QY70K TRUCK CRANE

Maintenance Manual

Xuzhou Construction Machinery Group Co., Ltd. China

 Xuzhou Heavy Machinery Co., Ltd.

Preface

This maintenance manual is written in order to service and maintain QY70K

truck crane correctly so as to give full rein to the crane high performance, to
increase crane’s working efficiency and ensure safety and normal service life. It
aims at understanding the each main parts performance and working principle so
as to use and maintain this QY70K truck crane as soon as possible.
In this manual, main parts structure and principle diagram of QY70K is
attached. During maintenance, users can check out the spare parts that need to be
replaced conveniently according to QY70K Truck Crane Parts Catalog.
Please carefully preserve this maintenance manual together with other technical
documents as the basis of using and maintaining this crane. To the parts that need
qualified personnel to maintain and signed in the manual, users have no right to
maintain, otherwise they should bear all the responsibilities.
Our company will reserve the right to modify the design without notice for
improvement.

XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA

XUZHOU HEAVY MACHINERY CO., LTD.
Address: No.165 Tongshan Road Xuzhou Jiangsu Province, China
Post code: 221004
Service Tel: 0086-0516-83461183
Service Fax: 0086-0516-83461180
Spare Parts Tel: 0086-0516-83461183
2nd Edition in Jul. 2007

Contents

I. Maintenance and Service of Superstructure Operation………………………………………...1

II. Boom and Telescoping System………………………………………………….…………….2
III. Winch System………………………………………………………………….……………..4
IV. Swing System………………………………………………………………………………...7
V. Slewing Bearing……………………………………………………………………………..10
VI. Electrical Principle Diagram………………………………………………………………..11
VII. Electrical Maintenance…………………………………………………………………….19
VIII. Hydraulic Principle Diagram……………………………………………….…………….21
IX. Rotary Buffer Valve………………………………………………………………………...22
X. Elevating Cylinder…………………………………………………………………………...25
XI. Telescoping Cylinder I……………………………………………………………………...26
XII. Telescoping Cylinder II……………………………………………………………………28
XIII. Telescoping Balance Valve Spool………………………………………….……………..30
XIV. Hoist Balance Valve………………………………………………………………………32
XV. Elevating Balance Valve…………………………………………………………………...34
XVI. Hydraulic Motor…………………………………………………………………………..36
XVII. Superstructure Multi-way Valve…………………………………………………………37
XVIII. Foot-operated Brake Valve……………………………………………………………...40
XIX. Telescoping Control Valve………………………………………………………………..42
XX. Troubles and Troubleshooting……………………………………………………………..45
Total page……………………………………………………………………………………….49
I. Maintenance and Service of Superstructure Operation
1.1 Safety warning of maintenance
Make sure to be safe during maintenance, load or no-load operations must be stopped, it is
forbidden to repair cranes during operation!
Notes on checking and repairing:
a. It is forbidden to do welding when the vehicle is electriferous. Before welding, remove the
positive and negative cables from the accumulator. The distance between welded components
and welding machine earth line cannot exceed 0.16m, the earthing cable of welding machine
cannot be connected to the engine.
b. Personal injury and crane damage accident will happen if start the engine before having it
checked and repaired.
c. Before having the engine checked and repaired, place indication of “Warning” or “Troubles
in repair” on the crane control system.
Do not start or operate crane if warning indication is placed on the crane control system. If
needed, check the crane first and make sure that there are no personnel under or around the
crane.
d. Damaged crane boom or jib will cause serious accidents. Chord damage, pin shaft bending or
lost or welding seam crack will reduce the strength of boom and lattice boom. Check crane
booms everyday to see whether they are damaged. Cranes with damaged booms are not
allowed to be used.
(Note: because the booms are made of high strength steel, special repairing method is needed.
Please consult your dealers.)
e. Repair or adjust the crane in the condition that loads are on the hook block or booms are
extended, loads or booms may cause dangerous movements and result in accidents.
f. Before maintenance or repairing, first lower the loads onto the ground and lower the booms
on suitable support.
g. The pressure in hydraulic system will keep a long period, so release pressure in system
before adjusting or repairing. Before maintenance, if release pressure unreasonably, the crane
will cause dangerous movements or result in oil spray with high speed and sudden pipe
connection injection.

