electric components：Clean the startup machine and sensor interface carefully.
13.4 Stone environment
Generally, the crawler tension is loosen sometimes, beware of damages, cracks, abrasion and scars on the
traveling device, check bolts and nuts for loosen, falling off.
13.5 Rockfall site
The cab should be installed shield
13.6 Cold area
Use the lubrication with small stickiness,and charge the accumulator in advance
13.7 Other working environment
For the installing parts of A-frame, tensioner, working equipments are different, and so as its abrasion degrees.
During daily inspection, check the abrasion of pulleys and repalce in time.
When maintain and intall the lower guiding pulley, exchange direction can prolong guide track’s servicing life.
14 Notes for long term seal-up

If the crane is stored for a long term(shut down for above two weeks), in order to use without reducing the
machine capacity, please take the following measures:
Clean: Clean the crane wholely, and check the travel device for any abnormal.
Lubricate: Wipe the lubrication on the corrosive parts.
Accumulator: Remove and store after saturation charge, and dismantle end ground line.
Dustproof and moistureproof: exhaust cooling water, hang up the “NO WATER” brand, the crane should be stored
in the storeroom, and cover the diesel engine with membrane to prevent moisture.
Tools: Storage after sort and count.
Lubricate running: the crane should operate in low speed with no load monthly, this is in order to prevent abrasion
from membrane damages or rust during the next actual running, in addition, please notice the temprature changes
of cylinder cover.
Note
a. Lubricate running is after crane warming, and travel, slew, hoist repeat continuous movements.
b. Please notice the quality of lubrication after crane is running again, for lack of running, the lubrication is easy
to metamorphose.
26/39
Chapter 4 Failure Judgment Manual

1 Treatment for engine failure
No. Failure Reason Eliminate Remarks
Startup circuit joint loosen or
Check and tighten joint
erode
Engine doesn’t operate Check accumulator
1 Accumulator is insufficient
or operate slowly pressure
charge
Replace startup engine
Startup engine failure
1. Check, repair and
Cannot operate normally in replace cold startup assist
Difficult in engine start cold weather devices
2 up or cannot startup Air in the fuel system 2. Exhaust the fuel system
(exhaust smoke) Impurity in the fuel and check suction pipe
leakage
3. Filtrate the fuel change
1. Add fuel
Engine rotates but not No fuel in the oil tank
2.Drain the fuel-water
3 startsup(no smoke Water or other impurity plug
separator or replace the
exhaust) the fuel filter
fuel filter
1.Exhaust the fuel system
and check suction pipe
Air in the fuel system for leakage
Plug the fuel filter 2. Drain the fuel-water
Engine can startup but
4 Fuel is cered due to cold separator or replace the
cannot go on rotating
weather fuel filter
Impurity in the fuel 3. Replace the fuel used in
cold weather
4. Filtrate or replace fuel
1. Add oil to the oil tank

Engine idle speed not Oil level is too low 2. Exhaust the fuel system
5
stable Air in the fuel system and check suction pipe
for leakage
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1. Add or drain engine oil
2. Check it whether lost
Engine oil level is incorrect rain cover, infusing hole
Engine oil is diluted by water cove, engine dipstick
6 Lubrication pressure is
Specification is incorrect and replace engine oil
too low
Plug the engine oil filter 3. Replace engine oil
4. Replace engine oil and
filter
Lubrication pressure is
7 Specification is incorrecet Replace engine oil
too high
Coolant level is too low Add coolant
Coolant temperature is Radiator damage or plugged Check water tank radiator,
8
too high by impurity clean and repair
fan driven strap loosen Check strap tension pulley
1. Check water tank,
heater, tube and joint,
Water tank or heater leakage find out leakage
9 Coolant wastage
Engine exterior leakage 2. Check the engine and
parts for leakage in the
seal or washer
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Rust in the coolant, not use Drain and wash cooling system,
10 Impurity in coolant correct mixture with fill correct mixture with antifreeze
antifreeze and water and water
Too much engine oil

11 Impurity in lubrication Replace engine oil and filter
deposits
1. The engine load is great 1. Replace low gear

Too much smoke exhaust
12 2. Air in the fuel system 2. Exhaust the fuel system
with load
3. Plug in the air filter 3.Clean or replace air filter
Engine cannot reach rated

