Manual Do Guindaste

STC75 Truck Crane
User’s Guide
Hunan SANY Auto Hoisting Machinery Co., Ltd.

Address：Changsha Jinzhou Development Zone, Hunan, China Postal Code: 410600
http://www.sanygroup.com Tel：0731.85831153 Fax：0731.84031999.523
I
Preface
Hunan SANY Auto Hoisting Machinery Co., Ltd. sincerely thanks you for purchasing SANY fully-hydraulic
truck crane. SANY is dedicated to providing you with first-rate products, first-rate quality and first-rate
service.
This Maintenance Manual contains the detailed information and instructions for the structural features,
working principles, and maintenance and repair items about STC75 truck crane.
In order to ensure the high-efficiency performance of the truck crane, we strongly recommend that you
read and understand this Maintenance Manual carefully before operation. This will help you:
¾ Get to know the structure and performance of the truck crane
¾ Avoid danger or malfunction due to improper operation
¾ Increase the reliability and prolong the service life of the truck crane
¾ Reduce the maintenance cost and down time.
It is also recommended that you keep this guide within reach during operation. Only when you completely
understand the User’s Guide can you operate the machine expertly and safely.
Thank you for your trust in SANY, and we wish you great success in your business.
Special Instructions:
z This manual shall be kept in the cab cabinet or the tool box of truck crane.
z This manual contains the instructions of regular technical maintenance and common troubleshooting.
z This manual is a summary of the basic maintenance techniques. The operator needs to develop his
technique and skill by further understanding the equipment and its performances.
z As a result of gradual improvement and upgrading in the product design and for the difference of
product models, some details of figures and words in this manual may be not quite identical with your
machine.
z Please read this manual carefully before operation and conduct maintenance strictly by using the
required tools, specified methods and procedures. For any injury or damage resulted from violative
operation, Hunan SANY Automobile Manufacture Co., Ltd. shall not bear any responsibility.
z For any question on the machine or this manual, please enquiry the service engineers of our
company.
II
Reading Guidance
I. Information Guidance
1. Information
This Maintenance Manual is provided to facilitate your use and maintenance of the machine. It should
be always put in the cab for your reference at any time. If it is damaged or lost, you should order
another one from our company.
The Maintenance Manual consists of two chapters on superstructure and undercarriage, to cover the
information and instructions for safety, working principles, lubrication maintenance and troubleshooting.
Some photos or figured details or optional components shown in the Manual may differ from your
machine. For facilitating the explanation, the protective plate and machine cover have been
dismantled.
This Maintenance Manual may not include the alteration to the machine as a result of gradual
improvement and upgrading in the product design, so it shall be carefully read and studied, and be
stored together with the machine.
For any question on the machine or the User’s Guide, please contact Hunan SANY Automobile
Manufacture Co., Ltd. for the latest information.
2. Safety
Safety is the precondition for all operations. In order to protect your safety and others’, please use this
equipment properly and conduct maintenance timely. In the maintenance manual, this Manual
specifies the safety-related items that must be noticed when using and maintaining this equipment,
and requires the operator to understand relevant safety measures.
3. Technical Specifications
This part includes such content as basic structures, performance parameters and working principles,
which help your full acquaintance with the machine.
4. Malfunctions and Maintenance
This part as the main subject of this manual provides core instruction for the maintenance of this
product. The referred malfunctions and their related adjustment, disassembly and maintenance involve
common malfunctions and troubleshooting methods. In the table of regular check is listed the subjects
and periods of regular check and maintenance.
5. Engine Maintenance
The proper maintenance and overhaul are essential to guarantee the normal operation of the machine
and the engine. The owner of the engine of engineering machinery is liable for carrying out
maintenance in conformity with the maintenance requirements stated in the Spare Parts Drawing
Volume, Maintenance Manual, Operation Manual and User’s Guide.
It is forbidden for any untrained person to repair or maintain the engine or the machine. Any personnel
taking on repair, maintenance, sales, rent or trade of the machine or engine are prohibited to dismantle,
modify or disable the devices or elements in relation to the emission, installed on or in the machine or
the engine in accordance with the laws and regulations. Some parts in the machine or engine including
exhaust, fuel, electric, and intake or cooling systems may involve the emission, so they cannot be
altered at liberty without prior approval.
6. Capacity of Machine
The newly-added optional or refitted parts unrecognized by SANY Automobile Manufacture Co., Ltd.
may go beyond the advanced defaulted capacities of the machine, and accordingly produce bad effect
on its performance including stability and system compatibility, especially the brake function and the
steering function. For any safety accident owing to the addition or the refitting mentioned above, we
shall not bear any responsibility. However, if the addition of components or the partial refitting is
III
required under special case or claimed by the user, the user shall contact us in advance, and we will
provide the most reasonable opinions and suggestions.
7. Explanation of Signs
Danger
On the sign boards, such signs that mean the hazard as “Danger”, “Warning” or “Caution” are used
together with the . The sign of “Danger” means the direct danger, which may cause death or
serious injury if no preventive measure is taken.
Warning
It means the potential danger, which may cause death or serious injury if no preventive measure is
taken.
Caution
It means the potential danger, which may cause slight or moderate injury if no preventive measure is
taken.
The sign of “Danger” or “Warning” shall be established nearby the place where the special hazard is
easy to occur, while the general precautions shall be listed on the sign of “Caution”.
In the User’s Guide, the sign of “Caution” is also used to call attention to the safety indication.
Important
In order to avoid the confusion between the indication for machine protection and that for personnel
safety, the sign of “Important” is established, which means the machine may be damaged in case of
misoperation.
Notes
It is used to give the additional instructions to some specific information.
Prompt
It is used to give the directive instructions to some specific information.
2. General Safety Requirements

The safety items in maintenance work refer to the security measures that maintainers, inspectors and
lubricators need to pay attention to.
a)Working area (measures taken for the safety in working spots)
1) move the products into maintenance area;
2) separate the maintenance area with barriers;
3) anti-crashing measures shall be taken when several products working in the same area.
b) Security measures for products
1) Attach a warning marker on the crane, as shown in the figure below:
IV
Dangerous
Being maintained.
No powering!
Fig. 1 Example of Safety Words
Fig. 2 Example of Safety Signs

(Indicating that before maintenance or repair work is began,
the engine shall be shut down and the key shall be taken out)
2) Cut off the power supply or lock the power switch, to avoid unauthorized re-energization
3) Before maintenance, conduct electric discharging to release the stored energetic hydraulic power,
pneumatic power and electric power.
4) To check all performances after power-off, all power supplies shall be cut off at first in advance;
5) Place wood blocks under the wheels to prevent the crane from unexpected moving;
6) As to the relevant cases not covered in this manual or the information at specific working conditions,
it is recommended to turn to the manufacturer for help.
c) Personal protective measures：
1) Wear protective equipment, as shown in the figure below (safety belt, safety helmet, safety
glasses, etc.)
2) Make use of supporting columns or blocks;
V
3) Appoint professional personnel or qualified workers as required by the working tasks;
4) Move and deal with hazardous materials in proper way.
d) Operation:
1) Use safe and reliable steel wires;
2) Use workbench in appropriate places;
3) Take appropriate security measures when welding near bearings, circuits and oil cylinder.
VI
Contents
Preface ........................................................................................................................................................ II
Part I Superstructure of Truck Crane........................................................................................................... 1
1. General ................................................................................................................................................... 1
1.1 Product Model ....................................................................................................................................... 1
1.2 Fundamental Structure .......................................................................................................................... 1
1.2.1 Composition of Superstructure ............................................................................................ 1
1.2.2 Composition of Chassis ....................................................................................................... 2
1.3 Overall Dimensions and Working Principles ......................................................................................... 2
1.3.1 Overall Dimensions.............................................................................................................. 2
1.3.2 Working Principle ................................................................................................................. 2
2. Boom system ......................................................................................................................................... 3

2.1 Composition of Main Boom ................................................................................................................... 3
2.2 Composition of Jib ................................................................................................................................. 3
2.3 Schematic Diagram of Telescopic Mechanism...................................................................................... 4
2.3.1 Working Principle of Synchronous Extension ...................................................................... 4
2.3.2 Working Principle of Synchronous Retraction ..................................................................... 5
2.4 Replacement of Base Boom.................................................................................................................. 5
2.4.1 The base boom shall be replaced in the following cases .................................................... 5
2.4.2 Disassembly Steps .............................................................................................................. 5
2.4.3 Assembly Method................................................................................................................. 7
2.5. Replacement of 2nd Section of Boom ................................................................................................... 8
2.5.1 The 2nd section of boom shall be replaced in the following cases ....................................... 8
2.5.2 Disassembly Steps .............................................................................................................. 8
2.5.3 Assembly Method................................................................................................................. 9
2.6. Replacement of 3rd Section of Boom.................................................................................................. 10
2.6.1. The 3rd section of boom shall be replaced in the following cases .................................... 10
2.6.2 Disassembly Steps ............................................................................................................ 10
2.6.3. Assembly Method.............................................................................................................. 12
2.7 Replacement of 4th Boom .................................................................................................................... 12
2.7.1 The 4th boom shall be replaced in the following cases ...................................................... 12
2.7.3. Assembly Method.............................................................................................................. 14
2.8 Replacement of 5th Section of Boom................................................................................................... 14
2.8.1 The 5th section of boom shall be replaced in the following cases...................................... 14
2.8.2 Disassembly Steps............................................................................................................. 15
2.8.3 Assembly Method............................................................................................................... 16
2.8.4 Adjustment Method of Extension & Retraction Rope......................................................... 16
2.9 Replacement of Jib.............................................................................................................................. 17
2.9.1 The jib shall be replaced in the following cases................................................................. 17
2.9.2 Disassembly Steps ........................................................................................................... 17
2.9.3 Assembly Method .............................................................................................................. 18
2.10 Replacement of Telescopic Mechanism ............................................................................................ 18
2.10.1 The telescopic mechanism should be disassembled and assembled in the following
conditions (the reason of the boom structure is excluded) ......................................................... 19
2.10.2 Disassembly of Guide Wheel Assembly .......................................................................... 19
2.10.3 Assembly Method ............................................................................................................ 20
2.11 Replacement of Components of Boom Top Sheave.......................................................................... 20
2.11.1 The boom top sheave is required to be disassembled and assembled in the following
conditions: ................................................................................................................................... 21
2.11.2 Disassembly Steps ........................................................................................................... 21
2.11.3 Assembly Method ............................................................................................................. 21
2.12 Necessary Tools.................................................................................................................. 22
3. Turntable Assembly............................................................................................................................. 23
3.1 Disassembly and Assembly of Balance Weight .................................................................................. 23
3.1.1 The balance weight shall be disassembled in the following cases.................................... 23
VII
3.1.3 Assembly Method............................................................................................................... 24
3.2 Replacement of Slewing Reducer ....................................................................................................... 24
3.2.1 The slewing reducer shall be disassembled in the following cases................................... 24
3.2.3 Assembly Method............................................................................................................... 25
3.3 Replacement of Turntable ................................................................................................................... 25
3.3.1 The turntable shall be disassembled in the following cases: ............................................. 25
3.3.3 Assembly Method............................................................................................................... 26
3.4 Replacement of Slewing Bearing ........................................................................................................ 27
3.4.1 The slewing bearing shall be disassembled in the following cases:.................................. 27
3.4.2 Disassembly and Assembly Steps ..................................................................................... 27
3.5 Replacement of Rope Guard............................................................................................................... 27
3.5.1 The rope guard shall be disassembled in the following cases: ......................................... 27
3.5.3 Assembly Method............................................................................................................... 29
3.6 Necessary tools
4. Lifting Mechanism.................................................................................................................................. 30
4.1 Replacement of Main Grab Hook ........................................................................................................ 30
4.1.1 The main grab hook shall be disassembled in the following cases: .................................. 30
4.1.3. Assembly Method.............................................................................................................. 31
4.2 Replacement of Auxiliary Grab Hook .................................................................................................. 31
4.2.1 The auxiliary grab hook shall be dismantled in the following cases: ................................. 31
4.2.3 Assembly Method............................................................................................................... 32
4.3 Replacement of Main and Auxiliary Wire Ropes ................................................................................. 33
4.3.1 The wire rope shall be replaced in the following cases: .................................................... 33
4.3.3 Assembly Method............................................................................................................... 33
4.4 Replacement of Main and Auxiliary Winch Reducers ......................................................................... 33
4.4.1 The winch reducer shall be disassembled in the following cases ..................................... 33
4.4.3 Assembly Method............................................................................................................... 34
4.5 Necessary tools
5. Control Mechanism of Superstructure.............................................................................................. 34
5.1 Operation of STC75S .......................................................................................................................... 35
5.1.1 Overview ............................................................................................................................ 35
5.1.2 Operating Device ............................................................................................................... 35
5.2 Operation of STC75Y .......................................................................................................................... 35
5.2.1 Overview ............................................................................................................................ 35
5.2.2 Configuration of Electrical Elements inside Operating Room............................................ 36
5.2.3 Control Board of Instrument Panel .................................................................................... 37
5.2.4 Instruction for electric cabinet
5.2.5 Operation of display
5.3 A/C Device of Operating Room ........................................................................................................... 39
5.4 Replacement of Operating Room........................................................................................................ 40
5.4.1 The operating room shall be disassembled in the following cases:................................... 40
5.4.3 Assembly Method............................................................................................................... 41
6. Hydraulic System................................................................................................................................... 42
6.1Principles of Hydraulic System............................................................................................................. 42
6.1.1 Hydraulic System of STC750S Superstructure.................................................................. 42
6.1.2 Hydraulic System of STC750Y Superstructure
6.1.3 Principle of Superstructure Hydraulic System ................................................................... 43
6.1.4 Technical Parameters ........................................................................................................ 44
6.1.5 Instructions for Hydraulic Oil .............................................................................................. 44
VIII
6.1.6 Precautions for Maintenance of Hydraulic System ............................................................ 44
6.2 Main Oil Pump and Maintenance Thereof........................................................................................... 45
6.2.1 Structure of Hydraulic Pump .............................................................................................. 45
6.2.2 Analysis on Common Malfunctions of Hydraulic Pump ..................................................... 45
6.2.3 Replacement Steps of Hydraulic Pump ............................................................................. 46
6.2.4 Necessary Tools................................................................................................................. 46
6.3 Multi-way Valve of Undercarriages and Maintenance ......................................................................... 47
6.3.1 Structure and Principle of the Multi-way Valve of Undercarriages..................................... 47
6.3.2 Analysis on Common Malfunctions of Multi-way Valve of Undercarriages ....................... 47
6.3.3 Replacement of Multi-way Valve of Undercarriages .......................................................... 47
6.4 Multi-way Valve of Superstructure and Maintenance .......................................................................... 48
6.4.1 Structure and Function of the Main Valve of Superstructure ............................................. 48
6.4.2 Analysis on Common Malfunctions.................................................................................... 49
6.4.3 Replacement of Main Valve of Superstructure .................................................................. 49
6.4.4 Necessary tools
6.5 Structure and Maintenance of Central Slewing Body.......................................................................... 50
6.5.1 Structure and Function of Central Slewing Body ............................................................... 50
6.5.2 Diagnosis of Common Malfunction and Troubleshooting on Central Slewing Body ......... 50
6.6 Structure and Maintenance of Luffing Oil Cylinder.............................................................................. 51
6.6.1 Structure and Function of Luffing Oil Cylinder ................................................................... 51
6.6.2 Analysis on Common Malfunctions of Luffing Oil Cylinder ................................................ 52
6.6.3 Replacement of Luffing Cylinder........................................................................................ 53
6.6.4 Necessary Tools for Disassembly and Assembly of Luffing Cylinder ................................ 53
6.7 Structure and Maintenance of Telescopic Cylinder ............................................................................. 54
6.7.1 Structure and Function of Telescopic Cylinder................................................................... 54
6.7.2 Analysis on Common Malfunctions of Telescopic Cylinder................................................ 55
6.7.3 Replacement of Telescopic Cylinder.................................................................................. 55
6.7.4 Necessary Tools and Precautions for Disassembly and Assembly of Telescopic Cylinder 56
6.8 Structure, Function and Maintenance of Oil Cylinder of 5th Outrigger................................................. 57
6.8.1 Structure and Function of Oil Cylinder of 5th Outrigger ...................................................... 57
6.8.2 Analysis on Common Malfunctions of Oil Cylinder of the 5th Outrigger ............................. 58
6.8.3 Replacement of Oil Cylinder of 5th Outrigger ..................................................................... 58
6.8.4 Necessary Tools for Disassembly and Assembly of Oil Cylinder of 5th Outrigger.............. 59
6.9 Structure, Function and Maintenance of Vertical Oil Cylinder............................................................. 59
6.10 Structure, Function and Maintenance of Horizontal Oil Cylinder ...................................................... 59
6.10.1 Structure and Function of Horizontal Oil Cylinder............................................................ 59
6.10.2 Analysis on Common Malfunctions of Horizontal Oil Cylinder......................................... 60
6.10.3 Replacement of Horizontal Oil Cylinder........................................................................... 61
6.10.4 Necessary Tools for Disassembly and Assembly of Horizontal Oil Cylinder ................... 62
6.11 Structure and Maintenance of Winch Hydraulic Motor ...................................................................... 62
6.11.1 Structure and Working Principle of Winch Motor ............................................................. 62
6.11.2 Analysis on Common Malfunctions of Winch Motor......................................................... 63
6.11.3 Replacement of Winch Motor........................................................................................... 64
6.11.4 Replacement of Internal Parts of Winch Motor ................................................................ 64
6.11.5 Necessary Tools ............................................................................................................... 64
6.12 Structure and Maintenance of Slewing Motor ................................................................................... 65
6.12.1 Structure, Working Principle and Common Malfunctions of Slewing Motor .................... 65
6.12.2 Replacement Steps of Slewing Motor.............................................................................. 66
6.12.3 Replacement of Parts of Slewing Motor .......................................................................... 66
6.12.4 Necessary Tools............................................................................................................... 66
7. Electrical System of Superstructure ...................................................................................................... 67