1
II. Boom and Telescoping System
2.1 Parts Function Description
2.1.1 Boom and its telescoping system
Boom is the main component to which force is applied, it bears all kinds of external loads
during working besides the dead weight of crane. Telescoping system is the necessary system to
realize the boom length changing.
2.1.2 Telescoping balance valve spool
Telescoping balance valve spool in the telescoping system can prevent retraction of the
cylinder when the control lever is in the neutral position, but also avoid the phenomenon of
runaway of the boom retracting speed caused by lifting loads when the lever is in the retraction
position. Besides, telescoping balance valve spool also has the function of preventing oil cylinder
rapid retracting when the damage occurs to hose of boom telescoping pipeline.
2.2 Working Principle (see the following figure)
Truck crane has five boom sections, the 2nd, 3rd, 4th and 5th boom sections driven by two
telescoping cylinders telescope sequentially and synchronously. After the 2nd, 3rd, 4th and 5th
boom sections driven by telescoping cylinder I extend at the same time, the 3rd, 4th and 5th boom
sections driven by telescoping cylinder II and wire ropes extend synchronously; while retracting,
first the 3rd, 4th and 5th boom sections driven by telescoping cylinder II and wire ropes retract
synchronously, then the 2nd, 3rd, 4th and 5th boom sections driven by telescoping cylinder I retract
at the same time. The pressure of pressure-limited valve is adjusted to 18Mpa in order to avoid
piston rod crooking because of too high pressure when the boom is extending. Telescoping
balance valve is fitted in the oil circuit in order to keep the boom steady or stopping safely when
it is retracting.
2.3 Adjustment of Wire Ropes and Slide Block
2.3.1 Users should check and adjust booms’ extension and retraction every month, because while
using truck crane, force is applied to wire ropes and cables in the boom working process and its
length will change. If the boom does not extend and retract synchronously or vibration appears,
users should adjust in time and begin operating until these phenomena disappear. Otherwise,
wire ropes and cables will remove from the chute and be cracked so as to cause serious results.
Please do periodic adjustments in order to keep normal operation. The method is as following:
Operate the boom elevation angle to 60°, keep each boom section fully extended and then
retracted, repeat for several times. Extend the 3rd, 4th and 5th boom sections for some distance,
and then lower the booms, synchronously adjust the nut on the thin cable II of 5th section and nut
on the thin cable I of 4th boom section until the 3rd, 4th and 5th sections telescope simultaneously
with no vibration. Then tighten the nut on thin cable. When booms are fully retracted, if the
clearance between the booms on the boom head exceeds 1~2mm, weld spacers in front of boom
2
head, otherwise the force applied to oil cylinder and cable will be influenced.
Note:
■ If the booms vibrate while adjusting, coat grease on the interface of the slide block
between two booms.
■ Booms cannot be fully extended and lowered while greasing, only two sections can be
extended to coat.
2.3.2 The slide blocks have all been adjusted well when the truck crane is delivered to the
consumers. No adjustment is needed only when boom crooking, lateral loading and deflection
increasing because of serious frictional damage or some other reasons. Users can adjust the slide
block on the boom head by themselves, but the slide block on the base boom must be adjusted by
qualified personnel.

3
III. Winch System
3.1 Brief Introduction of Winch Reducer
Winch reducer consists of winch drum and reducer. This reducer is a 2-stage planetary gear
reducer mechanism, the bearings in the reducer are scroll bearing with high load-bearing capacity,
and type of internal lubrication is oil-bath lubrication. The output shaft of reducer is connected
with winch drum through bolts, wet brake is installed on the input shaft. The diagram is as Fig.
3-1 and 3-2 shows.
3.2 Use and Operation
During working, observe whether there is any oil leakage on the interface of brake and motor
and tightness of bolts and screws. Deal with the abnormal phenomena in time.
Replace oil after a new vehicle works for 100 hours, and then replace oil for the second time
after 500 hours. Hereafter replace lubrication oil every 1000 hours or one year (replace oil every
year if the vehicle works no more than 1000 hours in one year). It is better to operate the crane
for 15 minutes when replacing oil so as to exhaust lubricated oil.

4
 16 8 7 6 1 4 11 2

Brake oil port

Filling and
draining plug

3 15 14 15 12 13 9 10

Reducer Brake Structure (Fig. 3-1)

5
 Wire rope wedge

Reducer

Bearing block

Winch drum

Winch Reducer Structure Diagram (Fig. 3-2)

No. Part No. Part name Qty Remark

1 Supporting shaft 1
2 Piston 1
3 Drive shaft 1
4 Spring 2.5×11.5×37 16
5 Retaining ring 1
6 Snap ring 140×4 1
7 Retaining ring 1
8 Snap ring 90 1
9 Internal friction disc 7
10 External friction disc 8
11 Spring 1.6×6.5×37 8
12 Supporting ring 112×118.4×1.4P 2
13 X-ring ZP0347 1
14 Supporting ring 136×145.4×1.4P 2
15 X-ring ZP0346 1
16 O-ring 170×3.55 1

6
IV. Swing System
4.1 Parts Working Principle and Structure
Slewing reducer is installed on the turntable, this mechanism consists of slewing reducer and
hydraulic motor. High-speed hydraulic motor drives 3-stage planetary reducer to output power
through pinion which does external meshing action with the slewing bearing fixed on the frame.
Its revolution and rotation drive the superstructure rotating.
The brake in swing mechanism is multi-disc wet brake that is in constant-closed
State. The brake stays in constant-open state when the pressure oil is filled into it, so the
mechanism can work freely.
4.2 Use and Maintenance
Swing mechanism cannot be deposited and operated in the environment with corrosive gas
such as acid alkali. Swing mechanism should not work beyond its rated loads. The environmental
temperature should be in the specified scale, and trademark of the lubrication oil and
replacement period are referred to operation manual.