13 Overloading Reduce load or use low gear
speed with load
1. Reduce load or use low gear

1. Over loading
2. Drain engine oil to suitable oil
2. Lubrication level is too
level
14 Output power is too low high
3. Exhaust fuel system and check
3. Air in the fuel system
suction oil pipe for leakage
4. Fuel quality is weak
4. Use high quality fuel
1 Use high quality fuel

1.Impurity in fuel
15 Engine flameout 2 Exhaust fuel system and check
2.Air in the fuel system
1. Replace with low gear

1. Engine overload
16 Fuel burst 2. Fuel quality is weak
3. Exhaust fuel system and check
3. Air in the fuel system
1. Check, correct leakage

1. Fuel leakage
17 Too much fuel consume 2. Fuel quality is weak
3. Operate gear, speed reduction
3. Operation is incorrect
and idle speed
Tighten driven strap, make sure

Driven strap tension
water pump, belt pulley, fan shaft
18 Too big engine noise insuffient or abnormal
shell and alternating electric
during high load running
engine’s operation normal or not
1.Accumulator joint loosen 1.Clean, tighten accumulator joint
Alternating electric engine or eroded 2. Check and adjust belt tension
19 discharge or insufficient 2.Alternating electric pulley
charge engine belt slippery 3. Tighten fixed screw of belt
3.The belt pulley loosen pulley

29/39
2. Malfunction disposal of hydraulic system
Rema
No. Malfunction Reason Exclude
rk
1. Pilot pump malfunction

2. Pilot overflow valve 1.Check and replace pilot Stop
malfunction pump imme
Engine runs
3. Absorbing oil filter 2.Check, adjust overflow valve diatel
1 normally,but no pilot
wall-up pressure y
pressure
4. Absorbing oil pipe cut off 3. Replace filter in focus
valve at the botoom of oil 4. Open valve
tank
1. Pilot system leaking
1. Look up leaking place
2.Absorbing oil filter
Engine runs normally, 2. Clean and replace filter
2 wall-up
pilot pressure is low 3. Check, adjust overflow
3. Pilot overflow valve
pressure
malfunction
1. Hydraulic pump
1. Repair or replace main
malfunction
Engine runs normally, pump
2. Pilot operating valve
convey operation 2. Check pilot operating valve
3 malfunction
handle, no movement 3. Check adjust safety valve
3. Main safety valve
for machine overflow pressure
malfunction
4. Clean pipeline element
4. Valve or pipeline wall-up
1. Absorbing oil pipe Stop
overflow valve at the the
1. Open valve
bottom of oil tank don’t crane
2. Check, adjust safety valve
open. imme
overflow pressure
2. Slewing safety valve diatel
Slewing without 3. Check or replace slewing
4 malfunction y
movement pump
3. Slewing pump ※
4. Press slewing brake
malfunction
solenoid valve button
4. Slewing brake don’t open
5. Clean filter net
5. Absorbing oil filter
wall-up
5 Slewing without force 1. Slewing motor in vent 1. Check or replace motor
30/39
2. Overload 2. Lessen load

3. Slewing system valve, 3.Clean pipeline and element
pipeline wall-up.
1. Track telescopic handle
1. Track telescopic handle
Left traveling without at telescopic position
6 rotation traveling position
movement 2. Track telescopic valve
2. Clean telescopic valve
wall-up
1. Traveling resistance
1. Reduce traveling speed
2. Central slewing joint or
2. Clean central slewing joint
pipeline wall-up
Traveling without or traveling hydraulic
3. Traveling motor leaking
7 movement or no force pipeline
4. Hydraulic pump
for movement 3. Check or replace motor
malfunction
4. Check or replace pump
5. Traveling brake valve
5. Check or adjust brake valve
malfunction
1 Pump or motor leaking 1 Check or replace pump,
2 Hydraulic pipeline wall-up motor
8 Element low speed 3 Filter walls-up 2 Clean pipeline
4 Pilot handle isn’t in right 3 Clean filter
position 4 Adjust transit pilot handle
1.Main safety valve