7.1 SYML Torque Limiter ........................................................................................................................... 67
7.1.1 Composition and Functions of SYML Torque Limiter ........................................................ 67
7.1.2 Basic Troubleshooting Methods ........................................................................................ 67
7.2 Length/angle Sensor ........................................................................................................................... 69
7.2.1 Structure & Principle .......................................................................................................... 69
7.3 Height Limiting Switch (Overwinding Prevention Switch).................................................................... 70
7.3.1 Structure and Principle....................................................................................................... 70
IX
7.4 Other Electrical System Malfunctions of Superstructure..................................................................... 71
8. Maintenance .......................................................................................................................................... 73
8.1 General Check..................................................................................................................................... 73
8.1.1 Check of Work Oil Liquid Level.......................................................................................... 73
8.1.2 Check whether all safety equipment are at proper locations and with complete functions 73
8.2 Check of Driving Device ...................................................................................................................... 73
8.3 Check of Hydraulic System ................................................................................................................. 73
8.3.1 Hydraulic Oil Tank.............................................................................................................. 73
8.3.2 Hydraulic Pump.................................................................................................................. 73
8.3.3 Overflow Valve ................................................................................................................... 73
8.3.4 Control Valve ..................................................................................................................... 74
8.3.5 Luffing and Telescopic Cylinders....................................................................................... 74
8.3.6 Pipeline .............................................................................................................................. 74
8.4 Check of Slewing Mechanism ............................................................................................................. 74
8.4.1 Brake.................................................................................................................................. 74
8.4.2 Slewing Connector............................................................................................................. 74
8.4.3 Reductor and Slewing Mechanism .................................................................................... 74
8.5 Check of Derrick Mechanism of Main Boom ....................................................................................... 74
8.5.1 Luffing Cylinder of Main Boom........................................................................................... 74
8.5.2 Balanced Valve .................................................................................................................. 75
8.6 Check of Telescopic Mechanism of Main Boom.................................................................................. 75
8.6.1 Main Boom ......................................................................................................................... 75
8.6.2 Telescopic Cylinder of Main Boom .................................................................................... 75
8.6.3 Jib....................................................................................................................................... 75
8.6.4 Steel Wire........................................................................................................................... 75
8.7 Check of Lifting Mechanism ................................................................................................................ 75
8.7.1 Reductor............................................................................................................................. 75
8.7.2 Brake.................................................................................................................................. 76
8.7.3 Balanced Valve .................................................................................................................. 76
8.7.4 Winding Drum .................................................................................................................... 76
8.7.5 Jib....................................................................................................................................... 76
8.7.6 Lifting Hook and Sheave.................................................................................................... 76
8.7.7 Steel Rope ......................................................................................................................... 76
8.8 Check of Control System of Truck Crane ............................................................................................ 76
8.8.1 Start Switch ........................................................................................................................ 76
8.8.2 Wiper.................................................................................................................................. 77
8.8.3 Inner Lamp ......................................................................................................................... 77
8.8.4 Buzzer ................................................................................................................................ 77
8.8.5 Automatic Force Limiter ..................................................................................................... 77
8.8.6 Overwinding Stop Device (altitude limiter)......................................................................... 77
8.8.7 Superstructure Cab............................................................................................................ 77
8.8.8 Pressure Gauge................................................................................................................. 77
8.8.9 Control Handle and Pedal.................................................................................................. 77
8.8.10 Working Lamp.................................................................................................................. 77
8.8.11 Top Lamp of Boom .......................................................................................................... 77
8.9 Check of Outrigger Mechanism........................................................................................................... 77
8.9.1 Vertical Cylinder of Outrigger............................................................................................. 77
8.9.2 Fixed Outrigger Box, Movable Outrigger Box and Level Cylinder of Outrigger................. 78
8.9.3 Control Valve of Outrigger ................................................................................................. 78
8.9.4 Leveling Gauge.................................................................................................................. 78
8.9.5 5th Outrigger Cylinder......................................................................................................... 78
8.10 Lubrication of Superstructure ............................................................................................................ 79
9. Common Malfunctions and Troubleshooting of Superstructure ............................................................ 82

9.1 Overview.............................................................................................................................................. 82
9.2 Diagnosis of Common Malfunctions and Troubleshooting on Mechanical System of Superstructure 82
9.3 Diagnosis of Common Malfunctions and Troubleshooting on Hydraulic System................................ 83
9.4 Diagnosis of Common Malfunctions and Troubleshooting on Electrical System ................................ 85
X
Part I Superstructure of Truck Crane
1. General
1.1 Product Model
“SANY” cranes, manufactured by Hunan SANY Auto Hoisting Machinery Co., Ltd., embody the domestic
and overseas advanced techniques, and feature the unique appearance---streamline shape, the broad
visibility cab, the flexible maneuver, the flexible driving control system, the stable double H outriggers, the
strong telescopic boom, the new-typed truss frame jib, and the superstructure system which is easy to be
operated. The truck crane produced by our company takes the leading position in the domestic truck crane
technology with its excellent operating features, powerful lifting capacity and ease of operation. At present,
the mass-produced products are mainly the fully hydraulic truck crane, which can be divided into the pilot
control type and manual control type according to the control method, with the tonnage from QY16 to
QY100 whole series. QAY200 and QAY400 all-terrain cranes are being developed. This Maintaining
Instructions describes the troubleshooting for common malfunctions and the knowledge of regular
technical maintenance for our new product, STC75 truck crane.
1.2 Fundamental Structure

The STC75 truck crane principally consists of boom system, turntable assembly, hydraulic system,
electrical system and chassis (Fig. 1-1).
1-Boom system 2-Chassis 3.Electrical system

4.Hydraulic system 5-Turntable assembly
Fig 1-1 General Diagram of STC75 Truck Crane
1.2.1 Composition of Superstructure

The superstructure is mainly composed of boom system, turntable assembly, hydraulic system, electrical
system, etc.
1. The boom system consists of main boom, jib, telescopic mechanism, and sheave at boom end.
2. The turntable assembly mainly includes the turntable, slewing support, slewing reducer and balance
weight.
3. The winch mechanism mainly consists of winch reducer, main hook, auxiliary hook, steel rope and
rope guard and other parts.
4. The superstructure operating mechanism mainly consists of operating room, operating mechanism of
superstructure, console, air conditioner of superstructure and various labels.
5. The hydraulic system consists of the hydraulic systems of superstructure and undercarriages on truck
crane.
1
6. The electrical system consists of the electrical systems for main boom, jib and turntable.
1.2.2 Composition of Chassis
The chassis is composed of power system, power train, traveling system, brake system, steering system,
cab, A/C system and electrical system.
1.3 Overall Dimensions and Working Principles

1.3.1 Overall Dimensions
Fig 1.2 Overall Dimensions

1.3.2 Working Principle
The truck crane can transfer the engine’s power to the main oil pump through the PTO device, and hence
make the whole hydraulic system have hydraulic energy for various actions. The hydraulic energy can,
through the control mechanisms of superstructure and undercarriages, be transferred to each actuating
part -- oil cylinder and motor. The telescopic cylinder I can drive the 2nd boom to stretch out by
pin-connected joint of cylinder, and the telescopic cylinder II drive the telescopic mechanism to make 3rd,
4th and 5th booms simultaneously retract. The luffing cylinder can make the whole boom system operate up
and down, and the slewing motor can drive the slewing mechanism to stably turn 360° through the slewing
reducer, and hence ensure that the hook can reach the target distance and position. The winch motor can,
by winch reducer and wire rope, drive the hook up and down, and transfer materials
2
Part II Boom system
The boom system is the core part of truck crane, and also the most important bearing structural member
for lifting. The strength and rigidity of the boom system have a direct effect on the performance of truck
crane. The boom system mainly includes main boom, jib, telescopic mechanism, and sheave at the end of
boom, and also such auxiliary structural members as boom-between slide block, block set, rope guard
contact roller and rope supporting board bracket.
Presently, the main boom of QY50C and that above 50 tons’ capacity is composed of base boom, 2nd, 3rd,
4th and 5th sections of boom. Among booms, the MC nylon slide block is adopted for supporting horizontally
or vertically, with the interval between slide block and main boom generally at 4mm, which depends on the
processing level of main boom. If the interval is larger, the handle strength and rigidity of main boom will be
lower. If the interval is smaller but the manufacture deviation of main boom is larger, in other words,
straightness, parallelism, verticality or torsion coefficient of the boom is bad, the disturbance will be easy to
occur, resulting into boom shaking or with noise.
2.1 Composition of Main Boom

The main boom of STC75 is composed of base boom, 2nd, 3rd, 4th and 5th sections of boom. Among booms,
the MC nylon slide block is adopted for supporting. As shown in Fig. 2-1, main boom mainly consists of
boom sections (total of 5), sheave at the end of boom, slide block among booms, fixed sheave block, rope
guard contact roller, slide plate bracket for supporting rope and the connecting shaft among main boom,
turntable and upper pin-connected joint luffing cylinder.
Fig. 2-1 Composition of Main Boom

1-Rope supporting contact roller 2-Rope supporting contact roller 3-Rope guard contact roller
4-Sheave block 5-Sheave at the end of boom 6-Base boom 7-2nd section of boom 8-3rd section of
boom 9-4th section of boom 10-5th section of boom
2.2 Composition of Jib

The jib is the key lifting and bearing part of the truck crane and also the key steel structure member. The
combination of truss structure and solid-web structure is now adopted in the jib of the STC75 truck crane.
The function of the jib is to make up the insufficient operation height for the main boom and expand the
operation area. It is composed of boom seat, boom, connecting plate, boom head, bearing rack, bracket
assembly and other parts, as shown in Fig. 2.2.
3
1-Cross pin 2-Clamp pin 3-Boom seat assembly 4-Boom assembly 5-Folding boom
6-Retainer pin 7-Sheave assembly 8-Bracket assembly 9-Sheave
Fig. 2-2 Composition of Jib
2.3 Schematic Diagram of Telescopic Mechanism
1－Telescopic cylinder I 2－Telescopic cylinder II 3－2nd section of boom 4－3rd section of boom 5－
4th section of boom 6－5th section of boom 7－Extension sheave of 4th section of boom 8－Bracket
sheave of telescopic cylinder 9－Supporting sheave of bracket 10－Extension rope of 5th section of
boom 11－Retraction rope of 4th section of boom 12－Extension sheave of 5th section of boom 13－
Retraction sheave of 4th section of boom 14－Pin-connected joint shaft of telescopic cylinder 15－Base
boom
Fig. 2-3 Schematic Diagram of STC75 Telescopic Mechanism
2.3.1 Working Principle of Synchronous Extension
As the barrel of telescopic cylinder I is installed at the tail of the 2nd section of boom with axis pin, the
cylinder barrel stretches forward to drive the 2nd section of boom to stretch when the piston-side of
telescopic cylinder I gets oil in. The 3rd, 4th and 5th sections of boom inserted inside the 2nd section of boom
4
stretch out along with the 2nd section of boom. When the telescopic cylinder II stretches forward, the 3rd
section of boom would be driven to stretch out by the axis pin installed at the tail of 3rd section of boom, at
the mean time, the telescopic rope bypassing the sheave at the head of telescopic cylinder II drives the 4th
section of boom to extend and retract synchronously, while the wire rope bypassing from the tail of 5th
section of boom to the sheave of telescopic cylinder at the head of 4th section of boom drives the 5th
section of boom to stretch forward synchronously. (Practically, the free extension and retraction of
cylinders I and II have been fulfilled.)
2.3.2 Working Principle of Synchronous Retraction

The working principle of synchronous retraction is identical with the extension with reverse order.
2.4 Replacement of Base Boom

2.4.1 The base boom shall be replaced in the following cases
Fig 2-4(1) Outline Diagram of Base Boom
1. When the base boom bends, breaks, or distorts

In the normal condition, the base boom will not bend, break, or distort. However, in case of overload
or abnormal operation, such phenomena may occur, the base boom needs to be replaced.
2. When the main weld of base boom cracks and strength requirement cannot be met despite
rewelding
The main weld of base boom may crack due to long-time running of crane under high load, abnormal
operation or accident. If it is confirmed by the technical department that the base boom can’t meet
strength requirement despite rewelding, it needs to be replaced.
2.4.2 Disassembly Steps
1. Disassembly of main boom
Prompt
Before removing the base boom, the entire boom must be removed first.
The Disassembly Steps of main boom are as follows:
Step 1 Remove such parts that connect with the main boom as grab hook, jib, rope, hydraulic oil tube,
electric appliance.
Step 2 Fixed the main boom by crane and soft sling.
Important
Ensure the crane and soft sling are strong enough to support the entire boom assembly. Proper
backup plate maybe used to prevent the soft sling being bent and distorted at the edge of boom. And
avoid the soft sling or spreader sliding at the contact part of boom.
Step 3 Release the bolt 3, take down washer and shaft baffle 2, and eject the axis pin 1 by copper bar
5
to separate the boom from luffing oil cylinder.
Step 4 Release the bolt 6, take down washer and bearing end clamping plate 5, and eject the big
boom articulating shaft 4 by copper bar to separate boom from the turntable.
Step 5 Transfer the main boom by crane to special assembly field or specified site.
Prompt
Before lifting the main boom, it’s needed to align the center lines of two cranes, avoiding that the
moving route of boom during lifting is deflective, which collides the welding part of the turntable.
1-Axis pin 2-Shaft baffle 3-Bolt 4-Big boom articulating shaft

5-Big boom bearing end clamping plate 6-Bolt
Fig. 2-4(2) Disassembly Details of Main Boom
Danger
It’s forbidden to stand under the boom when the boom assembly is being lifted from the truck crane!
2. Disassembly of Base Boom
Base boom
2nd section
of boom
12-Bolt 13-Nut 14-Supporting block 15-Axis pin

16-Slide block ㈠
Fig. 2-4(3) Disassembly Fig. 2-4(4) Disassembly Details of base boom

Details of base boom
6
Step 1: Eject axis pin by copper bar to separate the base boom from the telescopic cylinder I;
Step 2: Release the nut 13, and then take down axis pin 15, support block 14, bolt 12, and then
slide block (I) 16 in sequence;
Step 3: Take out 2nd, 3rd, 4th and 5th sections of boom horizontally and slowly by crane and soft sling
and then transfer them to the special assembly field or specified site;
Step 4: Remove such parts on the base boom as rope guard roller, slide block, bearing and copper
sleeve, which are available for the next use.
Notes
Measure and record the position of the retraction rope as the reference value of adjusting the position
of retraction rope nut during reassembling the boom.
Important
When taking out 2nd, 3rd, 4th and 5th sections of boom, please make sure that the wire ropes are not
wrapped or shackled with the base boom so as to avoid any damage!
2.4.3 Assembly Method
Prompt
The method of assembling base boom is in the reverse order of disassembling.