7
 Reducer filling plug

17
7
18
6
14
4
15
9
13
5
11
10
12
8
16
2
20
1
19
3
22
21

8
No. Part No. Part name Qty Remark
1 800398 Motor base 1
2 300123 Socket head cap screw M10×35-8.8 12
3 467561 O-ring 97.5×2.65 1
4 908821 Brake housing 1
5 16936283 Piston 1
6 103915 Internal friction disc 2
7 103936 External friction disc 3
8 16423354 Spring 2.5×11.5×37 16
9 16423355 Spring 1.6×6.5×37 12
10 467550 O-ring 140×2.65 1
11 470002 X-ring ZP0350 1
12 461727 Supporting ring 40.6×147×1.4P 2
13 470003 X-ring ZP0347 1
14 461643 Supporting ring 112×118.4×1.4P 2
15 469501 Protecting plug N98 1
16 444505 Oil plug M12×1.5 1
17 908309 Retaining ring 3
18 800400 Drive shaft 1
19 16432124 Vent G1/2 1
20 462805 Combined seal ring 22 1
21 469507 Dust cap G100 1
22 469518 Retainer cup H15 1

9
V. Slewing Bearing
5.1 Parts Function
This part is a bearing device fitted in the connection of superstructure and lower structure. It
can bear superstructure swing part and the weight and moment of loads.
5.2 Working Principle
The structure type is single row 4 points contact ball type slewing bearing. The outer circle of
the slewing bearing is connected with turntable and the inner circle is connected with frame.
Steel ball is installed between the outer and inner circles to contact with circular arc sliding chute
by 4 points, it can bear axial force, radial force and tipping moment at the same time.
The re-tighten moment of the bolt is more than 1127N.m. Check it after the slewing bearing
works 500 hours and lubricate sliding chute once every 1000 hours.
5.3 Check and Maintain Standards of Slewing Bearing
Item
Axial Clearance Radial Clearance
Diameter
1120~1800 0.1~0.4 0.06~0.4

Note: diameter of sliding chute is marked on the slewing bearing scutcheon.

No. Part No. Part name Qty Remark

1 11411717 Bolt 48
2 11411718 Bolt 48
3 11411088 Slewing bearing 1

10
VI. Electrical Principle Diagram

11
12
13
14
15
16
17
18
VII. Electrical Maintenance
Electrical system consists of power supply circuit, starting circuit, pilot control circuit,
unloader circuit, rope-end protection circuit, instrument indicating circuit, lighting circuit,
moment limiter system and auxiliary circuit, etc.
Common troubles and solutions:
7.1 None electricity in superstructure
Circuit composition fuse→superstructure starting switch→power supply relay K0→
superstructure electric load→ground cable
Cause and Solution:
1) Fuse F1 burned-out Replace
2) Starting switch out of order Repair (takes Acc port instead of Br port)
or replace
3) Power supply relay burned Replace, connect wire 9 with wire 1L for temporary
treatment
4) Lead disconnected Reconnect wire or lay cables
7.2 Troubles in lamp circuit
Circuit composition power supply→fuse→switch→lamp→ground cable
Causes and Solutions:
1) Light bulb damaged Replace
2) Fuse burned Replace
3) Earthing faulty Repair
4) Lead disconnected Repair
5) Switch inoperative Replace or repair
7.3 Height limiter inoperative
Causes and Solutions:
1) Cord reel faulty
2) Lead disconnected Repair
3) Height limiter switch inoperative Replace
4) Rope of heavy hammer broken Replace
5) Solenoid valve inoperative Replace or repair
6) Solenoid valve earthing faulty Repair
7) Height limiter switch earthing faulty Repair
8) LMI faulty Contact with our service center
7.4 Wiper inoperative
Circuit composition power supply→fuse→switch→wiper motor

19
 Causes and Solutions:
1) Fuse burned Replace
2) Switch inoperative Replace
3) Motor damaged Replace
4) Earthing faulty Repair
5) Lead disconnected Repair
7.5 Rope-end limiter inoperative

Circuit composition power supply→fuse→forced release switch→rope-end limiter

switch (main winch)→rope-end solenoid valve→ground cable
Cause: it most happens in rope-end limiter, switch A2 and A3 are not adjusted well or A2 and
A3 are inoperative; then in the circuitry.
Solution:
(1) Open the rear cover of rope-end limiter and adjust wire rope three to five circles to make it
inosculated with switch contact or repair and replace A2、A3
(2) Check the circuitry and repair.