1. Adjust main safety valve
malfunction
pressure
2. Hydraulic pump
Main (aux.) hoist 2. Check or replace main pump
malfunction
9 without movement or 3. Adjust balance valve
3. Balance valve malfunction
no force for movement pressure
4. Hydraulic pipeline walls
4. Clean pipeline
up
5. Adjust load
5. Overload
1. Track telescopic switch is 1. Place switch in telescopic
Track can’t extend and at slewing position position
10
retract 2. Track telescopic valve 2. Check track telescopic
malfunction valve
1. Pilot pump malfunction 1. Check or replace pilot pump
Main(aux.)hoist clutch 2. Pilot system overflow 2. Check, adjust overflow
11
don’t disjoint valve malfunction pressure
3. Manual brake valve and 3. Check manual valve or
31/39
clutch hydraulic control hydraulic control valve

valve malfunction 4. Clean pipeline
4. Clutch system pipeline
walls up
1 Filter wall-up
1 Clean filter
Hydraulic system 2 Oil viscosity excess
12 2 Replace hydraulic oil
noise 3 Hydraulic oil temperature
3 Hydraulic system warm-up
is low
1. Cooling pump 1. Check or replace cooling
malfunction pump
2. Cooling motor 2. Check or replace motor
malfunction 3. Clean radiator or pipeline
3. Radiator or pipeline 4. Replace hydraulic oil
Hydraulic oil
wall-up 5. Add oil to oil level
13 temperature is
4. Hydraulic oil brand is not
overhigh
accurate
5. Hydraulic oil
metamorphose
6. Oil capacity isn’t enough
in oil tank
1. There is air in hydraulic
system
1. Exhaust
2. Pipeline fixation tube is
Hydraulic pipeline 2. Adjust, fixed pipeline
loose
14 oscillates 3. Clean valve piece
3. Overflow or safety valve
tempestuously 4. Check or replace pump,
walls up
motor or valve
4. Pump, motor, valve
malfunction
Oil leaking at 1. Joint don’t screw down 1. Tighten and fix joint
15
Hydraulic joint 2.Seal piece damage 2. Replace seal piece
1. Tube don’t accord with
1. Replace suitable tube
use pressure
16 Tube blows out 2. Replace tube
2. Tube aging, scratch
3. Clean tube and joint
3. Wall-up at tube joint
32/39
3 Treatment of mechanism driving failure

1.Different tension
degrees of right/left 1. Adjust tension track
1 Traveling deflection
track 2. Adjust tension track
2. Loosen track
1. Track tension is 1. Adjust tension track
excess 2 Fill, mat the firm and level
2. The road surface is ground
soft 3 Eliminate dust and stone
2 Traveling resistance
3.Track shoe and
driving, driven
pulley nips with
dust, stone
1. Track loosen 1.Adjust, tighten track
3 Track skid 2. Track shoe abrasion 2. Replace track shoe
3. Driver flange abrasion 3. Replace driver
1 Friction liner block of 1 Check,adjust space between
clutch abrasion drum and liner block
2 Friction block is wet 2 Hang up the brake, and the clutch
Main(aux)hoisting clutch
4 come away,to perforn hoisting
skid
operations for 2-3 min, repeat it
time after time, and grind moisture
on the surface
1 Friction liner block of 1 Check,adjust space between
brake abrasion drum and liner block
2 Friction lining band 2 Replace friction lining band
abrasion seriously 3.Cleanout the oil or replace
Main(aux)hoisting brake 3.Friction lining band friction lining band
5
skid touches oil 4 Step footpedal to semi-brake
4Friction block is wet status, and the clutch come away,to
perforn hoisting operations for 2-3
min, repeat it time after time until
it is normal
1. Traveling reduction
Main(aux)hoisting or gear failure 1. Repair reduction gear
6 derricking drum no 2. Pawls locking not 2. Come away pawls
rotating come away 3. Open brake
3.Main(aux) hoisting
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brake not open
Derricking,swing and Reduction gear brake
7 Repair or replace brake disc
traveling brake slippage disc abrasion
Link rod, pins, shafts
8 Operation hard to sledding Eliminate rust, fill oil
rusted
4 Treatment of electric device failure