The basic method of assembling base boom is as follows:
(a) Put the base boom on the processing support.
(b) Lift the 5th, 4th, 3rd and 2nd sections of boom to the front of base boom, and keep them in line.
(c) Smear extreme-pressure lithium-based grease EP2 on the external slideway of 2nd section of boom,
put 5th, 4th, 3rd and 2nd sections of boom in the base boom horizontally and slowly, ensuring the rear
slide block of 2nd section of boom can freely slide in the mounting groove; and then adjust the position
and interval of 2nd section of boom in the base boom with gaskets to the interval between base boom
and slide block not more than 3mm in vertical way and not more than 1.5mm in horizontal way.
(d) Adjust the base boom to align it with the mounting hole of piston rod on telescopic oil cylinder I, insert
the separating sleeve 8, plug the axis pin 7 into the mounting hole by copper bar, mount the baffle 6
and fix it with screw 5 and washer.
(e) Mount the slide block (I) 16 at the head of base boom, then mount bolt 12, support block 14, and axis
pin 15 in sequence, screw down the nut 13, and then adjust the interval between slide block (I) 16 and
2nd section of boom by use of nut 13, ensuring the interval within 1.5mm in horizontal way and within
3mm in vertical way.
(f) By using crane and soft sling, lift the boom assembly above the big boom articulating seat of turntable
and put the head of boom to the middle part of big boom articulating seat; smear proper lithium-based
grease on the big boom articulating shaft 4, and connect the big boom with the turntable; mount big
boom bearing end clamping plate 5, bolt 6 and washer, and then fix the bolt 5 to set the boom on the
support of boom.
(g) By using crane and soft sling, lift the luffing oil cylinder and control it to make the piston rod head
extend and contract in phase, and then align the piston rod head with the articulating seat of luffing oil
cylinder; smear lithium-based grease on the axis pin 1, and connect the luffing oil cylinder with the
boom, and then mount shaft baffle 2, bolt 3 and washer, finally screw down the bolt 3.
7
Caution
When disassembling and assembling boom, the operator need wear canvas gloves in case of being
cut.
2.5. Replacement of 2nd Section of Boom
2.5.1 The 2nd section of boom shall be replaced in the following cases
Fig. 2-5(1) Outline Diagram of 2nd Section of Boom

1. When the 2nd section of boom bends, breaks, or distorts
In the normal condition, the 2nd section of boom will not bend, break, distort or deformed. However, in
case of overload or abnormal operation, such phenomena may occur, and at this time the 2nd section
of boom needs to be replaced.
2. When the main weld of 2nd section of boom cracks, and the strength requirement cannot be
met despite rewelding
The main weld of 2nd section of boom may crack due to long-time running of crane under high load,
abnormal operation or accident. If it is confirmed by the technical department that the 2nd section of
boom can’t meet strength requirement despite rewelding, it needs to be replaced.
1. Disassembly of base boom: the base boom must be firstly removed before disassembling the 2nd
section of boom. See the Section 2.4.2 for Disassembly of Base Boom.
2. Disassembly of 2nd section of boom
1-Axis pin 2-Splint pin 3- Extension rope for 4th section of boom 4-Bolt
5-Shaft baffle 6-Axis pin 7-Telescopic cylinder 8- Retraction rope for 3rd section of boom
Fig. 2-5(2) Disassembly Details of 2nd Section of Boom
8
nd
2 Section of
Boom
rd
3 Section of
Boom
12-Bolt 13-Nut 14-Support block 15-Axis pin 16-Slide block ㈠

nd
Fig. 2-5(3) Disassembly Details of 2 Section of Boom
Step 1: Release the screw 3, remove the shaft-fixing plate 2, and eject the half shaft of oil cylinder I
by copper bar to separate the telescopic cylinder I from the 2nd section of boom;
Step 2: Release the bolt 6, and then take down the washer 7, eject the axis pin 4 by copper bar to
separate the telescopic cylinder II from the 2nd section of boom;
Step 3: Release the nut 13, and then take down axis pin 15, support block 14, bolt 12 and slide
block (1) 16 in sequence;
Step 4: Take out 3rd, 4th and 5th sections of boom horizontally and slowly by crane and soft sling and
then transfer them to the special assembly field or specified site;
Step 5: Remove such parts as rope guard roller, slide block, bearing and copper sleeve on the 2nd
section of boom, which is available for the next use.
Important
When taking out 3rd, 4th and 5th sections of boom, make sure that the wire ropes are not wrapped or
shackled with the base boom so as to avoid any damage!
Prompt
The method of assembling 2nd section of boom is in the reverse order of disassembling.
The method of assembling 2nd section of boom is as follows:
(a) Put the bass boom on the processing support.
(b) Lift the 5th, 4th and 3rd sections of boom to the front of 2nd section of boom, and keep them in line.
(c) Smear extreme-pressure lithium-based grease EP2 on the external slide way of 3rd section of
boom, put 5th, 4th and 3rd sections of boom in the 2nd section of boom horizontally and slowly,
ensuring the rear slide block of 3rd section of boom can freely slide in the mounting groove; and
then adjust the position and interval of 3rd section of boom in the base boom to the interval
between base boom and slide block not more than 3mm in vertical way and not more than 1.5mm
in horizontal way.
(d) Adjust the 2nd section of boom to align its mounting hole of the piston rod on the telescopic
cylinder II, hit the axis pin 1 into the mounting hole by copper bar, mount the shaft baffle and fix it
with screw;
(e) Adjust the 2nd section of boom to align its mounting hole of the piston rod on the telescopic
cylinder II, hit the axis pin 4 into the mounting hole by copper bar, mount the shaft baffle and fix it
with screw;
9
(f) Mount the slide block (1) 16 at the head of 2nd section of boom, then mount bolt 12, support block
14, and axis pin 15 in sequence, screw down the nut 13, and then adjust the interval between
slide block (1) 16 and 3rd section of boom by use of nut 13, ensuring the interval within 1.5mm in
horizontal way and within 3mm in vertical way;
(g) Adjust the telescopic boom ropes to make the 3rd, 4th and 5th sections of boom steadily and
smoothly contract synchronously;
(h) Lift the boom assembly right ahead the big boom articulated bracket of slewing table with crane
and soft sling, gently place the head of the cargo boom in the middle of the big boom articulated
bracket of slewing table, coat the big boom articulated shaft 4 with adequate amount of
lithium-based grease, connect the big boom and slewing table, and then mount the big boom
shaft end pressure plate 5, bolt 6 and washer, fixed the bolt 5 and then place the boom on the its
support;
(i) Lift the luffing cylinder with crane and soft sling, at the mean time, operate it to make the head of
the piston rod contract, after both coordinates, to make the head of the piston rod of the luffing
cylinder and the articulated bracket of the boom luffing cylinder fit. After the axis pin 1 is coated
with lithium-based grease, connect the luffing cylinder and boom, mount the shaft baffle 2, bolt 3
and washer, and then screw down the bolt 3.
2.6. Replacement of 3rd Section of Boom

2.6.1. The 3rd section of boom shall be replaced in the following cases
Fig. 2-6(1) Outline Diagram of 3rd Section of Boom

1. When the 3rd section of boom bends, breaks, or distorts
In the normal condition, the 3rd section of boom will not bend, break or distort. However, in case of
overload or abnormal operation, such phenomena may occur, when the 3rd section of boom needs to
be replaced.
2. When the main weld of 3rd section of boom cracks, and can’t meet strength requirement despite
rewelding.
The main weld of 3rd section of boom may crack due to long-time running of crane under high load,
abnormal operation or accident. If it is confirmed by the technical department that the 3rd section of
1. Diassembly of 2nd section of boom: the 2nd section of boom must be firstly dismounted before
disassembling the 3rd section of boom. See the Section 2-4-2 for Disassembly of 2nd Section of Boom.
2. Disassembly of 3rd section of boom
10
1-Axis pin 2- Splint pin 3-Telescopic rope of 5th section of boom 4-Bolt
5- Shaft baffle 6-Axis pin 7-Telescopic cylinder 8- Retraction rope for 4th section of boom
Fig. 2-6(2) Disassembly Details of 3rd Section of Boom
3rd section of boom
4th section
of boom
9-Nut 10-Pin 11-Support block 12-Bolt 13-Slide block

Fig. 2-6(3) Disassembly Details of 3rd Section of Boom (Head)
Step 1: Release the bolt 4 and the washer, and then take down the shaft baffle 5 and axis pin 6 to
separate the telescopic cylinder 7from the 2nd section of boom;
Step 2: Release the splint pin 2, and then take down the axis pin 1 to separate the 4th section of
boom extension rope 3 from the 2nd section of boom;
Step 3: Separate the 3rd section of boom contraction rope 8 with the rear sheave of the 2nd section of
boom;
Step 4: Release the nut 9, take down pin 10, support block 11 and bolt 12, and then take out the
slide block 13;
Step 5: Take out 3rd and 4th sections of boom horizontally and slowly by crane and soft sling and
then transfer them to the special assembly field or specified site;
Step 6: Remove such parts as sheave and slide block, which are available for the next use.
Important
When taking out 4th and 5th sections of boom components, make sure that the wire ropes are not
wrapped or shackled with the 3rd section of boom so as to avoid any damage!
11
2.6.3. Assembly Method
Prompt
The method of assembling 3rd section of boom is in the reverse order of disassembling.
The method of assembling 3rd section of boom is as follows:
(a) Put the 3rd section of boom on the processing support.
(b) Lift the 5th and 4th sections of boom to the front of 3rd section of boom, and keep them in line.
(c) Smear extreme-pressure lithium-based grease EP2 on the external slideway of 4th section of
boom, put the 5th and 4th sections of boom in the 3rd section of boom horizontally and slowly,
ensuring the rear slide block of 4th section of boom can freely slide in the mounting groove; and
then adjust the position and interval of 4th section of boom in the 3rd section of boom to the
interval between 3rd section of boom and slide block not more than 3mm in vertical way and not
more than 1.5mm in horizontal way.
(d) Adjust the 3rd section of boom to align the mounting hole of the barrel on the telescopic cylinder II
with its rear mounting hole of the 3rd section of boom, plug the axis pin 6, mount the shaft baffle 5
and then fix it with bolt 4 and washer;
(e) Mount the 4th section of boom contraction rope 8 into the rear sheave of the 3rd section of boom;
(f) Mount the slide block 13 at the head of 3rd section of boom, then mount bolt 12, support block 11,
and pin 10 in sequence, screw down the nut 9, and then adjust the interval between slide block
13 and 4th section of boom by use of nut 9, ensuring the interval within 1.5mm in horizontal way
and within 3mm in vertical way;
(g) Assemble base boom and main boom assembly as shown in Section 2-1-3.
2.7 Replacement of 4th Boom

2.7.1 The 4th boom shall be replaced in the following cases
Fig. 2-7(1) Outline Diagram of 4th Section of Boom

1. When the 4th section of boom bends, breaks, or distorts
In the normal condition, the 4th section of boom will not bend, break or distort. However, in case of
overload or abnormal operation, such phenomena may occur, at this time the 4th section of boom
needs to be replaced.
2. When the main weld of 4th section of boom cracks, and strength requirement cannot be met
despite rewelding
The main weld of 4th section of boom may crack due to long-time running of crane under high load,
abnormal operation or accident. If it is confirmed by the technical department that the 4th section of
1. Disassembly of 3rd section of boom: the 3rd section of boom must be firstly dismounted before
removing 4th section of boom. See the Section 2-5-2 for Disassembly of 3rd Section of Boom.
2. Disassembly of 4th section of boom
12
th
Retraction rope of 4 Extension rope of 4
th
Telescopic
section of boom section of boom cylinder
th
Retraction rope of Tail of 4
5th section of boom section of
boom
th
4 section of boom
th
1-Screw 2-Nut 3- Rope baffle 4-Retraction rope of 5 section of boom 5- Retainer ring 6-Axis pin
6-Extension rope of 4th section of boom 8-Bolt 9-Shaft baffle 10-Axis pin 11-Retraction rope of 4th section of
boom
Fig 2-7(2) Disassembly Details of 4th Section of Boom
5th section of 4th section

boom of boom
Telescopic cylinder I
Telescopic cylinder II
12-Nut 13-Pin 14-Support block 15-Bolt 16-Slide block17-Bolt 18-Shaft baffle

19-Screw 20-Axis pin 21-Sheave 22-Bolt 23-Baffle
Fig. 2-7(3) Disassembly Details of 4th Section of Boom (head)
Step 1: Release the screw 1 and nut 2, and take down the rope baffle 3 to separate the 5th section of
boom contraction rope with the sheave at the rear of the 4th section of boom;
Step 2: Release the retainer ring 5, and take down the axis pin 6 to separate the 4th section of boom
extension rope with the bracket at the rear of the 4th section of boom;
Step 3: Release the bolt 8, take down shaft baffle 9 and axis pin 10, and then take down the 4th
section of boom contraction rope;
Step 4: Release the nut 12, and take down the pin 13, support block 14 and bolt 15 in sequence,
and then take out the slide block 16;
Step 5: Release the bolt 22 and then take down the baffle 23;
Step 6: Release the bolt 17, and take down the shaft baffle 18; release the screw 19, and then take
down the axis pin 20 and sheave 21 to separate the 4th section of boom extension rope with the 4th
13
section of boom;
Step 7: Take out 5th section of boom horizontally and slowly by crane and soft sling and then transfer
them to the special assembly field or specified site;
Step 8: Remove such parts as support and slide block, which are available for the next use.
Important
When taking out the 5th boom and telescopic cylinder, make sure that the wire ropes are not wrapped
or shackled with the 4th section of boom so as to avoid any damage!
Prompt
The method of assembling the 4th section of boom is in the reverse order of disassembling.
The Assembly Method of the 4th Section of Boom:
(a) Put the 4th section of boom on the processing support;
(b) Lift the 5th section of boom and telescopic cylinder components to the front of 4th section of boom,
and then make them in line;
(c) Smear extreme-pressure lithium-based grease EP2 on the external slideway of 5th section of
boom, put 5th section of boom and telescopic cylinder components in the 4th section of boom
horizontally and slowly, ensuring the rear slide block of 5th section of boom can freely slide in the
mounting groove; and then adjust the position and interval of 5th section of boom in the 4th section
of boom to make the interval between the 4th section of boom and slide block not more than 3mm
in vertical way and not more than 1.5mm in horizontal way;
(d) Align the mounting hole at the head of the 4th section of boom extension rope with that of the
bracket at the rear of the 4th section of boom, and then mount the axis pin 6 and retainer ring 5;
(e) Mount the 4th section of boom contraction rope 11 onto the bracket at the rear of the 4th section of
boom, install the axis pin 10 and shaft baffle 9 in, and then fix them with bolt 8 and washer;
(f) Fit the slide block 16 at the corresponding location at the head of the 4th section of boom, and
then mount the bolt 15, support block 14 and pin 13 in sequence; screw on the nut 12, and then
adjust the interval between slide block 16 and 5th section of boom by use of nut 12, ensuring the
interval within 1.5mm in horizontal way and within 3mm in vertical way;
(g) Assemble 3rd section of boom, 2nd section of boom, base boom and main boom assembly as
shown in Section 2-5-3.
2.8 Replacement of 5th Section of Boom

2.8.1 The 5th section of boom shall be replaced in the following cases
Fig. 2-8(1) Outline Diagram of 5th Section of Boom