20
VIII. Hydraulic Principle Diagram

21
IX. Rotary Buffer Valve
Construction and Function:

No. Part No. Part name Qty Remark

1 0041133039920970 Pressure valve 1
2 033015066 Valve body 1
3 04441800040290A Check valve 4
4 110201145 Sealing ring 2

5 110408003 G3/8” Plug 1

22
Function:
Buffer braking on the swing mechanism can lower the inertia quantum while breaking in the
state of heavy loads.
Working principle:
The basic working principle of rotary buffer valve is overflow and energy consumption to the
swing hydraulic system. It can make the swing mechanism of truck crane brake in time, and not
make the braking process too brief so as to realize the efficiency of swing braking and buffering.
1. Reverse rotating position
In neutral position, hydraulic control change valve is in braking state. When the swing pilot
control lever in the operator’s cab is pulled outside, there is electricity in proportional solenoid
valve so as to keep swing change valve in the left position as the figure shows. The pressure oil
flows from P to A, A that connects with slewing motor drives turntable rotating to the left of the
truck crane, that is anticlockwise rotation. When the slewing pilot control lever is pulled inside,
the oil filled from hydraulic control oil port b keep hydraulic control change valve in the right
position as the figure shows, the pressure oil flows from P to B, B that connects with slewing
motor drives turntable rotating to the right of the truck crane, that is clockwise rotation.
2. Neutral brake position
When swing pilot control lever is in neutral position, the swing change valve stays in neutral
position and does not change directions. The passage from pressure oil P to oil circuits A and B is
blocked, oil returns to oil tank with low pressure by the diffluent valve on swing change valve,
so there is no pressure oil from Port xl to external control port of relief valve on swing buffer
valve. At this time, if swing system has no mechanical braking, the turntable continues to rotate
along the original direction and the inertia impact will be caused. The pressure at oil circuit exit
goes up rapidly, when the pressure goes up to 3Mpa adjusted by relief valve, the oil liquid
exhausted from the oil circuit exit will overflow from the relief valve and enter another oil port,
the vacuum in that oil port will be filled up by check valve. Then the motor and relief valve form
loop to circulate. The relief valve is external control type, setting pressure is 3～20Mpa，when
external control pressure is 0Mpa, setting pressure of relief valve is 3Mpa; when external control
pressure is higher than 30bar, setting pressure of relief valve is 20Mpa.
Because energy will be consumed when opening the relief valve, inertia energy in the swing
system is consumed to achieve braking in the process of opening relief valve. But the needed
time is longer than that of mechanical brake, so it can cut down the braking impact. The
cushioning effect, that is the needed time for braking, can be adjusted by the pressure of relief
valve.
3. Free rotation
When a certain angle exists between the wire rope on the hook and the heavy loads that have
23
already feel to the ground, keep the wire rope vertical in order to eliminate the angle. When
swing operation stops, there is no electricity in swing change valve, the relief valve installed in
swing buffer valve opens with the function of spring force (about 3MPa). Solenoid valve is
electrified to keep the pilot relief valve and exhaust port L1 interlinked which means the pressure
in the oil port of motor is approaching zero. At this time pilot lever of winch raises, the turntable
is rotated by the pulling force of the heavy loads when the wire rope is tightened, vacuum in the
oil port will be filled up by check valve.

24
X. Elevating Cylinder
Construction and Function:

No. Part No. Part Name Qty Remark

1 Y-seal d280×260×17 2
2 Wear ring 2
3 Piston 1
4 O-ring180×5.7 2
5 Cylinder 1
6 Piston rod 1
7 Guide sleeve 1
8 Y-Seal d240×260×14 1
9 Backup ringφ240×φ260×3 2
10 O-ring280×5.7 1
11 O-ring250×5.7 1
12 Backup ring A250×2 1
13 DA17 Dust ring 1
14 Spherical plain bearing GEG120ES-2RS

Disassembly and Reassembly

(1) Support ring, sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(2) Piston rod, piston and cylinder
If small scratch is found on the sliding surface, use fine oilstone to polish it.

25
XI. Telescoping Cylinder I
Construction and Function:

No. Part No. Part Name Qty Remark

1 Piston rod 1
2 O-ring 65×3.1 1
3 O-ring 50×3.1 1
4 Balance valve 1
5 DA17 Dust ring 1
6 Wear ring d150×24.5×3 1
7 Y-seal d150×170×15 1
8 Assembled seal d150×165.1×6.3 1
9 O-ring185×5.7 2
10 Wear ring 1
11 Guide sleeve 1
12 Cylinder 1
13 Piston 1
14 Y-seal D170×150×16.5 2
15 Backup ring φ170×φ150×3 2
16 Wear ring D170×24.5×2.5 2
17 O-ring130×5.7 2
18 O-ring55×3.1 4
19 Little rod 1
20 Assembled seal d38×48.7×4.2 2
21 Y-seal d38×46×6.3 2
22 O-ring 60×3.1 2
23 Little guide sleeve 1

Disassembly and Reassembly

(1) When the piston rod assembly is pulled out from cylinder, pay attention not to damage the
surface of piston rod, piston and sealing ring.
26
(2) In order to make the piston rod cover easy to rotate, the cylinder should be aimed at the
central of piston rod.
(3) Support ring, sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(4) Piston rod, piston and cylinder
If small scratch is found on the sliding surface, use fine oilstone to polish it.
When the piston rod assembly is inserted into cylinder, coat enough hydraulic oil on the
sliding surface beforehand to avoid the damage of support ring, sealing ring, etc.