1Battery connection cut
off 1 Check the connection battery end
The whole crane no
1 2Battery connection 2 Connect again
electricity
incorrect 3 Replace fuse tube
3.Fuse tube F1 breaks
1 104,105# connection 1 Check the connection end
Startup electric engine
2 cut off 2 Check K1 relay for damage or
cannot start
2 K1 relay no actions not
Startup electric engine no Check the battery, if it is feeder,
3 The battery is feeder
power please charge
Rev gauge, water
temperature gauge, engine
4 oil pressure gauge failure, F2 fuse tube is broken Replace F2 fuse tube
generate electricity
indicator light is off
1Check S6、S7、S8 limit switch
1 S6、S7、S8 limit switch
Over-hoist prevention normal or not
5 failure
indicator light is off 2 Check connection for cutting off
2.Connection cut off
or not
1S9 release button 1 Check S9 button
failure 2 Replace indicator light
Working indicator light is
6 2 H2 indicator light is 3 Check the connection for cutting
off
damage off or not
3 The connection cut off
1 S10 switch failure
1Repair or replace switch
2Y4 solenoid valve
2 Repair or replace
7 The whole crane no swing failure
3 Connect it again
3 The connection cut off
34/39
Chapter 5 Grease Recommendation List
1 Engine lubrication recommendation list
Suitable
temperature ℃ -40 -30 -20 -10 0 10 20 30 40 50
Trademark
SAE15W/40CF-4
SAE10W/30CF-4
SAE5W/50CF-4
Use high viscidity lubrication can improve engine oil consumption, and under cold weather it improves engine’s
running, while under high temperature working environment, keep lubricate. Under most weather the SAE15W-40
is recommended
Some restricted ones, it needs to use low viscidity engine oil, such as SAE10W-30. When the surrounding
temperature is under -5℃,it will help startup and supply enough engine oil flow. But long time use low viscidity
engine oil will reduce engine’s service life due to abrasion.
D114 diesel engine is used by this crane, whose engine oil must use the special one (CF-4) produced by China
Petrochemical GreatWall Lubrication Group.
2 Engine fuel oil recommendation list
Light diesel oil（GB252-81）
Suitable temperature℃
-40 -30 -20 -10 0 10 20 30 40 50
Trademark
10#
0#
-10#
-20#
-35#
Note:a. Under most of working conditions, use ASTH2# fuel and the diesel engine with min.cetane40℃ to gain
best economy and performance. Under high altitude or low temperatue, it needs the fuel with cetane greater than
35/39
40℃ to avoid flameout and too much smoke.
b.Use low sulfur fuel, its cloud point is lower than min fuel temperature10℃ at least. The cloud point means the
temperature of wax cystalloid starts to form
c.Use the commercial general diesel engine oil, whose sulfur should be lower than 0.5%
d.When filling the oil, please keep fuel clean and without moisture or impurity
3 Lubrication recommendation list
Suitable season
Names Summer Winter
3# Two sulfur nolybdenum lithium

2# Two sulfur nolybdenum lithium
Note：
The highest working temperature of lubrication is 20～30°C lower than its dropping point
4 Gear oil recommendation list
Industrial gear oil
Suitable temperature℃
-40 -30 -20 -10 0 10 20 30 40 50
Trademark
SAE90-120
5 Hydraulic oil recommendation list
Suitable temperature℃ -40
-30 -20 -10 0 10 20 30 40 50
Trademark
N68 or DIN51519VG68
N46 or DIN51519VG46
Chapter 6 Use and Maintenance of Slewing Bearing

Use and maintenance of slewing bearing
Inspect the preload force of bolts at either sides bearing after first 100 working hours, subsequent inspection and
preload fastening every 500hrs. Stop the crane for inspection if abnormality such as noise or power abrupt
increase occurs.
Preload force for the bolt M27 of the bearing: 1200Nm.
Warning
z If replace slewing bearing, do it including all the bolts on it

z Exert preload force according to regulations of operation
instruction, or it will cause damage and shorten service life.
36/39
Appendix
1 Jugement of wind speed
Wind speed Names Grade Status （on the ground）
（m/s）
0-0.5 Calm 0 Calm; smoke rises vertically
0.6-1.7 Light air 1 Direction of wind shown by drifting of smoke but not
by wind vanes
1.8-3.3 Light 2 Wind felt on the face; leaves rustle; ordinary vane
breeze moved by wind
3.4-5.2 Gentle 3 Leases and small twigs in constant motion; wind
breeze extends light flag
5.3-7.4 Moderate 4 Raises dust and loose paper; twigs and small branches
breeze are moved
7.5-9.8 Fresh 5 Small trees in leaf begin to sway ; crested wavelets
breeze form on inland waters
9.9-12.4 Strong 6 Large branches in motion; telegraph wires whistle;
umbrellas used with difficulty
breeze
12.5-15.2 Moderate 7 Whole trees in motion.
gale
15.3-18.2 Fresh 8 Breaks twigs off trees; generally impedes progress
gale outdoors
18.3-21.5 Strong 9 Slight structural damages occurs(chimney pots and
gale slates removed)
21.6-25.1 Whole 10 Trees uprooted; considerable structural damage occurs
gale
25.2-29 Storm 11 Widespread storm damage (very rarely experience)
29- Hurricane 12
Note: the wind speed is in this table measured 10m high away from the ground
37/39
2 Screw thread connection tighten moment table（JG/T 5011.11-92）