1. When the 5th section of boom bends, breaks, or distorts
In the normal condition, the 5th section of boom will not bend, break, distort. However, in case of
14
overload or abnormal operation, such phenomena may occur, when the 5th section of boom needs to
be replaced.
2. When the main weld of 5th section of boom cracks, and strength requirement cannot be met
despite rewelding
The main weld of 5th section of boom may crack due to long-time running of crane under high load,
abnormal operation or accident. If it is confirmed by the technical department that the 5th section of
Disassembly Steps
1-Nut 2-Nut 3-Washer 4-Retraction rope of 5th section of rope 5-Bolt 6-Shaft
th
baffle 7-Axis pin 8-Sheave 9- Extension rope of 5 section of boom
Fig 2-8(2) Disassembly Details of 5th Section of Boom
Step 1: Separate the 4th and 5th section of boom with the telescopic cylinder components in
accordance with the Section 2-6-2.
Step 2: Release the nut 1, nut 2 and washer 3 to separate the contraction rope 4 of 5th section of
boom with the head of the 5th section of boom;
Step 3: Release the bolt 5, and take down the shaft baffle 6, axis pin 7 and sheave 8, and then take
down the extension rope 9 of 5th section of boom;
Step 4: Move the telescopic cylinder together with extension rope of 4th section of boom and
contraction rope of 5th section of boom horizontally and slowly by lift truck and soft sling out of the 5th
section of boom;
Step 5: Dismount such parts as sheave block and support, which are available for the next use.
Important
15
When taking out the telescopic cylinder, make sure that the wire ropes are not wrapped or shackled
with the 5th section of boom so as to avoid any damage!
Prompt
The method of assembling 5th section of boom is in the reverse order of disassembling.
The Assembly Method of the 5th Section of Boom:
(a) Put the 5th section of boom on the processing support;
(b) Lift the telescopic cylinder components to the front of 5th section of boom by crane and soft sling
and then mount it into the barrel of 5th section of boom horizontally and slowly;
(c) Mount the corresponding end of the extension rope of 5th section of boom into the sheave 8,
making the mounting hole align with that at the rear of the 5th section of boom; mount the axis pin
7 in, and then fix the shaft baffle 6 to the adequate location with bolt 5 and washer;
(d) Mount the contraction rope 4 of 5th section of boom at the adequate location of the head of the 5th
section of boom, and then screw down and fix it with nut 1, nut 2 and washer 3 with 2 contraction
ropes having same tightening torque, about 40N.m.
(e) Assemble 4th, 3rd, 2nd sections of boom and base boom as well as main boom assembly as
shown in Section 2-6-3.
Notes
(d) When mount retraction rope 4 for 5th section of boom, make sure 2 retraction ropes at the same
tightening torque, viz. about 40N.m.
2.8.4 Adjustment Method of Extension & Retraction Rope
When replacing 2nd, 3rd, 4th and 5th sections of boom, after the main boom is assembled, the rope should
be adjusted as follows, so as to ensure all booms can extend or retract synchronously. The adjusting steps
are as follows:
Prompt
When adjusting extension & retraction rope, make sure that the truck crane is under non-load state.
Adjusting steps are as follows:
1-Adjustment cushion block (I) 2- Adjustment cushion block (II) 3- Adjustment cushion block (III)
4-Adjustment cushion block (Ⅳ) 5-Alignment mechanism
Fig. 2-8(3) Adjustment Details for Wire rope
16
1. After assembling the main boom, pretension the boom retraction adjusting nut for the preparation of
adjustment;
2. Make the telescopic cylinder Ⅱ return back to the original position, measure the interval between the
heads of 2nd and 3rd sections of boom Δ1, and then select the adjusting cushion block (I) with a
thickness of [Δ1+(1~2)];
3 Take down the cushion block between the heads of 3rd and 4th sections of boom, and then mount well
the adjusting cushion block (I) between the heads of 2nd and 3rd sections of boom; make the telescopic
cylinder II return back to the original position (with zero interval between the heads of 2nd and 3rd
sections of boom), and screw down the retraction rope for 4th section of boom with a torque of
4.5~5kg.m, measure the interval between the heads of 3rd and 4th sections of boom Δ2, and then
select the adjusting cushion block (II) with a thickness of Δ2±1; after mount well the adjusting cushion
block (II) between the heads of 3rd and 4th sections of boom, make the telescopic cylinder return back
to the original position (with zero interval of the adjusting cushion block at the heads of 2nd and 3rd
sections of boom, and 3rd and 4th sections of boom);
4. Screw down the retraction rope for 5th section of boom with a torque of 3.5~4kg.m, measure the
interval between the heads of 4th and 5th sections of boom Δ3, and then select the adjusting cushion
block (III) with a thickness of Δ3±1; after mount well the adjusting cushion block (III) between the
heads of 4th and 5th sections of boom, make the telescopic cylinder II return back to the original
position (with zero interval of the adjusting cushion block at the heads of booms);
5. Make the main boom extend and retract for 3 times, and then check the extension of 3rd, 4th and 5th
sections of boom: if the deviation is less than 2mm; it indicates the adjustment is accepted, or else the
readjustment should be conducted;
6. After well adjusting the wire rope, use the alignment adjusting mechanisms (bolts and nuts) under
each boom and the slide block at the head of each boom to align all booms
Prompt
When adjusting the retraction rope, release the locking nut on the retraction rope first, for it cannot be
tightly fastened. After adjusting the rope, tightly fasten it.
2.9 Replacement of Jib

2.9.1 The jib shall be replaced in the following cases
1. When the jib bends, breaks, or distorts
In normal working condition, the jib will not get folded, broken off or distorted. If it does so due to
overload or wrong operation, the jib should be replaced.
2. When replacing the main boom, the jib should be also disassembled.
2.9.2 Disassembly Steps (See Fig. 2-9)
Step 1. If possible, put the jib in the special assembly field and specified site. If the boom can not be
handled, support and fix the jib with the lift truck and soft sling.
Step 2. Take out the Clamp Pin (2) from the four junction points and take down the cross pin (1).
Step 3. Move the jib with the lift truck and soft sling to the special assembly field and specified site.
17
1-Cross pin 2-Clamp pin 3-Bracket assembly 4-Folding boom bracket
Fig. 2-9 Disassembly and Assembly Details for Jib

(a) Lift the jib beside the support at the side of the main boom with lift truck and soft sling, and keep the jib
center and the 1st section of boom center at the same level.
(b) Alien the mounting hole of the side support for the jib with the one of the support of the main boom,
fixing the cross pin (1) and inserting the clamp pin (2) to the pin hole of the cross pin (1) for fixation.
(c) When mounting the bracket assembly and folding boom bracket, keep the jib center and the base
boom at the same level. Lift the bracket assembly and folding boom bracket by traveling crane, and
adjust the height of the bracket assembly till the upper idler roller of the jib tightly closes to the upper
surface of the bracket assembly. And then fix the bracket assembly and folding boom bracket on the
bent plate of the base boom by the bolt.
(d) Take out the wire rope of the middle sheave at the head of main boom and put it through the contact
roller of jib and sheave at the head of jib.
Important
When mounting the jib, always keep the jib center and the 1st section of boom center at the same
level.
Prompt
The mounting of the jib is jointly carried out by two traveling cranes. Make sure the rear end of the jib
at the top of the bracket assembly, and always keep the position of jib center horizontal.
2.10 Replacement of Telescopic Mechanism

STC75 truck crane’s main boom telescopic mechanism consists of two groups of reversed oil cylinders
and two groups of telescopic boom ropes. The piston rod pin-connected joint of the telescopic cylinder I is
mounted on one boom, and the cylinder pin-connected joint of the telescopic cylinder I is mounted on the
2nd section of boom; The piston rod pin-connected joint of the telescopic cylinder II is mounted on the 2nd
section of boom, and the cylinder pin-connected joint of the telescopic cylinder II is mounted on the 3rd
18
section of boom. The barrel of the telescopic cylinder I is mounted on that of the telescopic cylinder II, and
can slide freely and steadily on the barrel of the telescopic cylinder II by guide elements.
Fig. 2-10(1) Configuration for Telescopic Mechanism (I)

2.10.1 The telescopic mechanism should be disassembled and assembled in the following
conditions (the reason of the boom structure is excluded)
1. If the rope of the telescopic boom is broken off, folded or seriously distorted, it must be
replaced.
In normal condition, the service lift for the rope can meet the requirements for using truck crane.
However, in the condition that the rope is fractured, cracked or frayed to an extent due to friction,
blockage, coiling or overload, it must be replaced.
2. If the sheave and bearing of the telescopic mechanism are damaged, they must be replaced.
If the sheave and bearing are damaged since the rope is coiled, blocked or overloaded, they must be
replaced.
3. If the telescopic oil cylinder leaks oil, it must be repaired or replaced.
The oil cylinder must be repaired or replaced if the sealing elements are damaged or the piston is
frayed.
Notes
The steps for assembling and disassembling the telescopic boom rope, rope retainer and axis pin etc.
shall not be reiterated as the ones have been introduced in the part of the assembly and disassembly
for the main boom.
2.10.2 Disassembly of Guide Wheel Assembly
1-Nut 2-Washer 3-Washer 4--Rope retaining clamp 5-Axis pin 6-Baffle 7-Washer 8-Bolt
9-Sheave components 10-Rope retaining shaft 11-Pin 12-Bolt
Fig. 2-10(2) Disassembly and Assembly Details for Guide Wheel Assembly
19
Step 1. Slowly and horizontally move out the components of the telescopic cylinder with the crane and
soft sling from the barrel for 3rd section of boom to the special assembly field and specified site.
Step 2. Screw off the Nut (1) and take down the Washer (2), and (3) and the Rope Retaining Block
(4).
Step 3. Take down the Pin (11) and take out the Rope Retaining Shaft (10).
Step 4. Release off the Bolt (8), take down the Washer (7) and the Baffle (6), prop up the Axis Pin (5)
with Copper Bar, and take down the Sheave Component (9) and the separating sleeve.
Step 5. Take out the extension rope for the 4th section of boom from the components of the telescopic
cylinder II.
Step 6. Release the Bolt (12), and take down the washer to separate the guide wheel assembly with
the telescopic cylinder.
(a) Alien the mounting hole of guide wheel bracket and the screwed hole of the telescopic cylinder. Fix
and screw down the washer and Bolt (12).
(b) Pull the extension rope for the 4th section of boom and one end of the 2nd section of boom through the
center of the guide wheel bracket from lower to upper, place the rope against the bracket so as to
have enough washers to install the Sheave Assembly (9).
(c) Alien the center hole of the Sheave Component (9) and separating sleeve boom and the bracket
mounting hole, hammer the Axis Pin (5) with copper bar, fix the Baffle (6), Washer (7) and Bolt (8) and
screw down the bolt, set the extension rope for the 4th section of boom into the sheave.
(d) Mount the Rope Retaining Shaft (10) and fix it with the Split Pin (11).
(e) Fix the Rope Retaining Block (4), Washer (2) and Washer (3), and screw them down with the Nut (1).
(f) Set the boom retraction rope for the 5th section of boom into the rope slot of the guide wheel bracket,
mount the rope retaining plate and screw down it with the screw. Bind the extension rope for the 4th
section of boom and the retraction rope for the 5th section of boom onto the telescopic cylinder so as
to prevent them falling down.
(g) Install the ready telescopic cylinder assembly into the 5th section of boom with the crane and soft sling
in slow and horizontal way. And finish the whole assembly according to the assembly method for the
(2-8-3) 5th section of boom.
Important
(a) During the installation of the telescopic mechanism, each rope should be coated with the lithium
based grease with thickness of 1-2mm. The rope should be prevented from sliding and dragging
on the metal surface or ground so as not to be scratched and frayed.
(b) The internal surface for each wheel and outer ring of shaft sleeve must be coated with lithium
based grease. The oil cup must be filled with oil grease. All the rolling wheels and sheaves
should be able to rotate flexibly after installation.
(c) Various rope retainers should be reliably installed. Before installing the rope retainer, the rope
should be correctly installed and be able to successfully extend and retract.
2.11 Replacement of Components of Boom Top Sheave

Set the components of boom top sheave at the front of the head of the 5th section of boom. The boom top
sheave is a kind of lifting mechanism with one sheave. The jacking operation with auxiliary hook and single
scale factor is generally adopted. With the boom top sheave, the efficiency for the jacking operation of
main boom can be improved, but the suspended load will be limited to the operation of the single-bundle
20
rope. The lifting weight of STC75 boom top sheave is no more than 4t.
The components of boom top sheave include sheave bracket, boom top sheave, bearing, shaft, rope
retaining device etc.
1-Cross pin 2-Spring pin 3-Sheave bracket at the end of boom 4-Shaft 5- Snap gauge 6-Bolt 7-Washer
8-Sheave assembly 9- Separating collar 10-Retainer pin 11-Pin
Fig. 2-11 Components of Boom End Sheave
2.11.1 The boom top sheave is required to be disassembled and assembled in the following
conditions:
1. When the sheave or bearing must be replaced due to damage
When the sheave is damaged or it rotates unfavorably as the bearing is damaged or blocked, the
components of Boom top sheave must be disassembled for replacing the sheave and bearing.
2. When replacement is necessary due as the components of sheave bracket distorts, broken or
damaged
In normal condition, the components of the sheave bracket will not distort or damaged. However, if the
components is distorted or damaged due to accidents or overload so as to fail to satisfy the strength,
the components of sheave bracket must be replaced.
Step 1. Operate the main boom to pull off the spring pin 2, take off the cross pin 1 and the sheave at
the end of boom and put them at the suitable assembly field or specified site.
Step 2. Take off the retainer pin 10, pin 11 to make the auxiliary wire rope (together with auxiliary hook)
fall from sheave groove.
Step 3. Take off shaft 4, snap gauge 5, bolt 6, washer 7, and separating collar 9 to make the sheave
assembly 8 at the end of boom fall from the head of 5th section of boom.
(a) Put the sheave assembly 8 at the end of boom, separating collar 9 and shaft 4 in the corresponding
holes of sheave bracket 3 at the end of boom and align them, and install the snap gauge 5 and
washer 7, and screw down the bolt 6.
(b) Install the wire rope of auxiliary winch into the sheave groove, and install the retainer pin 10 and pin
11.
(c) Put the assembled sheave assembly at the end of boom at the corresponding mounting position at the
head of 5th section of boom with the mounting holes aligned, and install the cross pin 1 and insert the
spring pin 2 to fix it.
21
2.12 Necessary Tools
Description Type Number
Adjustable Spanner 300 2
Lift Truck - 2
Hanging Belt 5T 2
Hanging Belt 3T 2
Socket Wrench - 1
Slotted Blade Driver - 1
Open End Wrench 6-27 1
Inner Hexagon Spanner 6~19 1
Torque Spanner - 1
Copper Bar Φ40×300/Φ80×300 1 for each type
Grease Gun - 1
Clearance Gauge - 1
Canvas gloves 5
22
Chapter III Turntable Assembly
The slewing system consists of turntable, slewing bearing, slewing reducer and balance weight. The
superstructure of crane can slew by such a means that the hydraulic slewing motor will drive the slewing
reducer, and the pinion at the output end of the reducer will mesh with the inner ring gear of slewing
bearing that is unable to turn because it is fixed on the base ring of chassis with bolts. Therefore, the
slewing reducer on the bottom plate of turntable can, driven by the pinion, turn 360° together with the
turntable that will drive the upper part to slew.
1- Turntable 2- Balance weight 3-Slewing reducer 4-Slewing bearing

Fig. 3-1(1) Structure of Slewing System
3.1 Disassembly and Assembly of Balance Weight

3.1.1 The balance weight shall be disassembled in the following cases
1. If the turntable shall be disassembled and assembled
If the turntable shall be disassembled and assembled, the balance weight shall be disassembled in
advance.
1-Balance weight 2-Washer 3-Bolt 4-Rubber screw plug 5-Bolt 6-Washer 7-Nut 8-Nut
Fig. 3-1(2) Disassembly and Assembly Details of Balance Weight
23
Step 1. Support the balance weight 1 with fork lift truck or suspend the lug of balance weight with
crane and soft cable based on the actual condition.
Step 2. Loosen the nut 8, and thin nut 7, and take off the bolt 5 and washer 6.
Step 3. Move the balance weight to special or appointed site by fork lift trunk or crane and soft cable.
Step 1. Support the balance weight 1 with fork lift trunk or suspend the lug of balance weight with
crane and soft cable based on the actual condition.
Step 2. Align the mounting holes of balance weight and those on turntable, and fix them with the bolt 5
and the washer 6.
Step 3. Screw down the thin nut 7, and then the nut 8.
Notes
For installation, the bolts shall be washed and coated with glue. The lock glue for screw thread shall
be coated at 360°direction of the thread.
3.2 Replacement of Slewing Reducer

The slewing reducer is installed on the bottom plate of turntable, and the pinion, turning on the bull gear,
will drive the turntable to slew together. Moreover, the eccentric mechanism is equipped in the slewing
reducer to adjust the meshing clearance between pinion and bull gear.
1-Slewing reducer 2-Bolt 3-Washer 4-Washer 5-Spring mat; 6-Bolt; 7-Gearbox cover
Fig. 3-2(1) Structure of Slewing Reducer
3.2.1 The slewing reducer shall be disassembled in the following cases
1. If the broken slewing reducer shall be repaired or replaced
If the slewing system appears abnormal slewing noise, great slewing impact or wide slewing clearance
that can’t be adjusted, and if it is determined that the slewing reducer generates malfunction, the
slewing reducer shall be repaired or replaced.
2. If the turntable shall be dismantled
If the turntable shall be dismantled, the slewing reducer shall be dismounted firstly.
Step1. Dismantle the slewing motor according to the relevant chapters or sections about the hydraulic
system.
Step2. Loosen the bolt 1 and washer 2, and move the slewing reducer to the special or appointed site
24
with crane.
Step1. Place the slewing reducer at the bottom place of turntable for instillation with crane, and screw
down the washer 2 and the bolt 1.
Step2. Install the slewing motor according to the relevant chapter or section about hydraulic system.
Notes
Prior to bolt installation, the gear mesh shall be checked. It is necessary to make sure that the
meshing space at the highest jumping point (3 gears with green marks) of the ring gear of bull gear
shall reach the target precision (about 0.15mm). If it is unacceptable, the space can be adjusted by
adjusting the eccentric mechanism in the slewing reducer till it is acceptable. Finally, the screw thread
shall be coated with Letai Anaerobic adhesive, and the bolts shall be screwed down in order at
180°symmetry direction. During the process of installing and dismantling the slewing reducer, the
engaging tooth of pinion and bull gear shall be protected from collision, friction and other human
damage.
3.3 Replacement of Turntable