27
XII. Telescoping Cylinder II
Construction and Function:

No. Part No. Part Name Qty Remark

1 Balance valve 1
2 O-ring 50×3.1 1
3 O-ring 65×3.1 1
4 DA17 Dust ring 1
5 Y-seal d170×185×16.5 1
6 Guide sleeve 1
7 Assembled seal d160×175.5×6.3 1
8 O-ring 200×5.7 2
9 Wear ring 1
10 Wear ring d170×14.8×3 1
11 Cylinder 1
12 Piston rod 1
13 Y-seal d190×170×16.5 2
14 Backstop ring φ190×φ170×3 2
15 Piston 1
16 Wear ring 2
17 O-ring 120×5.7 2

28
Disassembly and Reassembly
(1) When the piston rod assembly is pulled out from cylinder, pay attention not to damage the
surface of piston rod, piston and sealing ring.
(2) In order to make the piston rod cover easy to rotate, the cylinder should be aimed at the
central of piston rod.
(3) Support ring, sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(4) Piston rod, piston and cylinder
If small scratch is found on the sliding surface, use fine oilstone to polish it.
When the piston rod assembly is inserted into cylinder, coat enough hydraulic oil on the
sliding surface beforehand to avoid the damage of support ring, sealing ring, etc.

29
XIII. Telescoping Balance Valve Spool
Construction and Function:
Function:
Ensure that the telescoping mechanism of truck crane can stop at any height, and take the
effect of closedown no matter the engine stops working or not and the time is long or short.

A B

1 2 3 4 5 6 7 8 9 10

1. controlled piston
1--控制活塞 2.2--阀套 sleeve 3--控制活塞 4--单向阀弹簧
3. controlled piston 4. check
5--单向阀valve spring
5. check valve 6. balance valve spool 7. outer spring on balance valve spool
8--平衡阀芯上的内弹簧
6--平衡阀芯 7--平衡阀芯上的外弹簧
8. inner spring on balance valve spool 9. rear cover 10. O-ring
9--后螺盖 10--工作腔隔断O形圈
Working principle:
(1) Extension of telescoping cylinder
The oil entering from port B opens the check valve and flows to port A, that means oil flows
to large chamber of telescoping cylinder, the telescoping cylinder is in extending operation.
(2) Retraction of telescoping cylinder
The oil liquid in large chamber of telescoping cylinder flows to port A and is blocked by check
valve, at this time, the oil liquid in small chamber of telescoping cylinder acts on the port K of
control piston and impulses the balance valve spool compressing two main springs to move right
as the figure shows with a pressure of 45 bar. The flow from port A to port B realizes the
retraction of telescoping cylinder.
Use and repair:
(3) Dismounting and remounting of CCBH140/350 telescoping balance valve
The tool for dismounting and remounting is shown in Fig.2, use 2—M5 screw and rear cover
9 to connect rotation lever to pull out CCBH140/350 telescoping balance valve.
(4) Installation of CCBH140/350 telescoping balance valve
The specification of O-ring 10 is ф50X3.1，push CCBH140/350 telescoping balance valve in
after buttering on the O-ring.

30
 图 2
Fig.2

31
XIV. Hoist Balance Valve
Construction and Function:

32
Function:
This valve is used to avoid the runaway of hydraulic motor’s rotating speed caused by the
weight of lifting loads (the rotating speed of hydraulic motor exceeds oil supply quantity).
Working principle:
When the hydraulic motor is descending, the hydraulic oil on the descending side flows into
hydraulic motor and acts on the piston of balance valve through choke as the pilot pressure.
When this pressure exceeds spring tension, the piston is pushed upwards, the hydraulic oil that
flows from port A to B keeps the pressure caused by loads, the loads are descending at the same
time.
Disassembly and Reassembly
(1) Sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(2) Valve rod, piston and choke
Check whether the choke is blocked.
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth
or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check their smooth movement.

33
XV. Elevating Balance Valve
Construction and Function:

34
Function:
This valve is used to avoid the runaway of elevating cylinder ’s descending speed caused by
the weight of lifting loads (hydraulic cylinder cannot descend steadily).
Working principle:
When the elevating cylinder is descending, there is electricity in proportional magnet of
elevating balance valve so that it works. Meanwhile, the pilot oil acts on the piston of balance
valve as the pilot pressure through choke.
When this pressure exceeds spring tension, the piston is pushed upwards, the hydraulic oil that
flows from port A to B keeps the pressure caused by loads, the loads are descending at the same
time.
Disassembly and Reassembly
(1) Sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(2) Valve rod, piston and choke
Check whether the choke is blocked.
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth
or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check their smooth movement.
Common troubles and causes:
(1) No descending
Open Port Mx of elevating balance valve to check if pressure oil flows out; if no pressure oil
flows out, check whether there is electricity in proportional magnet of elevating balance valve
and choke is blocked; if pressure oil flows out, check whether there is electricity in proportional
magnet of multi-way valve.
(2) Descend too fast
Adjust current of proportional electric magnet in elevating balance valve.