（Reference parts） Unit：N·m
Performance 4.6 4.8 5.8 6.8 8.8 10.9 12.9
grade
Guaranteed stress 230 310 380 440 600 830 970
Mpa
M6 4-5 5-6 7-8 8-9 10-12 14-17 17-20
M8 10-11 13-15 16-18 18-22 25-30 34-41 41-48
M8×1 10-12 14-17 17-20 20-23 27-32 37-43 43-52
M10 19-23 26-31 31-36 36-43 49-59 68-81 81-96
M10×1 21-25 28-34 35-41 41-48 55-66 76-90 90-106
M12 33-39 45-53 55-64 64-76 86-103 119-141 141-167
M12×1.5 35-41 47-56 57-67 67-79 90-108 124-147 147-174
M14 53-63 71-85 87-103 103-120 137-164 189-224 224-265
M14×1.5 57-68 77-92 94-110 110-131 149-179 206-243 243-289
M16 82-98 111-132 136-160 160-188 214-256 295-350 350-414
M16×1.5 87-104 118-141 144-170 170-200 228-273 314-372 372-441
M18 113-135 152-182 186-219 219-259 294-353 406-481 481-570
M18×1.5 127-152 171-205 210-247 247-291 331-397 457-541 54-641
M20 160-192 216-258 264-312 312-366 417-500 576-683 683-808
M20×1.5 178-213 239-287 294-345 345-407 463-555 640-758 758-897
M22 218-261 293-351 360-431 416-499 568-680 786-941 918-1099
Screw thresd specification
M22×1.5 239-286 322-386 395-473 458-548 624-747 863-1034 1009-1208

M24 277-331 373-446 457-547 529-634 722-864 998-1195 1167-1397
M24×2 301-360 406-486 497-595 576-589 785-940 1086-130 1269-1520
0
M27 405-485 546-653 669-801 774-801 1056-1264 1461-174 1707-2044
9
M27×2 437-524 589-706 723-865 837-1002 1141-1366 1578-189 1845-2208
0
M30 550-658 741-887 908-1087 1050-125 1434-1717 1984-237 2318-2775
9 5
M30×2 608-728 820-982 1005-120 1164-139 1587-1900 2196-262 2566-3072
3 3 9
M36 961-1150 1295-155 1587-190 1838-220 2500-3000 3466-415 4051-4850
0 0 0 0
M36×3 1017-121 1371-164 1680-201 1946-252 2653-3176 3670-439 4289-5135
8 1 1 9 4
M42 1536-183 2071-247 2538-303 2939-351 4008-4798 5544-663 6479-7757
9 9 9 9 7
M42×3 1653-197 2228-266 2731-326 3162-378 4312-5162 5965-714 6921-8345
9 7 9 6 1
M48 2308-276 3110-372 3813-436 4415-528 6020-7207 8327-996 9732-11651
3 3 4 5 9
38/39
M48×3 2513-300 3387-405 4152-497 5207-575 6556-7848 9069-108 10598-1268
8 5 0 5 57 8
3 The relations between actual working pressure and using service life of hydraulic tube
As shown in the diagram, when the actual working pressure is 1.25 times of proposed working pressure, whose
service life is half of normal
39/39

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QUY50C

Hydraulic Crawler Crane

Fuwa Heavy Industry Co.,Ltd

Chapter 1 Performance and Parameter for Main Element ……………………...........…………………1/39