In an integral welded structure, the turntable can be divided into four parts according to its functions,
namely the seat washer of bottom plate, the main body, the connecting support, and the tail case. The seat
washer of bottom plate is a fundamental fixing part that connects the turntable and the chassis through the
slewing bearing. The superstructure will, during the operation, transmit all acting forces suffered to the
chassis through the seat washer of bottom plate. The connecting support, in the front of the top side of
bottom plate, can connect the lower articulation point of luffing oil cylinder. As a box-type structural part,
the tail case has two groups of holes in the same sizes and shapes, which will be used to install the main
winch reducer and the auxiliary winch reducer with the same models. The main and auxiliary lift wire ropes
shall be wrapped on the reducer’s drum, by which the main and auxiliary hooks will be driven to rise and
drop. Behind the drum of winch reducer is a rope presser. The main body of turntable refers to the
combination of two parallel and vertical side plates and multi-groups of box-type structures at the bottom
plate of turntable, which combine the turntable into a rigid structural body.
Fig. 3-3(1) Structure of Turntable

3.3.1 The turntable shall be disassembled in the following cases:
1. The turntable shall be replaced because of abnormal noise and damage.
If the turntable structure gives out abnormal noise, which is proved by test and flaw detection to fail to
25
meet the requirement, or if the turntable structure is damaged due to accident, the table shall be
maintained intensively or replaced.
2. The broken slewing bearing shall be replaced
If the broken slewing bearing shall be repaired or replaced, the turntable shall be disassembled.
Step1. Dismount the main lift boom, luffing oil cylinder, balancing weight, and Operating room that
connect with the turntable based on relevant chapters;
Step2. Loosen the adaptor connecting the hydraulic system of superstructure on truck crane and the
central slewing body, and seal the adaptor to avoid the pollution on the pipeline;
Step3. Fix the turntable with crane and soft cable, loosen the nut 2, take off the bolt 1, loosen and take
off the bolt 3. Place the turntable at the special or appointed site.
Step4. Dismount the winch motor, winch reducer, slewing motor, slewing reducer, hydraulic pipeline
and main valve that connect with the turntable according to relevant chapters or sections.
Bottom plate of
turntable
Slewing
support
1-Turnable 2-Nut 3-Slewing support

Fig. 3-3(2) Disassembly and Assembly Details of Turntable
Step1. Install the winch motor, winch reducer, hydraulic pipeline and main valve that connect with the
turntable based on relevant chapters or sections;
Step2. Lift the assembled turntable to the slewing support with crane and soft cable (the hydraulic
pipeline shall be protected), align the turntable with the mounting hole for the bolts of the outer ring of
slewing bearing, make sure that the quenched soft belt of the outer ring of slewing bearing is located
at the side of turntable, then install the bolt in the corresponding threaded holes;
Step3. Screw down the bolts and the nuts with the 1350N.m force.
Notes
Before installation, the bolts shall be coated with Letai adhesive and screwed down symmetrically and
orderly at the 180°direction in three times. For the last time, the moment of 1350N.m will be adopted.
The interval of three times shall not be too long, so as to make sure that the thread adhesive can
reach the target moment before concretion.
26
3.4 Replacement of Slewing Bearing
3.4.1 The slewing bearing shall be disassembled in the following cases:
The slewing bearing shall be repaired or replaced due to abnormal noise and damage;
If the slewing bearing generates abnormal noise or is broken, it shall be repaired or replaced.
3.4.2 Disassembly and Assembly Steps
It is easy to dismantle and install the slewing bearing. For dismantlement, firstly dismount the
turntable from slewing bearing, and then loosen and take off the bolt 1 to dismantle the slewing
bearing. For assembly, lift the slewing bearing to the seat washer of chassis, align the threaded hole,
fit and screw down the bolt 1 with the torque of 1350N.m.
1-Slewing bearer 2-Chassis washer 3-Bolt 4-Slewing reductor

Fig. 3-4 Disassembly and Assembly of Slewing Bearing
Notes
Before installation, the bolts shall be coated with Letai adhesive, and screwed down symmetrically
and orderly at the 180°direction in three times. For the last time, the moment of 1350N.m will be
adopted. The interval of three times shall not be too long, so as to make sure that the thread adhesive
can reach the target torque before concretion.
3.5 Replacement of Rope Guard

3.5.1 The rope guard shall be disassembled in the following cases:
1. The rope guard will be installed behind the drums of main and auxiliary winch reducers, which can
ensure the orderly progress of rope winding, and prevent the drum from random winding.
27
Turntable
1-Rope guard 2-Bolt 3-Washer 4-Nut

Fig. 3-5(1) Disassembly and Assembly Details of Rope Guard
2. If the rope guard is broken and fails to ensure the orderly rope winding, it shall be repaired or
replaced.
If the rope guard fails to normally operate due to breakage of spring, carrying roller or bearing, and
fails to prevent the drum from random wining, the spring, idler or bearing shall be repaired or replaced.
Bracket
5-Spring 6-Nut 7-Connecting rod 8-Rock boom 9- Retainer ring 10-Axis Pin
11-Bolt 12-Washer 13-Gasket 14-Idler 15- Separating collar 16-Bearing 17-Retainer ring
18-Idler 19-Shaft
Fig. 3-5(2) Disassembly and Assembly Details of Rope Guard
Step1. Loosen the bolt 2 and the nut 4, take off the washer 3, and dismount the rope presser 1 from
the turntable;
Step2. If the spring 5 shall be replaced due to rupture, inefficiency, or shortage of elasticity, loosen the
28
nut 6, take off and replace the spring 5 from the connecting rod and the rock boom 8.
Step3. If the bearing 16 shall be replaced due to blockage or damage, loosen the retainer ring 9, take
off the axis pin 10, separate the rock boom 8 from support, loosen the bolt 11, take off the washer 12,
the gasket 13, the idler 14 and the separating collar 15, gently knock off the rock boom 8 from the
shaft 19, loosen the retainer ring 17, and take off and replace the bearing 16.
Step4. If the idler 18 is so worn that shall be replaced, dismount it from the shaft 19 and replace it with
a new one.
Step1. Push the bearing 16 into the rock boom 8, and fit the retainer ring 17 for later use.
Step2. Equip the idler 18 on the shaft 19, fit two separating collars 15, press two rock booms on the
shaft 19 from both ends, refit two separating collars 15, the idler 14 and the gasket 13, and fasten
them with the bolt 11 and the washer 12 from both ends of the shaft 19.
Step3. Align the mounting hole of rock boom 8 with that of support, install the axis pin 10, and fix it
with the retainer ring 9.
Step4. Fit the spring 5 on the connecting rod 7 and the rock boom 8, and adjust the spring 5 to a
proper tightness through the nut 6.
Step5. Install the assembled rope presser on the turntable with the bolt 2, the nut 4 and the washer
3.6 Necessary Tools

Name Model Qty.
Adjustable spanner 300 2
Crane - 1
Suspending strap 5T 1
Suspending strap 3T 2
Fork - 1
Box spanner - 1
Slotted blade driver - 1
Ringent spanner 6-27 1
Hexagon spanner 6~19 1
Torsion spanner 900N.m 1
Copper bar Φ80×300/Φ40×300 1 for each type
Grease gun - 1
Open mouth tongs - 1
29
ChapterIV Lifting Mechanism
The lifting mechanism principally consists of the main and auxiliary winch reducers, the main and auxiliary
grab hooks, and the main and auxiliary wire ropes. The hydraulic motor will drive the main winch reducer
to slew, and the main lift wire rope can drive the main grab hook to rise or fall through the fixed pulley block
below the front end of main boom and through the movable sheave block on the main hook. The turning
direction of hydraulic motor can be replaced by adjusting its oil supply direction, so as to make the main
hook rise and fall (also applicable for the auxiliary hook).
1-Main winch reducer 2-Auxiary winch reducer 3-Main grab hook 4-Auxiliary grab hook
5-Main wire rope 6-Auxiliary wire rope 7-Fixed device of grab hook 8-Rope hitch
Fig. 4-1(1) Structure of Lifting Mechanism
4.1 Replacement of Main Grab Hook

4.1.1 The main grab hook shall be disassembled in the following cases:
1. The sheave or bearing of main grab hook is broken and shall be repaired or replaced.
If the sheave or bearing of main grab hook is broken, the main hook shall be disassembled for repair
or replacement.
2. The fall of the wire rope of grab hook shall be adjusted.
The required lifting speed can be achieved by adjusting the fall of wire rope based on the actual lifting
weight.
Step1. Drop the main grab hook 6 at the special pallet or appointed worksite.
Step2. Dismount the clamp pin 2, take out the axis pin 1, and separate the wedge sleeve 3 from the
4th section of boom.
Step3. Loosen the nut of rope clamp 5, and pull out the wire rope and the wedge 4 from the wedge
sleeve 5.
Step4. Loosen and take off the rope retaining shaft 15, pull out the wire rope from the sheave groove
of grab hook, and disassemble the main hook.
Step5. If the bearing or sheave is broken and shall be repaired or replaced, loosen the nut 7, take off
the shaft 8 and the bush 9, then loosen the screw 11 to take off the shaft buffer 10, knock out the shaft
30
12 with copper bar, dismantle the sheave block from the main grab hook, and finally take out the
bearing 13 from the sheave 14.
1-Axis Pin 2-Clamp pin 3-Wedge sleeve

4-Wedge 5-Rope clamp 6-Main grab
hook 7-Nut 8-Shaft 9-Bush 10-Shaft
baffle 11-Screw 12-Shaft 13-Bearing
14-Sheave 15-Rope retaining shaft Fig. 4-1(3) Disassembly and
Assembly of Main Grab Hook
Fig. 4-1(2) Disassembly and
Assembly of Main Grab Hook
Step1. Fit the retainer ring into the retainer ring groove of the sheave 14, and push the bearing 13 in it.
Step2. Align the mounting hole of assembled sheave with that of the side plate of main grab hook,
knock into the shaft 12 with copper bar, install the shaft baffle 11, and fix it with the screw 11.
Step3. Install the bush 9 between two side plates, pass the shaft 8 through it, and fix it with the nut 7.
Step4. Wind the main wire rope in the sheave groove of main grab hook according to the
corresponding fall, install and screw down the rope retaining shaft 15.
Step5. Wind the main wire rope with the wedge rope groove, and put them into the wedge sleeve
together, install the rope clamp 5, and screw down the nut.
Step6. Align the mounting hole of wedge sleeve with that of the corresponding support at the 4th
section of boom, fit the lock in it, and pass the clamp pin 2 through the pinhole for fixation.
Notes
Concerning the installation of the rope clamp 5, make sure that the pressure plate of rope clamp is
installed at the longer end of wire rope.
4.2 Replacement of Auxiliary Grab Hook

4.2.1 The auxiliary grab hook shall be dismantled in the following cases:
1. If the auxiliary grab hook generates the following problems, the hook shall be discarded or
replaced.
If the hook generates 10% of crack or worn risky section, the aperture width is 15% larger than the
former size, and the risky section or hook neck appears plastic distortion and torsion, the auxiliary
31
grab hook shall be dismantled and replaced with a new one (which is also applicable for the main grab
hook in case of the above situations).
2. If the bearing in auxiliary grab hook is broken and shall be replaced.
The auxiliary grab hook shall be disassembled if the bearing is broken and shall be replaced.
1-Rope clamp 2-Wedge 3-Wedge sleeve

4-Auxiliary grab hook 5-Hook frame 6-
Counterweight 7-Nut 8-Bolt 9- Splint pin
Fig. 4-2(2) Disassembly and Assembly
10-Nut 11-Bearing 12-Hook
of Auxiliary Grab Hook
Fig. 4-2(1) Disassembly and
Assembly of Auxiliary Grab Hook
Step1. Drop the auxiliary grab hook 4 at the special pallet or appointed worksite;
Step2. Loosen the nut of the rope clamp 1, and pull out the wire rope and the wedge 2 from the
wedge sleeve 3;
Step3. Take off the splint pin and axis pin, dismount the wedge sleeve 3 from the auxiliary grab hook
4, and then the auxiliary hook;
Step4. If the hook or bearing is broken and shall be replaced with a new one, loosen the nut 7 and the
bolt 8, take off the counterweight 6 and then the splint pin 9, loosen the nut 10, and take off the hook
12 and the bearing 11 from the hook frame 5.
Step1. Fit the hook 12 into the hook frame 5, and press the bearing 11 in it.
Step2. Fit and screw down the nut 10, align the pinhole of nut with that of hook, and pass the splint pin
9 through it.
Step3. Equip the counterweight 6, align it with the mounting hole for the bolts on the hook frame 5,
install the bolt 8, and fix it with the nut 7.
Step4. Wind the auxiliary wire rope in the rope groove of wedge 2, put them into the wedge sleeve 3
together, install the rope clamp 1, and screw down the nut. Align the mounting hole for wedge sleeve
with that at the top of auxiliary hook, install the axis pin, and fix it with splint pin.
Notes
As for installation of the rope clamp 1, make sure that the pressure plate of rope clamp is installed at
the long end of wire rope.
32
4.3 Replacement of Main and Auxiliary Wire Ropes
As the important carrying part for lifting, it is necessary to check and periodically maintain the wire rope
commonly used.
4.3.1 The wire rope shall be replaced in the following cases:
1. If the main and auxiliary wire ropes generate the following problems, they shall be discarded
or replaced.
The wire rope shall be discarded in the following cases: a. the band breakage; b. the wire breakage
reaches the specified quantity based on the GB5972; c. rope core breakage; d. wire extrusion, rope
band extrusion, twist, or severe distortion; e. severe rust corrosion; f. the diameter of wire rope is
reduced by over 7% due to abrasion, or the diameter of outer wire is worn by over 40%.
Step1. Dismount the main and auxiliary grab hooks according to the foresaid chapters.
Step2. Separate the wire rope from the sheave at the front of boom, and turn on the winch reducer to
loosen most wire ropes from the drum.
Step3. Dismantle the rope guard and rope baffle from the turntable according to relevant chapters,
loosen the rope clamp at the winch reducer, pull the wire rope and the rope wedge with the wedge
sleeve of winch reducer, and fully loosen the wire rope from the drum.
Step1. Wind the wire rope on the drum of winch reducer for 2-3 circles, put the one end of wire rope
and the rope wedge in the wedge sleeve of winch reducer, install the rope clamp and fix it.
Step2. Equip the rope guard and the rope baffle according to relevant chapters, and turn on the winch
reducer to orderly install most wire ropes on the drum.
Step3. Install the wire rope in the sheave block in the front of boom through the rope bearing frame
and rope guard on the boom, and based on the required fall.
Step4. Equip the main and auxiliary grab hook based on relevant chapters.
4.4 Replacement of Main and Auxiliary Winch Reducers

4.4.1 The winch reducer shall be disassembled in the following cases
1. The winch reducer fails and shall be repaired or replaced
The winch reducer shall be dismantled if its bearing shall be replaced due to blockage or abrasion, if
the gear case shall be repaired or replaced due to crack or oil leakage, and if the drum shall be
replaced due to crack.
2. The winch reducer shall be disassembled if the turntable shall be repaired or replaced.
33
1-Washer 2-Reducer assembly 3-Washer 4-Bolt 5 -Bolt
Fig. 4-3(1) Disassembly and Assembly of Winch Reducer
Step1. Disassemble the rope guard, winch motor and wire rope;
Step2. Fix the winch reducer with crane and soft sling, loosen bolts 4 and 5 and take off washer 1, 3.
Step3. Place the winch reducer at the special pallet or appointed site with the crane.
Step1. Suspend the winch reducer to the corresponding place of the winch case of turntable with the
crane, install and align the threaded hole, fit the washer 4 and the bolts 1 and 3, and screw them down
with the torques of 77.5N.m and 370N.m;
Step2. Assemble the rope guard, winch motor and wire rope based on relevant chapters.
Notes
Please check whether the gear oil in redactor is enough, if not, please have it filled before the
installation of winch redactor.
4.5 necessary tools
Name Mode Quantity

Adjustable spanner 300 2 piece
Crane - 1 piece
Spreader belt 3T 2 piece
Socket spanner - 1set
Screwdriver - 1piece
Open spanner 6-27 1 piece
Inner-hexagon spanner 6~19 1 set
Copper rod Φ40×300 1 piece
Grease gun - 1 piece
Open pliers -- 1 piece
Torque spanner 200N.m 1 piece
Chapter VI. Control Mechanism of Superstructure

The control methods of hydraulic system of STC75 superstructure are divided into S-type (manual push
34
rod) and Y-type (hydraulic piloted control).
5.1 Operation of STC75S

5.1.1 Overview
Operating room of superstructure includes the housing of operating room, door, handle, control device,
instrument panel component, lamp support, seat, accessories of operating room and ventilation,
heater and air conditioner etc. Fig 5.1 is the side view of operating room of crane STC75.
Fig. 5-1 Operating Room of Superstructure