35
XVI. Hydraulic Motor
Construction and Function:

Function:
Hydraulic motor with bend axial piston type design is variable motor. It is the executive
element of system that is responsible to change hydraulic energy into mechanical energy.
Working principle:
The hydraulic motor works when an inclination exists between cylinder and output shaft.
Changing the inclination between cylinder and output shaft can change the oil suction quantity of
hydraulic motor in order to change the rotation speed and torque of the motor (see the figure).
The torque of hydraulic motor depends on its working volume, input pressure and flow. When
input pressure is certain, working volume is larger, torque of hydraulic motor is bigger. When
input flow is certain, working volume is smaller, rotation speed of hydraulic motor is higher.
This is the basic working principle of variable hydraulic motor.
Troubles and Causes:
(1) No pressure in hydraulic motor
Open the leakage oil pipe of the motor to check the leakage. The motor without troubles has
very low leakage, if the leakage is high, troubles of no pressure will be caused.
(2) Loads cannot be elevated with normal pressure and no motor leakage.
The variable mechanism of motor is out of order, or the bolts are adjusted incorrectly.
36
XVII. Superstructure Multi-way Valve
Construction and Function:

37
No. Part No. Part name Qty Remark
1 Bolt M16×50×250 3
2 Valve for pump 1 inlet 1
3 Valve for telescoping and elevating 1
4 Valve for pump 2 inlet 1
5 Valve for main winch and auxiliary winch 1
6 Cap 1
7 Bolt M16×50×260 1
8 Bolt M16×50×220 2
9 Nut M16 12 GB/T6170-2000
10 Washer 16 6 GB93-87
11 Washer 16 6 GB95-85
12 Name plate 1
13 Shuttle valve 4 GB95-85
14 Blanking piugs for port tappings M22×1.5 1
15 Washer Φ22 1

16 O-ring 29×3.55 3 JIS-P

17 O-ring 14×2.4 1 JIS-P

18 O-ring 29×3.55 3 JIS-P
19 O-ring 14×2.4 2 JIS-P
20 O-ring 7×2.5 1 JIS-P
21 O-ring 29×3.55 3 JIS-P
22 O-ring 14×2.5 1 JIS-P
23 O-ring 29×3.55 1 JIS-P
24 O-ring 29×3.55 2 JIS-P
25 Secondary relief valve 3 PR1 PR2 PR3
26 High pressure relief valve 2 V1 V2
27 Diffluent valve 2 PC1 PC2
28 Confluent valve 1 Ps

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Function:
This valve can complete the action of superstructure hydraulic circuit, and realize the
automatic shift between single pump and double pumps to supply oil in telescoping system,
elevating system, main winch and auxiliary winch. Also it can realize the composite proportional
hydraulic control of direction, flow and pressure, and achieve proportional stepless speed
governing of several executive mechanisms when operating simultaneously with different loads.
Disassembly and Reassembly:
(1) Valve block
Don’t grease on the O-rings among each block.
(2) Sealing ring
In principle, replace all these parts by new parts.
Install the oil seal into valve rod from the both ends, and don’t put oil seal through the recess
of valve rod.
(3) Valve rod and check valve
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth
or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check their smooth movement.
After some valve blocks are disassembled, the valve rod should be assembled in the original
valve block.

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XVIII. Foot-operated Brake Valve
Construction and Function:

Function:
It is used for emergency brake of swing system.
Working principle:
When crane is in emergency state and needs to stop the swing system at once, step on the foot
pedal in operator’s cab, so the relay triggers electric signal by controlling oil pressure (more than
0.6Mpa) in order to inform electric system to disconnect pilot solenoid valve (mark number is
Y8 and Y9) on swing change valve, then the valve spool of swing change valve returns to neutral
position. Stop oil supplying to swing motor, meanwhile, release controlling solenoid valve (Y7)
to make swing brake in braking state, then the function of emergency swing brake can be
achieved.
Dismounting and remounting:
(1) Valve block
Do not grease on the O-rings among each valve block.
(2) Sealing ring
In principle, replace all these parts by new parts.
Install the oil seal into valve rod from the both ends, and don’t put oil seal through the recess
of valve rod.
(3) Valve rod and check valve
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth

40
or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check their smooth movement.
After some valve blocks are disassembled, the valve rod should be assembled in the original
valve block.