1.1 Mobile set……………………………………………………………………………………………1/39

1.2 Hydraulic element…………………………………………………………………………………2/39

1.2.1 Main pump………………………………………………………………………………………2/39

1.2.2 Main valve…………………………………………………………………………………………2/39

1.3 Main hoisting motor(with balance valve)…………………………………………………………2/39

1.3.1 Derricking motor（with balance valve）……………………………………………………………2/39

1.3.2 Swing motor…………………………………………...………………………...….......................2/39

1.3.3 Traveling motor.................................…………………………………...….……………………...2/39

1.3.4 Pilot pump................................……………………………...…...….…………………….............3/39

1.3.5 Main hoisting, derricking pilot valve...............................…………...…...….…………………….3/39

1.3.6 Traveling pilot valve............................……………………………...…...….……………………..3/39

1.4 Drive element..........................…………………...………...…...…..…………………….................3/39

1.4.1 Swing reduction gear.......................………………...……...…...….……………………...............3/39

1.4.2 Traveling reduction gear......................………………...….…...…...….……………………..........3/39

Chapter 2 Schematic Diagram……………………………………………………………………3/39

2.1 Strcture diagram…………………………………………………………………………………3/39

2.2 Power drive diagram………………………………………………………………………………4/39

2.3 Hydraulic schematic diagram……………………………………………………………………5/39

2.4 Electric system schematic diagram…………………………………….....…………………………6/39

Chapter 3 Inspection, Repair and Maintenance………………………….........…………………………7/39

3.1.1 Items for daily inspection and maintenance……………………………….........…………………7/39

3.1.2 Items for monthly inspection, repairation and maintenance……........................................………8/39

3.2 Requirements for inspection and maintenance………………………........…………………………9/39

3.2.1 Notes for inspection and maintenance………………………………………………......................9/39

3.1 Intervals for grease infusing…………………………………………………..……………………10/39

3.2 Precautions of grease infusing……………………………………………………………………10/39

4 Maintenance of mobile set…………………………………………………………………………11/39

4.1 Inspection and replacement schedule of engine parts……………………………………………11/39

4.3 Contents of inspection and replacement……………………………………………………………13/39

5 Maintenance of reduction gear…………………………………………….....………………………12/39

5.1 Oil filling diagram………………………………….......................…..……………………………12/39

5.2 Inspection diagram for hydraulic oil tank……………………….....................................................15/39

5.3 Contents of inspection and replacement……………………………....……………………………13/39

5.5 Replacement of filter element………..……………………………...………………..……………16/39

5.5.1 Clean and replacement……..……………………………......………………………...................16/39

5.6 Hydraulic oil change.………………………...…......…..………………..…...................................16/39

5.7 Cleanliness of oil suction filter……………...…......….....………………........................................17/39

5.8 Replacement for filter element of vent device………...…......…....………...………......................17/39

5.9 Replacement of servo system filter……...…......…....……..………................................................17/39

5.10 Cleanliness and replacement of hydraulic pipeline…......…....……..….....……............................17/39

6.Inspection and tighten key parts of bolt specification...…....……..…....……..................18/39

6.1 Tighten moment of hydraulic tubing…...…......….....………………...............................................18/39

6.2 Bolts inspection tighten table…...…......…....……..……….............................................................19/39

7.1 Maintenance during operating....……..……….................................................................................20/39

8.4 Replacement of friction lining band.……….....................................................………....................22/39

8.5 Adjustment of lightening pedal force..……….....................................................................……….22/39

9 Inspection and adjustment of clutch.………......................................................................………......22/39

9.1 Inspection diagram.………....................................................................………...............................22/39

10 Inspection and adjustment of derricking brake..........................................................………............23/39

11 Adjustment of crawler tension……...................................................................……….....................23/39

12 Inspection and replacement of wire rope..................................................…….................................24/39

13 Inspection and maintenance under special working environment...........................................……...24/39

13.1 Rain and snow operation......................................……..........................................…….................25/39

13.2 Seashore operation....................................…….........................................…….............................25/39

14 Notes for long term seal-up.................................……........................................…….......................26/39

2 Treatment of hydraulic system failure………………..…………..…..………… ......……………….30/39

3 Treatment of mechanism driving failure……..…………..………….…….....…………..……… ….33/39

4 Treatment of electric device failure………………..…………………......………....…………… ….34/39

Chapter 5 Grease Recommendation List……………………….….............………………………. ….32/39

1 Engine lubrication recommendation list………………….………...................…………………. ….35/39