5.1.2 Operating Device
Fig. 5-2 Operating Device
5.2 Operation of STC75Y

5.2.1 Overview
Operating room of superstructure includes the housing of operating room, door, handle, control device,
instrument panel component, lamp support, seat, accessories of operating room and ventilation, heater
and air conditioner etc. Fig 5.3 is the side view of operating room of crane. STC75
35
Fig 5-3 Operating Room of Superstructure
1. Door 2. Housing 3. Control device 4. Handle 5. Instrument panel component
6. Lamp support 7. Glass 8. Seat
5.2.2 Configuration of Electrical Elements inside Operating Room
Fig. 5-4 Configuration of Electrical Elements inside Operating Room

A) ——Pedal switch B) ——Basic machine of force limiter
C) ——Buzzer D) ——Display of force limiter
E) ——Motor of front windscreen wiper F) ——Motor of roof window wiper
G) ——Top lamp H) ——Fan
I) ——Operating panel J) ——Release switch for overload
k)——Eletric cabinet
36
5.2.3 Control Board of Instrument Panel
Fig. 5-5 Control Board of Instrument Panel
H1——Indicator lamp of height limiter S1——Ignition switch

H2——Alarm lamp for too high water temperature S3——Stopping switch of engine
H3——Indicator lamp of main power supply S4——Switch of outline lamp
H4——Switch of telescopic boom Overwinding indication S5——Switch of working lamp
H5——Three-layer protection indicator lamp S6——Switch of windscreen wiper
H6——Alarm lamp for too low oil pressure S9——Switch of oil cooler
H7——Alarm lamp S10——Main switch
H8——Working indicator lamp of auxiliary winch S11——Changeover switch of telescopic/auxiliary
winch S13——Maintenance switch
S15——Switch of free sliding
S12——Release switch for overwinding S14——Changeover switch of cylinderI/II
S17——Washer switch
Description of functions of each switch:

Ignition switch: Put start key into ignition switch, turn it clockwise to I position, the power
supply turns on, the uppercarriage control system supplys power. Continue turning the
key to III position, the engine will star up, the starup time does not exceed 5 seconds
every time, the alternation starup time does not exceed 15 seconds. If you can’t star up
2~3 times, you should check the reason.
Flameout switch: Press the engine's hold-up switch, the engine will be flameout 1~2
seconds later, after disentangling the switch will be restoration automatically.
Instrument lamp switch: Press the instrument lamp switch, all of the floodlight inside the
rocker switch will light up.
Outline lamp switch: Press the outline lamp switch, the front & rear outline lamps of
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superstructure, the wall ceiling lamp and the outline lamp of undercarriage will light up.
Working lamp switch: When setting this switch to I position, the working lamp of console
will light up, When setting it to II position, the working lamps of boom and the working
lamp of console will light up at the same time.
Wiper switch: When setting this switch to I position, the front windshield wiper will work at
low speed; when setting it to II position, the wiper will work at high speed;
Washer switch: When pressing this switch, the washer motor will begin to work, and the
nozzle of wiper will eject the washing liquid;
Caution: In case of sunny day, using the wiper without washing liquid may cause
damage of glass; if no washing liquid is available, the continuous running time of wiper
shall be not more than 5s, or else, the washer motor may be burned out. Thus, don’t use
the wiper if no washing liquid is available;
Oil cooler switch: When pressing this switch, the oil cooling fan begins to work;
Note: When the temperature of hydraulic oil exceeds a certain value, the temperature
control switch adopted by oil cooler will be enabled automatically, and the oil cooling fan
will begin to work even though this switch is not pressed down;
Overwinding release switch: When pressing this switch, both the height limit protection
and the protection for extension/retraction with load will be released. So, it should be
used carefully;
Overload release switch: When pressing this switch, the overload protection will be
cancelled. It is used only for overhaul and commissioning, and can’t be pressed during
the normal working of crane, or else, for any damage due to the breach, our company
shall not bear any responsibility;
Master switch: Only after turning on this switch, pressure setting up in the system, can
crane be work in gear.
Governor switch of winch: the winch speed can be increased when the governor switch is switched on at
the torque of 10%~55%;
Changeover switch of telescopic/auxiliary winch: this switch is used for the working conditions changeover
between auxiliary and telescopic boom;
Switch of free sliding: switch on this switch if wire rope can not align vertically with heavy load when the
load is being landed, then the turntable will move automatically to align the qire rope vertically;
Repair switch: extend/retract srd, 4th, 5th section of boom at the state of base boom; once this switch is
used in other state except the state of base boom, the buzzer will give out alarm sound with display of
“please change over at the state of base boom”, also the telescopic action will be stopped;
Changeover switch of cylinderI/II: cylinder I can be changed over to cylinder II when cylinder I extend fully
through this switch.
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5.2.4Instruction of electric cabinet（Fig.5-6）
Main body of
t li it
Relay
Terminal block Fuse
Fig. 5-6
K1 —— Power control od display screen K2 —— Power supply control of working lamp
K3 —— Power control of oil cooler K4、K5—— Protection control of flameout
F1 —— Power supply fuse of display screen F2 —— Main power supply fuse
F3 —— Power supply fuse of instrument lamp F4 —— Power supply fuse of outline lamp
F5 —— Power supply fuse of working lamp F6 —— Power supply fuse of windscreen wiper
F7 —— Power supply fuse of horn, fan F8 —— Power supply fuse of oil cooler
F9 —— Power supply fuse of air conditioner F10—— Power supply fuse of main control valve
5.3 A/C Device of Operating Room

Component of A/C device of operating room is as shown in Fig. 5-7.
39
Fig 5-7 A/C Device of Operating Room
5.4 Replacement of Operating Room

The operating room of superstructure is fixed on the turntable of crane by bolts with turntable bracket.
5.4.1 The operating room shall be disassembled in the following cases:
1. If the broken operating room shall be repaired or replaced
If the operating room is damaged due to accident and can’t be repaired at the crane, it shall be
disassembled.
2. If the turntable shall be disassembled
If the turntable shall be disassembled, the operating room shall be disassembled firstly.
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1- Instrument platform component 2-lamp support 3-nut 4-Nut 5-shock pad 6-washer 7-nut
8-pad 9-bolt 10-Washer 11-washer 12-Aluminium handle 13.operating room
Fig 5-8(1) Disassembly and Assembly Details of Operating Room

Step1. Fix the Operating room with crane and soft sling;
Step 2: Remove the two-force rod assembly, throttle pedal and throttle support.
Step3. Loosen the connecting jack for the electric control cabinet circuit of operating room and the
electric control circuit of the whole crane;
Step4. Loosen the nut 7 and the bolt 4, and take off the washer 6 and shock pad 5.
Step5. Place the operating room at the special or appointed site with crane.
Step1. Place the Operating room at the turntable support for installation with the crane.
Step2. Install the washer 6 and shock pad 5, screw down the nut 7 and the bolt 4, and then
pre-tighten them.
Step3. Connect the connecting jack for the electric control cabinet circuit of operating room and the
electric control circuit of whole crane, and check it;
Step4. Install the two-force rod assembly, throttle pedal and throttle support and ensure the firm
connection of each part and check the operating handle, throttle pedal to confirm that they can
operate freely, return precisely without stagnation and abnormal noise.
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6. Hydraulic System
6.1Principles of Hydraulic System
The hydraulic system of STC75 superstructure can be classified as S-type (manual push rod) and Y-type
(hydraulic piloted control) according to the control method. Hydraulic systems are all open systems. The
hydraulic system consists of hydraulic pump station, hydraulic systems of undercarriages and
superstructure. The hydraulic system of superstructure includes the slewing system, luffing system,
telescopic system, main and auxiliary winch system; of which hydraulic pump station is connected with
superstructure by central slewing body. The various systems of superstructure fulfill the control by the units
of a multi-way valve.
6.1.1 Hydraulic System of STC75 Superstructure
The load feedback variable hydraulic system is adopted for STC75S system, and the main oil pump is
composed by variable plunger pump and gear pump. The plunger pump provides power for all actions of
superstructure except for slewing, and gear pump provides the power for the outrigger of undercarriages
and the slewing of superstructure. The main valve of superstructure is a pressure compensation
proportional valve which realizes the control over the slewing, extension/retraction, luffing and winch of
superstructure. The main overflow valve and secondary overflow valve are set at the various working oil
circuits of main valve to assure that the working mechanisms are operating within the allowable pressure.
The slewing is carried out by a slewing reducer driven by the slewing motor to actuate the turntable to slew
round the center. The rotary cushion valve and one-way throttle valve with accumulator are set in the
circuit to ensure stable and safe startup and stopping of slewing, so as to eliminate the impact during
slewing.
The extension/retraction is carried out by driving the second, third and fourth sections of boom to
extend/retract by telescopic cylinder through the rope laying mechanism. The balanced valve for
extension/retraction is set in the circuit to maintain the stability of retraction and to block the hydraulic oil in
the telescopic cylinder in case of no extension/retraction action so as to maintain the working length of
main boom.
The luffing is carried out by controlling the lifting/descending of the first section of boom by extension/
retraction of luffing cylinder. The balanced valve for luffing is set in the circuit to maintain the stability of
descending and to block hydraulic oil in the luffing cylinder in case of no luffing so as to maintain the
working length of main boom.
The winch is carried out by driving the winch reducer by winch motor to actuate the rotary drum, wire rope
and hook to lift or descend. The balanced valve for winch is set in the circuit to maintain the stability of
hook descending and prevent stalling. The switching system between the high/low speeds makes the
winch capable of running at high speed in case of light load to assure the operating efficiency and running
at low speed in case of heavy load to assure the stable operation and the lifting capacity of winch.
6.1.2 Hydraulic System of STC75 Superstructure
The load feedback variable hydraulic system is adopted for STC75Y system, and the main oil pump is
composed by variable plunger pump and gear pump. The plunger pump provides power for all actions of
superstructure except for slewing, and gear pump provides the power for the outrigger of undercarriages
and the slewing of superstructure. The main valve is a hydraulic piloted control valve with the load
feedback which realizes the control over the luffing, extension/retraction and winch and controls the
operating speed without the interference of load. The main overflow valve and secondary overflow valve
are set at the various working oil circuits of main valve to assure that the working mechanisms are
operating within the allowable pressure. The slewing is controlled by an independent hydraulic control
slewing valve.
The working principles of slewing, luffing, extension/retraction and winch are the same as that of STC75S
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As for the hydraulic piloted control, the hydraulic piloted handle is applied to control the pressure of piloted
oil circuit, so as to actuate the valve cores of main valve and slewing valve of superstructure to achieve all
actions of the superstructure. The left piloted handle controls the extension/retraction of main boom and
lifting/descending and slewing of auxiliary hook, while the right piloted handle controls the
lifting/descending of main hook and the luffing of main boom. The left and right piloted handles are
respectively located on the left and right armrest boxes of seat in the operating room.
The setting of safety protection, hydraulic oil cooler and air conditioner drive are the same as that of
STC75S.
6.1.3 Principle of Superstructure Hydraulic System
The hydraulic systems of STC75S and STC75Y are as shown in Fig. 6.1 and Fig. 6.2.
Fig. 6.1 Schematic Diagram of Hydraulic System of STC75S Truck Crane
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Fig. 6.2 Schematic Diagram of Hydraulic System of STC75Y Truck Crane
6.1.4 Technical Parameters
Max working pressure of main oil circuit 25 Mpa (for setting pressure of each overflow valve, see the
calibration value shown on the schematic drawing)
Max. working pressure of oil circuits of slewing mechanism and outrigger: 20 Mpa
Capacity of oil tank: 1000 L
Precision of high-pressure oil filter: 10μ
6.1.5 Instructions for Hydraulic Oil

(a) Please use the hydraulic oil recommended by our company, and don’t use any blended oil.
(b) Use oil filling machine to fill the hydraulic oil and don’t pour it in directly.
(c) Make sure the hydraulic oil is clean, and change hydraulic oil strictly according to working time.
Hydraulic Oil Recommended by Our Company for Different Environments

No. Use Condition Name of Oil Remarks
Caltex HD46
Normal region (ambient
1 Kunlun HV46 Normal type
temperature is within10~40℃)
Great Wall 6146
Lowe-temperature region (ambient Low-temperature
2 Shell VG32 (Tellus)
temperature is down to -30℃) type
High-temperature region (ambient High-temperature
3 Shell VG68
temperature is higher than 40℃) type
6.1.6 Precautions for Maintenance of Hydraulic System

(a) It is necessary to stop the equipment operation and release the pressure or treat the hydraulic oil
44
circuit when replacing the hydraulic elements and removing the oil pipe.
(b) The adjustment of system pressure and main oil pump, as well as the removal and replacement of
hydraulic parts shall be carried out under the guidance of hydraulic engineer and service engineer of
our company and it is prohibited to adjust randomly.
(c) It is necessary to pay attention to the sealing of oil port and keeping the hydraulic pipeline clean when
removing the oil pipe and the special attention shall be paid to that the oil pipe or valve piece shall not
be removed under the dusty or sandy environment and it is unallowable to wear gloves during the
working process.
(d) It is necessary to check whether it is necessary to replace the filter core regularly. When the
high-pressure filter is blocked, the warning device above the high-pressure filter would turn to “red”
from normal “green” during the operation of system. It is necessary to replace the filter core.
(e) The hydraulic part is critical to system, please use our original hydraulic part specified by our
company.
(f) It is necessary to check whether the hydraulic oil has deteriorated or is contaminated regularly. It is
necessary to replace timely or filtrate periodically to extend the service life of hydraulic system and
reduce the frequency of malfunction, so as to save the valuable time and reduce the economic losses.
6.2 Main Oil Pump and Maintenance Thereof

6.2.1 Structure of Hydraulic Pump
The hydraulic pump adopted for this series of crane is composed of plunger pump and gear pump, as
shown in Fig. 6-3.
1－Hydaulic pump 2－double-Gear pump

Fig. 6-3(1) Oil Pump Assembly
6.2.2 Analysis on Common Malfunctions of Hydraulic Pump

The analysis on the common malfunctions of hydraulic pump is presented in Table 6-1, which lists the
malfunctions possibly caused in relation to the hydraulic pump, and can be used for inspection as
reference. Many parts generate such malfunctions, but only the reasons related to the hydraulic pump and
irrelevant to the product quality and design are listed in the table. As for the troubleshooting of the same
malfunctions at other parts, please refer to other chapters. It is necessary to carefully analyze on site
whether it is caused by the pump itself or by installation, so as to conduct the purposeful servicing.
45
Table 6-1 Common Malfunctions of Hydraulic Pump
Malfunction Cause Troubleshooting
With noise Insufficient oil amount Fill oil
Hydraulic The oil suction pipe with air in Repair or exhaust
Pump The mounting bolt loose Screw down
The hydraulic oil polluted Change oil or filter
The transmission shaft vibrating Repair
The universal joint abraded Replace
The hydraulic pump with malfunction Repair or replace
6.2.3 Replacement Steps of Hydraulic Pump

Step1. Close the cut-off valve at the oil outlet of oil tank, and repeatedly pull the control handles on
the superstructure to unload the main oil circuit and avoid the oil jetting when disassembly.
Step2. Dismantle the fixed flange for oil tube at the oil inlet and outlet of plunger pump, and seal the
oil tube inlet or outlet with clean plastic cover or plug to prevent the hydraulic circuit from mixing with
foreign pollutants.
Step3. Loosen the screw on the clutch connecting with the input shaft of plunger pump by the driver.
Step4. Screw off the bolt and nut fixing the plunger pump on the flange, prize the assembly end face
of plunger pump with the driver, and pull out the input shaft of hydraulic pump from the clutch.
Step5. Pass the new hydraulic pump shaft through the clutch of output shaft of engine, match the
plunger pump with the protrudent edge of fixed end face of flange, and screw down the bolt and nut
with the ringent spanner. When assembly, coat some consistent grease on the shaft and shaft hole
and fastening adhesive on the threaded part.
Step6. Fasten the input shaft of clutch and plunger pump with check screw.
Step7. Connect the oil tube of hydraulic pump, and open the cut-off valve. Initiate and check whether
the oil pump exports the oil, and formally operate the machine after turning to be normal.
6.2.4 Necessary Tools
Name Model Qty.
Hexagon spanner 6～19 1
Ringent spanner 6～27 1
Copper bar Φ　40-300　　 1
Slotted blade driver － 1
Caution
1. It is better not to directly disassemble the hydraulic pump, and please contact our after-sale
service personnel if the hydraulic pump generates any internal problem that will be solved by
professional manufacturer.
2. Remember the mounting position of each joint and part during the disassembly.
3. Any part shall be cleaned before being installed in the pump, and the pump shall be free of
foreign substances. It is forbidden to dismantle the hydraulic pump with hammer or other hard
tools or by means of beating. It is better not to damage the parts or scrape the seal cooperating
face during the disassembly.
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6.3 Multi-way Valve of Undercarriages and Maintenance
6.3.1 Structure and Principle of the Multi-way Valve of Undercarriages
SANY company provides two types of multi-way valve of undercarriages, namely the integral type and the
sheet type, all of which are the sextuple multi-valve block, as shown in the System Diagram. The integral
type refers to the combination of sextuple steering valve and accessory valve, while the sheet type is
made up of multiple main steering valve, accessory valve and connecting board that are connected by
bolts. These two types share the same external structure generally, which is shown in the Fig. 6-4.
Fig. 6-4 Structure of Multi-way Valve of Undercarriages