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XIX. Telescoping Control Valve
Construction and Function:

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 No. Part No. Part Name Qty Remark
1 Plate 2
2 GB70-85 Screw M10X20 4
3 Cover plate and plug 1
4 GB70-85 Screw M8X20 4
5 Shuttle valve 1
6 Valve body 1
7 Taper plug ZG1/8 6
8 Solenoid change valve 3
9 Cover plate and plug 1
10 GB70-85 Screw M8X50 8
11 JB1001-77 Plug M18X1.5 2
12 JB982-77 Combined washer 18 2
13 Valve spool 1
14 Spring 1
15 Cover plate and plug 1
16 Relief valve 1
17 GB70-85 Screw M5X95 4

Function:
This valve is used for 1-stage and 2-stage telescopic switching.
Working principle:
It controls direction by excitation on magnet coil.
When electricity is put through magnet coil, the built-in push rod of magnet coil pushes valve
spool for oil circuit switching. When electricity is cut off, the valve spool returns by the action of
spring force.
The switching of valve spool can also be done by press down the manual push pin of magnet
coil.
Dismounting and remounting
(1) Sealing ring
In principle, replace all these parts by new parts. Coat hydraulic oil or grease before
reassembly, pay attention not to break or damage them when assembling.
(2) Valve rod, piston and choke
Check whether the choke is blocked.
Check the sliding surface, if small scratch is found on the sliding surface, use fine emery cloth
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or oilstone to polish it.
When the valve rod and piston are inserted into valve, coat hydraulic oil on the sliding surface
beforehand, and pay attention not to rotate them.
After the valve rod and piston are inserted into valve, check their smooth movement.
(3) Assembly
After assembling, push the manual push pin of magnet coil to check their smooth movement.