6.3.2 Analysis on Common Malfunctions of Multi-way Valve of Undercarriages
Analysis on the Common Malfunctions of the Multi-way Valve of Undercarriages is as shown in the
Table 6-2:
Table 6-2 Analysis on the Common Malfunctions of the Multi-way Valve of Undercarriages
Improper cooperating clearance between valve cover
and valve hole, or foreign substances in the Deburr, and clean it
Inflexible slide
cooperating clearance
valve, and great
Broken offsetting spring and bouncing spring Replace the spring
steering force
Overlarge hold force of dustproof seal ring Replace with proper seal
ring
Unreliable seal of O-ring Replace the seal ring
Damaged seal part due to valve core Brush plating, and renovate
Outside and
Wide cooperating clearance between valve core and
inside leakage Brush plating, and renovate
valve hole
Useless seal of O-ring between sheets Replace the seal ring
No pressure Blocked or damaged overflow valve Clean or replace it
6.3.3 Replacement of Multi-way Valve of Undercarriages

1. Disassembly Steps
The integral multi-way valve shall be totally replaced in case of malfunction, while the sheet multi-way
47
valve can be treated based on the following steps:
Step1. Release the pressure in the system, stop the machine, and dismantle the oil tube connecting
with the multi-way valve of undercarriages.
Step2. Loosen the long bolt connecting with all sheet valves, take off the sheets with malfunction,
clean or replace the seal ring.
2. Assembly Method
As for the sheet multi-way valve, the assembly steps are as follows:
Step1. Install the seal ring, pile up all sheet valves in order, and connect them with long bolts.
Step2. Restore all dismantled hydraulic pipelines.
3. Necessry Tools for Disassembly and Assembly of the Multi-way Valve of Undercarriages
Name Model Qty.
6.4 Multi-way Valve of Undercarriages and Maintenance

6.4.1 Structure and Function of the Main Valve of Superstructure
1. Structure of Main Valve of STC75’s Superstructure
The multi-way valve of superstructure is a quadruple multi-way valve block. From left to right are the
telescopic, luffing, auxiliary winch, and main winch.
Fig. 6-5 Structure of Main Valve of STC75’s Superstructure

2. Function of Main Valve of Superstructure
Four sheets of main valves of multi-way valve of STC75’s superstructure can respectively control four
oil circuits, namely luffing, telescopic, auxiliary winch and main winch oil circuits, and can control such
actions of superstructure as luffing, telescopic actions, and lifting.
48
6.4.2 Analysis on Common Malfunctions
Repositioning and positioning 1. Distortion of reset spring 1. Replace the reset spring
failure of slide valve 2. Distortion of positioning spring 2. Replace the positioning
3. Abrasion of positioning sleeve spring
4. Dirt between the valve body and 3. Replace the positioning
slide valve sleeve
5. Failure of control mechanism 4. Wash it
outside the valve 5. Adjust the control
6. Connecting bolt fastened too mechanism outside the valve
tightly leading to the distortion of 6. Screw down the connecting
valve body bolt again
Outer leakage 1. Damage of O-type seal rings on Replace the O-type seal ring
both ends of valve body
2. Damage of O-type seal rings
among the valve bodies
Unstable pressure or 1. Distortion of pressure-regulating 1. Replace the
pressure-increasing failure of spring pressure-regulating spring
safety valve 2. Abrasion of poppet valve 2. Replace the poppet valve
3. Looseness of locking nut 3. Screw down the locking nut
4. Blockage of damping hole of 4. Wash the main valve core to
main valve core make the damping hole
5. Stagnation of valve core unblocked
6. Failure of pump 5. Wash it
6. Repair the pump
Operating mechanism sinking 1. Increasing clearance between 1. Repair or replace the slide
obviously when the slide valve is at the valve body and slide valve due valve
the neutral position to the abrasion 2. Keep the slide valve aligned
2. Position of slide valve not 3. Replace the conical valve or
aligned remove the contamination
3. Conical valve abraded or 4. Replace the steel ball or
underlaid by contamination trim the edge
4 .Poor contact between the steel
ball and thee edge of seat inside
the R-type valve
6.4.3 Replacement of Main Valve of Superstructure

Step1. Release the pressure in the system, stop the machine, and remove the oil tube connecting
with the main valve of superstructure.
Step2. Loosen the long bolt connecting with all sheet valves, take off the sheets with malfunction,
clean or replace the seal ring.
2. Assembly Method
Step1. Install the seal ring, pile up all sheet valves in order, and connect them with long bolts.
Step2. Restore all dismantled hydraulic pipelines.
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6.4.4 Necessary Tools for Disassembly and Assembly of Main Valve of Superstructure
Name Model Qty.
6.5 Structure and Maintenance of Central Slewing Body

6.5.1 Structure and Function of Central Slewing Body
The central slewing body is a slewing connector which connects the pump station of undercarriages and
the hydraulic circuit of superstructure, and its principle is as shown in Fig 6-7. Through the central slewing
body, the oil source can led to the superstructure system from the hydraulic pump station of
undercarriages and it can be ensured that the superstructure can rotate unlimitedly against the
undercarriages, and its basic structure is as shown in Fig 6-7.
The lower end cover of central slewing body is fixed on the undercarriages and the core of central slewing
body is fixed on the lower end cover, and its joint face is sealed with O-ring. Pressure oil can flow into the
body core through the lower end cover of central slewing body, and is assigned to each oil port by the flow
channel inside the body core. The housing wraps the core and can slew freely against the core. The
pipeline of superstructure introduces the pressure oil from each structure of housing, so that the
superstructure can achieve the unlimited rotation against the undercarriages.
1-End cover 2-Fixing sleeve 3-Guide ring 4-Seal ring 5-Body core 6-Flange 7- Stud bolt 8-Washer
9-End cover 10-Screw 11-Coper ring 12-Star-type seal ring 13-Fixing plate 14-Screw 15-Washer
16-O-ring 17-O-ring 18-Washer 19-O-ring 20-Plug 21-Gasket
Fig. 6-7 Internal Structure of Central Slewing Body
6.5.2 Diagnosis of Common Malfunction and Troubleshooting on Central Slewing Body
1. Oil Interflowing in Central Slewing Body
In case of oil interflowing in the central slewing body, unscrew the screws 1 and 11 to take off the
housing of central slewing body to observe whether the rotary sealing 4 on the body core 5 is abraded
50
or broken, if so, replace the damaged sealing element.
2. Oil Leakage of Central Slewing Body
In case of the oil leakage on the joint face between end cover 10 and central slewing body housing 3,
unscrew the screw 11 to observe whether the O-rings 13-17 inside the circular groove of gasket 9 are
not aligned, positioned wrongly, distorted or abraded, and If so, replace the damaged sealing element.
In case of the oil leakage at the connectors of central slewing body, first check whether the seal ring
inside the connector is damaged or loose, and replace and re-assembly it if necessary.
3. Replacement of Sealing Element
1) Remove the housing, which is fixed at the body core by 4 hexagon socket head cap screws through a
top end cover.
2) Remove body core. Then take out screw from reverse end.
3) Cut off the damaged rotary seal ring and the inner O-ring with a blade to take off them.
4) Clean the groove on core for assembling the O-ring. The groove shall be kept clean during the
assembly process.
5) When assembling the new rotary seal ring, it is necessary to insert a slotted screwdriver half into the
ring, and then spread the seal ring with screwdriver and slowly slide it into the seal groove
6) The new rotary seal ring can be immersed into the boiling water for 10 minutes and coated with little
consistent grease if the assembly is hard to carry out.
7) Make sure not to cut off the sealing when removing and installing the housing.
8) In the case of oil leakage, first remove the body core to check whether the seal ring of end face is
intact.
6.6 Structure and Maintenance of Luffing Oil Cylinder

6.6.1 Structure and Function of Luffing Oil Cylinder
1. Structure of Luffing Oil Cylinder
The luffing oil cylinder principally consists of piston rod, piston, guide sleeve and cylinder body.
The guide sleeve and the piston can be used for seal and guide, and the seal ring on the piston can
separate the oil in rod-side chamber from that in piston-side chamber of oil cylinder. Differential
pressure will form in these two chambers when the system supplies oil to the oil cylinder, impulse the
piston to make a rectilinear motion in the cylinder, and consequently drive the piston rod to make a
rectilinear motion. The seal ring on the guide sleeve can prevent the oil in oil cylinder from overflowing
during the motion of piston rod.
The service time of the seal ring, O-ring and guide ring of the oil cylinder is restricted by the time and
the motion times. The seal ring and O-ring will fail to seal when used for some time, so the seal ring,
o-ring and guide ring shall be replaced during the overhaul of the luffing oil cylinder that has been
used for a certain period.
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1-Bush 2-Screw 3- Cylinder assembly 4-Screw 5-Piston 6- Guide ring 7- Seal ring
8-O-ring 9- Piston rod assembly 10-Bolt 11-Cover plate 12-Backup plate 13-Screw plug
14-Washer 15-Guide sleeve 16-Seal ring 17-Guide ring 18-O-ring 19- Retainer ring
20-Seal ring 21-Bolt 22-Washer 23- Dustproof ring 24-Retainer ring 25- Oscillating
bearing 26-Screw plug 27-Oil cup 28-Screw plug 29-Washer
Fig. 6-8(1) Structure of Luffing Oil Cylinder
2. Function of Luffing Oil Cylinder
The luffing oil cylinder is articulated on the turntable, and the piston rod is articulated on the boom.
The oil supply by the system can impel the oil cylinder to fall and rise, and drive the boom to vary in
certain amplitude.
6.6.2 Analysis on Common Malfunctions of Luffing Oil Cylinder
Table 6-3(1) presents the analysis on the common malfunctions of luffing oil cylinder:
Table 6-3(1) Analysis on Common Malfunctions of Luffing Oil Cylinder
Broken O-ring on the outer ring of guide sleeve Replace the O-ring
Oil leakage of guide
Broken oil seal on the inner ring of guide sleeve Replace the oil seal
sleeve
Pull damage of piston rod Replace the piston rod
Broken oil seal on the outer ring of piston Replace the oil seal
Broken O-ring of the piston rod Replace the O-ring
Incapacity of oil
Pull damage of cylinder Replace the cylinder body
cylinder
Deterioration of hydraulic oil Replace the hydraulic oil
Poor roundness of cylinder Replace the cylinder body
Different shafts of inner and outer rings of piston Replace the piston
Different shafts of inner and outer rings of guide Replace the guide sleeve
sleeve
Shake of oil cylinder Broken guide ring Replace the guide ring
Bend of piston rod Replace the piston rod
Broken front and rear axis pins of oil cylinder Replace the pin or sleeve
Poor installation and connection of oil cylinder Reinstall and adjust
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6.6.3 Replacement of Luffing Cylinder
Step1. Cut off the power supply, release the pressure, and stop the machine.
Step2. Drain out the oil in two chambers of oil cylinder, and avoid the environmental pollution.
Step3. Dismantle the oil tube, adaptor and balanced valve block that connect with the luffing oil
cylinder, and plug the oil tube.
Step4. Loosen the connecting bolt of guide sleeve and cylinder with hexagon spanner.
Step5. Horizontally fix one end of oil cylinder, and slowly pull out the piston rod after installing the
suspending strap by crane, forklift truck and other machines. The pull direction shall be as parallel as
possible with the axial direction of piston rod.
Step6. Take off the retainer ring from the piston with the snap ring pliers, disassemble the clipping key
cap, and take off the shaft lock key.
Step7. Screw two M16 screws in the screw hole of piston, and pull out the piston of luffing oil cylinder.
Step8. Install two M16 bolts in the through hole of guide sleeve, and pull out the guide sleeve from the
piston rod.
Step9. Take off the guide ring, oil seal, O-ring and other small parts of piston, piston rod and guide
sleeve.
Step10. Wrap the piston rod, piston and other parts with cloth or plastic.
2. Assembly Method
Step1. Deburr and clean all parts of oil cylinder.
Step2. Fit the guide sleeve on the piston rod.
(a) Coat the O-ring, seal rings, guide ring and dustproof ring with consistent grease, and install them
at the corresponding positions on guide sleeve.
(b) Coat the piston rod with consistent grease, and then pass the guide sleeve through the piston
rod.
Step3. Install the piston on the piston rod.
(a) Coat the O-ring 4 with consistent grease, and install it at the corresponding position on the piston
rod.
(b) Coat the oil seal and guide ring with consistent grease, and install them at the corresponding
positions on the piston.
(c) Wrap the piston rod with cloth, fix it with the vice, cover the piston on the piston rod, install 4
screws on the piston’s end face, turn the screws with spanner, and screw in the piston.
(d) Screw down the piston, and fit the shaft lock key, clipping key cap, and retainer ring.
Step4. Assemble the oil cylinder
(a) Clean the piston rod, guide sleeve and piston, and coat them with consistent grease.
(b) Horizontally fix the oil cylinder, lift the piston rod by traveling crane, align the cylinder body, install
the piston in the cylinder, and slowly pull it to screw in till the upper end face of guide sleeve is
lower than the groove seizing face of cylinder body.
(c) Turn the guide sleeve with crowbar to make the direction of connecting shaft hole in the guide
sleeve accord with that in the cylinder body, and then install the connecting bolts.
6.6.4 Necessary Tools for Disassembly and Assembly of Luffing Cylinder
1. Tools
Name Model Qty.
External snap ring pincers - 1
Copper bar Φ40×300 1
53
Traveling crane - 2
Suspending strap 2T Several
Ringent spanner 6 ~ 27 1
Vice 300 1
Crowbar - 1
2. Precautions
It is very difficult and costs much time to disassemble large oil cylinders such as luffing and telescopic
oil cylinders, so it is better to make sure that the reason is the internal leakage of cylinder before the
disassembly.
The cylinder shall be free of dirt before dismounting the piston and piston rod from the cylinder. And it
is forbidden to compulsorily beat out the piston from the cylinder, so as to prevent the cylinder and
piston surface from damage by dirt.
When disassembly, it is required to prevent the piston rod and piston surface from damage, and avoid
unnecessary random beat and ground collision. After disassembly, all parts shall be wrapped with
cloth and plastic and prevented from dust and water, and the small parts can be dipped into the oil
disc.
6.7 Structure and Maintenance of Telescopic Cylinder

6.7.1 Structure and Function of Telescopic Cylinder
STC75 truck crane has two telescopic cylinders.
1. Structure of Telescopic Cylinder
The telescopic cylinder is mainly made up of piston rod, guide sleeve, cylinder body, and piston.
o-ring and guide ring shall be replaced during the overhaul of the telescopic oil cylinder that has been
used for a certain period.
Fig. 6-9(1) Structure of Telescopic Cylinder I