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XX. Troubles and Troubleshooting
20.1 Lower pressure than designed value
① Low pressure in relief valve; Reset pressure.
② High pump leakage; Replace oil pump.
20.2 Cause analysis of hoist speed not reaching the designed demand without loads:
① Low volumetric efficiency in pump.
② Open diffluent valve in multi-way valve.
③ Inoperative confluent valve in multi-way valve.
④ Faulty multi-way valve.
⑤ High leakage in main safe valve.
⑥ High leakage in hydraulic motor.
⑦ If the motor is variable hydraulic motor, check whether the displacement is in the specified
minimum value.
20.3 Cause analysis of no pressure in swing system:
① No pressure or low pressure in hydraulic system: it has nothing to do with hydraulic pump
and the relief valve on chassis multi-way valve if the outriggers can be operated normally. Check
whether the outrigger valve lever on chassis multi-way valve is in neutral position. Check the
relief valve and swing valve on the central rotary joint and superstructure multi-way valve.
Check whether the pressure of relief valve on the hydraulic pump and chassis multi-way valve
reaches the specified value if the outriggers cannot be operated normally.
② Internal leakage in swing valve.
③ High drain flow rate in swing motor.
20.4 Cause analysis of no movement of swing but high swing pressure:
① Brake lock cannot be released while rotating.
② Seized swing motor.
20.5 Cause analysis of swing to one direction only:
① Check whether the bolt on valve rod of swing valve is loose, valve rod cannot reach one
direction.
② Damaged cylinder barrel plate in one direction on the slewing motor and high leakage.
20.6 Cause analysis of no free rotation and slide:
① Faulty rotary solenoid valve.
② Over high pressure in rotary counterbalance valve.
20.7 Cause analysis of low or no pressure in elevating system:
① Over low or no pressure in elevating system: check pump and safe valve on multi-way valve
(check telescoping system at the same time).
② Internal leakage caused by damaged elevating valve in multi-way valve.
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③ Separated damper of confluent valve in multi-way valve.
④ Internal leakage in elevating cylinder.
⑤ Faulty confluent valve in multi-way valve.
20.8 Cause analysis of unable to lower the boom with normal elevating pressure:
① Seized control valve in elevating balance valve cannot push the slide valve.
② Blocked throttle hole on control piston of elevation balance valve.
20.9 Cause analysis of unable to lower the elevation:
① Internal leakage in cylinder and over low pressure cannot open the balance valve so that oil
in the chamber without rod cannot return to oil tank or the oil tank will extend outward.
② Over low pressure adjustment of secondary relief valve on elevating valve of multi-way
valve.
20.10 Cause analysis of lowering elevation automatically:
① Untight internal seal in balance valve.
② Internal damage in oil cylinder.
③ Balance valve open because of high pressure in control system.
20.11 Cause analysis of elevation vibrating:
Vibration in both elevation raising and lowering
① Vibration and noise in both elevation raising and lowering, especially in the situation of over
high oil temperature and environmental temperature.
Elevating cylinder is over tight, mainly because the guide sleeve in the elevating cylinder or
nylon supporting ring on the piston are influenced by the environmental temperature and expand.
② Cause analysis of elevation vibrating during lowering:
Over high opening pressure in balance valve.
Over big throttle hole on the control piston of balance valve.
Over high pressure adjustment of secondary relief valve on elevating valve of multi-way
valve.
20.12 Cause analysis of hoist speed not reaching the designed requirement with heavy loads:
① Low volumetric efficiency in pump.
② Open diffluent valve in multi-way valve.
③ Inoperative confluent valve in multi-way valve.
④ Faulty multi-way valve.
⑤ High leakage in main safe valve.
⑥ High leakage in hydraulic motor.
⑦ If the motor is variable hydraulic motor, check whether the displacement is in the specified
minimum value.
20.13 Cause analysis of no rotation of winch because of low pressure
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① Faulty main safe valve.
② High leakage in hydraulic motor.
③ Little internal leakage in hydraulic pump.
④ Faulty multi-way valve.
20.14 Cause analysis of no rotation of winch when pressure is normal
① Overload.
② Inoperative brake.
Brake friction plate serious worn.
Contaminated brake friction plate
Air in the brake piping.
Leakage of brake liquid or defect in brake piping.
③ Faulty hydraulic motor.
④ Faulty speed reducer.
20.15 Cause analysis of winch vibrating:
① Not fully opened brake.
② Faulty multi-way valve.
③ Faulty hydraulic motor.
④ Faulty multi-way valve.
⑤ Unsteady winch system.
⑥ Over high pressure adjustment of secondary relief valve on winch valve of multi-way valve.
20.16 Cause analysis of rotation speed decreasing when winch is in operation
① High leakage in main safe valve.
② High leakage in hydraulic motor.
③ Low oil displacement in hydraulic motor.
④ Faulty multi-way valve.
⑤ Overload.
20.17 Cause analysis of automatic lowering when loads are lifted
① High counter pressure in return circuit.
② Inoperative brake.
③ High leakage in hydraulic motor.
④ Faulty balance valve.
20.18 Cause analysis of abnormal noise in winch operation:
① Damaged hydraulic motor.
② Damaged speed reducer.
③ Faulty balance valve.
④ High oil viscosity.
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⑤ Air entering.
⑥ Influence of outside vibration.
⑦ Contaminated oil.
⑧ Over high pressure adjustment of secondary relief valve on winch valve.
20.19 Cause analysis of no telescoping motion in telescoping system:
① Low system pressure; Check hydraulic pump and relief valve in multi-way valve (including
safe valve and secondary relief valve).
② Internal leakage in damaged telescoping valve of multi-way valve.
③ Internal damage in telescoping cylinder.
④ Separated damper in confluent valve in multi-way valve.
⑤ Faulty 1-stage and 2-stage telescoping shift valve.
20.20 Cause analysis of no retraction of boom and high pressure:
① Seized control piston in telescoping balance valve spool cannot push the slide valve.
② Blocked throttle hole on control piston in telescoping balance valve spool.
20.21 Cause analysis of vibrated boom telescoping:
① The guide sleeve in the elevating cylinder or nylon supporting ring on the piston are
influenced by the environmental temperature and expand.
② Over tight slide block on boom, bad lubrication.
20.22 Telescopic troubles in truck cranes with more than four booms:
① Cause analysis of no retraction of 3rd and 4th (3rd, 4th and 5th) boom sections and high
pressure:
The solenoid valve coil in 1-stage and 2-stage telescoping cylinder is in open circuit, valve spool
is seized or control circuit is in broken circuit.
Main valve spool of shift valve is seized in the original position.
② Cause analysis of no extension and retraction of 2 nd boom section and high pressure:
Faulty control circuitry makes solenoid valve electrified and in working state, or solenoid valve
spool is seized in opening position.
Main valve spool of shift valve is seized in the position where 2-stage cylinder is coupled.
20.23 Cause analysis of automatic retraction of boom:
① Untight internal seal in balance valve.
② Internal damage in oil cylinder.
③ Balance valve open because of high pressure in control system.
20.24 Cause analysis of automatic extension of boom: booms extend automatically and slowly
after the engine stops working. If the truck crane has more than four boom sections, the 3 rd and
4th (3rd, 4th and 5th) boom sections extend automatically when the 2nd section is retracting; the 2nd
section extends automatically when the 3rd and 4th (3rd, 4th and 5th) boom sections are retracting.
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① Internal damage in telescoping cylinder.
② Damaged balance valve.
③ Faulty telescoping shift valve.
20.25 Lower pressure than designed value
① Low designed pressure of relief valve; reset pressure.
② High leakage of oil pump; replace oil pump.

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XUZHOU HEAVY MACHINERY CO., LTD.
XUZHOU CONSTRUCTION MACHINERY GROUP CO., LTD. CHINA
Add：No.165 Tongshan Road, Xuzhou, Jiangsu, China
Tel：0086-0516-83462242 83462350
Fax：0086-0516-83461669
Post Code：221004
Website：http://www.xzzx.com.cn
E-mail：xzzxyx@pub.xz.jsinfo.net
Service Tel：0086-0516-83461183
Service Fax：0086-0516-83461180
Spare Parts Tel：0086-0516-83461183
2nd Edition in Jul. 2007