1-Cylinder barrel assembly 2-Piston 3-Piston rod 4-Guide sleeve
54
Fig 6-9(2) Structure of telescopic cylinder II
1-Cylinder barrel assembly 2-Piston 3-Piston rod 4-Guide sleeve
2. Function of Telescopic Cylinder
The piston rod of telescopic cylinder is articulated on the turntable, and the cylinder is articulated on
the 2nd section of boom. When the piston-side chamber of telescopic cylinder is filled with pressure oil,
the piston rod stops and the cylinder extends forward. The second boom can, driven by the
pin-connected joint shaft of cylinder, simultaneously extend with the telescopic cylinder. When the
rod-side chamber of telescopic cylinder is filled with pressure oil, the cylinder will retract. The 2nd
section of boom can, driven by the pin-connected joint shaft of cylinder, simultaneously retract with
the telescopic cylinder.
6.7.2 Analysis on Common Malfunctions of Telescopic Cylinder
Table 6-4 (1) presents the analysis on the common malfunctions of telescopic cylinder:
Table 6-4 (1) Analysis on Common Malfunctions of Telescopic Cylinder
Oil leakage of
guide sleeve
Broken O-ring of piston rod Replace the O-ring
Incapacity of
Pull damage of cylinder Replace the cylinder body
oil cylinder
Deterioration of hydraulic oil Replace the hydraulic oil
Poor roundness of cylinder Replace the cylinder body
Different shafts of inner and outer rings of guide
Replace the guide sleeve
sleeve
Shake of oil
Broken guide ring Replace the guide ring
cylinder
Broken front and rear axis pins of oil cylinder Replace the pin or sleeve
6.7.3 Replacement of Telescopic Cylinder
Step3. Dismantle the oil tube, adaptor and balanced valve block that connect with the telescopic oil
cylinder, and plug the oil tube.
55
Step4. Loosen connecting bolt of guide sleeve and cylinder with hexagon spanner.
Step5. Horizontally fix one end of oil cylinder, and slowly pull out the piston rod after installing the
suspending strap by crane, forklift truck and other machines. The pull direction shall be as parallel as
possible with the axial direction of piston rod.
Step6. Take off the retainer ring from the piston with the snap ring pliers, disassemble the clipping key
cap, and take off the shaft lock key.
Step7. Screw two M16 screws in the screw hole of piston, and pull out the piston of luffing oil cylinder.
piston rod.
Step9. Take off the piston, the guide sleeve, and the guide ring, oil seal and O-ring of piston rod.
2. Assembly Method
(a) Coat the O-ring, oil seal, guide ring and dustproof ring with consistent grease, and install them at
the corresponding positions on guide sleeve.
(b) Coat the piston rod with consistent grease, and then pass the guide sleeve through the piston
rod.
(a) Coat the O-ring with consistent grease, and install it at the corresponding position on the piston
rod.
(b) Coat the oil seal and guide ring with consistent grease, and install them at the corresponding
positions on the piston.
(c) Wrap the piston rod with cloth, fix it with the vice, cover the piston on the piston rod, install 4
screws on the piston’s end face, and turn the screws with spanner to screw in the piston.
(d) After screwing down the piston, fit the shaft lock key and clipping key cap, and install the retainer
ring on the piston with the snap ring pliers.
(b) Horizontally fix the oil cylinder, lift the piston rod by traveling crane, align the cylinder body, install
the piston in the cylinder, and slowly pull it to screw in till the upper end face of guide sleeve is
lower than the groove seizing face of cylinder body.
6.7.4 Necessary Tools and Precautions for Disassembly and Assembly of Telescopic Cylinder
1. Tools
Name Model Qty.
Traveling crane - 2
Suspending strap 2T Several
Ringent spanner 6 ~ 27 1
Vice 300 1
Crowbar - 1
56
2. Precautions
It is very difficult and costs much time to disassemble large oil cylinders such as luffing and telescopic
oil cylinders, so it is better to make sure that the reason is the internal leakage of cylinder before the
disassembly.
The cylinder shall be free of dirt before dismounting the piston and piston rod from the cylinder. And it
is forbidden to compulsorily beat out the piston from the cylinder, so as to prevent the cylinder and
piston surface from damage by dirt.
When disassembly, it is required to prevent the piston rod and piston surface from damage, and avoid
unnecessary random beat and ground collision.
After disassembly, all parts shall be wrapped with cloth and plastic and prevented from dust and water,
and the small parts can be dipped into the oil disc.
6.8 Structure, Function and Maintenance of Oil Cylinder of 5th Outrigger

6.8.1 Structure and Function of Oil Cylinder of 5th Outrigger
1. Structure of Oil Cylinder of 5th Outrigger
■ The oil cylinder of 5th outrigger principally consists of piston rod, guide sleeve, cylinder, and piston.
■ The guide sleeve and the piston can be used for seal and guide, and the seal ring on the piston can
rectilinear motion.
■ The seal ring on the guide sleeve can prevent the oil in oil cylinder from overflowing during the
motion of piston rod. The service time of the seal ring, O-ring and guide ring of the oil cylinder is
restricted by the time and the motion times. The seal ring and O-ring will fail to seal when used for
some time, so the seal ring, o-ring and guide ring shall be replaced during the overhaul of the crane
that has been used for a certain period.
1-Cylinder assembly 2-Screw 3-Seal ring for hole 4-Piston 5-O-ring 6-Retainer ring 7-Piston
rod 8-Guide sleeve 9-Guide ring 10-O-ring 11-Retainer ring 12-Seal ring for shaft 13-Seal ring
for shaft 14-Dustproof ring 15-Screw
Fig. 6-10(1) Structure of Oil Cylinder of 5th Outrigger
2. Function of Oil Cylinder of 5th Outrigger
Located under the cab, the 5th outrigger can, if extends, provide one stress support point to enhance
the stability of crane running in front, and to slew the crane within the scope of 360 degree (In view of
the stability, backside>side>front; during the slewing, consider the replacement of the maximum lift
57
weight of crane due to changeable directions).
6.8.2 Analysis on Common Malfunctions of Oil Cylinder of the 5th Outrigger
The analysis on the common malfunctions of the oil cylinder of the 5th outrigger is shown in the following
table.
Table 6-4(1) Analysis on Common Malfunctions of Oil Cylinder of 5th Outrigger
Oil leakage of guide sleeve Broken oil seal on the inner ring of guide sleeve Replace the oil seal
Pull damage of cylinder Replace the cylinder
body
Incapacity of oil cylinder
Deterioration of hydraulic oil Replace the hydraulic
oil
Poor roundness of cylinder Replace the cylinder
body
Different shafts of inner and outer rings of guide Replace the guide
sleeve sleeve
Shake of oil cylinder
Broken front and rear axis pins of oil cylinder Replace the pin or
sleeve
6.8.3 Replacement of Oil Cylinder of 5th Outrigger

Step3. Dismantle the oil tube, adaptor and hydraulic lock that connect with the outrigger oil cylinder,
and plug the oil inlet.
Step4. Loosen the screw connecting guide sleeve and cylinder.
Step5. Screw two M5 screws in the screw hole of guide sleeve, and revolve out the guide sleeve.
Step6. Vertically fix the oil cylinder, and slowly pull out the piston after installing the suspending strap
by crane.
Step7. Loosen the screw connecting piston and piston rod with the driver.
Step8. Screw two M10 screws in the screw hole of piston, and pull out the piston of horizontal oil
cylinder.
Step9. Take off the guide ring, oil seal, O-ring and other small parts of piston, guide sleeve and piston
rod.
2. Assembly Method
(a) Coat the O-ring, oil seals, guide ring and dustproof ring with consistent grease, and install them
58
at the corresponding positions on guide sleeve.
(a) Coat the O-ring and the retainer ring with consistent grease, and install them at the
corresponding positions on the piston rod.
(b) Coat the seal ring 3 with consistent grease, and install it at the corresponding position on the
piston.
(c) Wrap the piston rod with cloth, fix it with vice, and turn the piston sleeve to the piston rod.
(d) After screwing down the piston, fasten the screw 2, and connect the piston and the piston rod.
(b) Vertically fix the oil cylinder, lift the piston rod by traveling crane, align the cylinder body, and
install the piston in the cylinder till the upper end face of guide sleeve is lower than the groove
seizing face of cylinder body.
(c) Firmly connect the guide sleeve and the cylinder with set screws.
6.8.4 Necessary Tools for Disassembly and Assembly of Oil Cylinder of 5th Outrigger
Name Model Qty.
Vice 300 1
Traveling crane - 1
Slotted blade driver 150 1
6.9 Structure, Function and Maintenance of Vertical Oil Cylinder

The structure, function, and disassembly and assembly procedure of vertical oil cylinder is generally the
same with that of the oil cylinder of the 5th outrigger, so it is unnecessary to repeat it.
6.10 Structure, Function and Maintenance of Horizontal Oil Cylinder

The dual oil cylinders are adopted for STC75 to fulfill the extension/retraction of horizontal movable
outrigger.
6.10.1 Structure and Function of Horizontal Oil Cylinder
1. Structure of Horizontal Oil Cylinder
The horizontal oil cylinder mainly consists of piston rod, guide sleeve, cylinder and piston.
o-ring and guide ring shall be replaced during the overhaul of the crane that has been used for a
certain period.
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1-Guide sleeve 2-Piston rod 3-Piston 4-Cylinder barrel assembly
Fig 6-11(1) Structure of Horizontal Oil CylinderI
1- Cylinder assembly 2-Piston 3-Piston rod 4-Guide sleeve

Fig. 6-11(2) Structure of Horizontal Oil CylinderII
2. Function of Horizontal Oil Cylinder

The horizontal oil cylinder is articulated on the chassis, and the piston rod is articulated with the
horizontal outrigger. The piston rod can, if extends, drive the horizontal outrigger to simultaneously
extend to form H-type outrigger; if retracts, the piston rod can drive the horizontal outrigger to retract
into the chassis.
6.10.2 Analysis on Common Malfunctions of Horizontal Oil Cylinder
The analysis on common malfunctions of horizontal oil cylinder is listed in the following table:
Table 6-5 (1) Analysis on Common Malfunctions of Oil Cylinder
Oil leakage of guide
sleeve
Incapacity of oil cylinder Broken oil seal on the outer ring of piston Replace the oil seal
Pull damage of cylinder Replace the cylinder
body
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Deterioration of hydraulic oil Replace the hydraulic
oil
Poor roundness of cylinder Replace the cylinder
body
Different shafts of inner and outer rings of guide Replace the guide
sleeve sleeve
Shake of oil cylinder
Broken front and rear axis pins of oil cylinder Replace the pin or
sleeve
Poor installation and connection of oil cylinder Reinstall and adjust it
6.10.3 Replacement of Horizontal Oil Cylinder

Step2. Drain out the oil in the oil cylinder, and avoid the environmental pollution.
Step3. Dismantle the oil tube and adaptor that connect with the outrigger oil cylinder, and plug the oil
inlet.
Step4. Loosen the connecting bolt of guide sleeve and cylinder.
Step5. Vertically fix the oil cylinder, and slowly pull out the piston rod after installing the suspending
strap by crane.
Step6. Take off the retainer ring from the piston with the snap ring pliers, disassemble the clipping
key cap, and take off the shaft lock key.
Step7. Screw two M8 screws in the screw hole of piston, and pull out the piston of horizontal oil
cylinder.
piston rod.
Step9. Take off the guide ring, oil seal, O-ring, dustproof ring and other small parts of piston, piston
rod and guide sleeve.
2. Assembly Method
1) Coat the O-ring, oil seal, guide ring and dustproof ring with consistent grease, and install them at
the corresponding positions on guide sleeve.
2) Coat the piston rod with consistent grease, and then pass the guide sleeve through the piston
rod.
(a) Coat the O-ring and the retainer ring with consistent grease, and install them at the
corresponding positions on the piston rod.
(b) Coat the oil seal with consistent grease, and install it at the corresponding plate on the piston.
(c) Cover the piston sleeve at the piston rod, install 4 screws on the end face of piston, and turn the
screws with spanner to screw the piston in.
(d) After screwing down the piston, fit the shaft lock key and clipping key cap, and then install the
retainer ring on the piston with snap ring pliers.
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(b) Vertically fix the oil cylinder, lift the piston rod by traveling crane, align the cylinder body, and
install the piston in the cylinder till the upper end face of guide sleeve is lower than the groove
seizing face of cylinder body.
6.10.4 Necessary Tools for Disassembly and Assembly of Horizontal Oil Cylinder
Name Model Qty.
Vice 300 1
Driver - 1
6.11 Structure and Maintenance of Winch Hydraulic Motor

6.11.1 Structure and Working Principle of Winch Motor
1. Structure of Winch Motor
The crane of this series adopts the oblique shaft variable plunger hydraulic pump (the motors for main
and auxiliary winches are of the same model). The motor is principally made up of output shaft,
bearing, central connecting rod, cylinder body, motor shell, limit screw, oil distribution disc, plug for
leakage orifice, spring clamp, and shaft seal, which are shown in the figure.
1-Output shaft 2-Bearing 3-Central connecting rod 4-Cylinder body 5-Motor shell 6-Limit
screw 7- Oil distribution disc 8-Plug for leakage orifice 9-Shaft seal 10-Spring clamp
Fig 6-12(1) Structure of Winch Motor
2. Working Principle of Winch Motor
Figure 6-12(2) presents the Working principle of winch motor. The pressure oil can enter the hydraulic
motor through the oil inlet and outlet (A or B) on the end plate 4, can enter the plunger chamber of
cylinder body 3 through the oil distribution disc, and can push out the plunger 2 to press on the
spherical hinge disc of output shaft. The component force of plunger’s press at the tangent direction of
circumference can generate the moment for output shaft to drive the output shaft 1 to turn. The
continuous supply of pressure oil can make the output shaft continuously revolve, and hence supply
the power for executing device.
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Oil-in
Oil-out
1-Output shaft 2-Plunger with piston ring 3-Cylinder body 4-End cover
Fig 6-12(2) Schematic Diagram for Operation
6.11.2 Analysis on Common Malfunctions of Winch Motor

The analysis on the common malfunctions of winch motor is presented in Table 6-6 (1), which lists the
malfunctions possibly caused in relation to the winch motor, and can be used for inspection as reference.
Many parts generate such malfunctions, but only the reasons related to the winch motor and irrelevant to
the product quality and design are listed in the table. As for the troubleshooting of the same malfunctions at
other parts, please refer to other chapters. It is necessary to carefully analyze on site whether it is caused
by the motor itself or by installation, so as to conduct the purposeful servicing.
Table 6-6(1) Common Malfunctions of Winch Motor
Malfunction Causes Related to the Winch Motor
Severe inside leakage, and much oil leaking from the oil drain tube:
The sliding cooperating face between the plunger and the cylinder hole is worn or
pulled into an axial through groove, so that the cooperating clearance between the
plunger and the cylinder hole is widened, and hence the pressure oil will leak into
the inside empty chamber of motor through this clearance (drain out from the oil
drain tube).
Slow raise and fall
The spring is overused, and the joint face of oil distribution disc and cylinder isn’t
of hook
close.
The bearing is worn, and the radial force generated by cylinder results in the
wedge-shaped clearance between the cylinder and the oil distribution disc.
Improper displacement adjustment:
The overlarge adjustment of the displacement of variable motor will also result in
slow speed.
The joint face isn’t close due to loose screws.
Oil leakage The sealing elements of joint face are broken.
The frame oil seal of output shaft is broken.
Loud noise, and Shoe looseness: It refers to the looseness of sliding shoe from plunger head, which
great vibration and is one of the common mechanical failures of axial plunger motor, and will intensify
pressure fluctuation vibration and noise. The main reason is the wedging of pollutant grains in the oil, or
63
the long service time.
The clutches of motor’s output shaft is installed with different centers.
The joint of pipeline adaptor is loose (esp. the oil inlet), so air enters the hydraulic
motor.
The journals of the bearings at two ends of output shaft are severely worn.
6.11.3 Replacement of Winch Motor

Step1. Make sure that the pump stops working, repeatedly turn the winch control handle to unload the
winch circuit, and avoid the oil jetting when disassembly.
Step2. Dismantle the oil-in & oil-out tube, oil drain tube and oil control tube connecting with winch
motor and winch balanced valve. And seal the tube orifice with clean plastic cover or plug in time, so
as to prevent the hydraulic circuit from pollutants.
Step3. Dismount the balanced valve from the hydraulic motor, and seal the joint.
Step4. Screw down the bolts connecting with winch motor and winch tube body, and pull out the
output shaft of winch motor from the winch spline.
2. Assembly Method
Step1. Coat the output shaft of new winch motor with a little butter, and insert it in the spline shaft of
winch drum. Coat the connecting bolt with fastening adhesive, and then install it on the flange of
winch drum.
Step2. Install the winch balanced valve, and make sure that the mounting direction is at the oil outlet
when the rope is releases.
Step3. Connect the oil tube with the winch motor and the balanced valve, and make sure that the oil
draining outlet is at the leakage orifice at the top of winch motor.
Step4. Fill oil to check whether the winch motor is properly installed, and operate the hook with load to
make sure that the balanced valve is properly installed and then formally put it into use.
6.11.4 Replacement of Internal Parts of Winch Motor
Disassembly Steps
(1) Screw down the screw fixing rear cover to take off the rear cover. And protect the oil distribution disc
and other parts.
(2) Pull out the piston cylinder, and place it at proper site.
(3) Clip out the spring clamp at the output shaft end with the external snap ring pincers, and dismantle the
end plate, bearing, and output shaft (with piston on the transmission shaft).
(4) Dismount the ball pressure plate of plunger to take off the piston.
(5) The assembly order is contrary to the disassembly order. However, it is required to align the oil
distribution disc when assembly (one axis pin for alignment).
1. Tools
Name Model Qty.
Ringent spanner 6~27 1
2. Precautions
It is better not to directly disassemble the winch motor, and please contact our after-sale service
personnel if the winch motor generates any internal problem that will be solved by professional
64
manufacturer.
Remember the mounting position of each joint and part during the disassembly.
Any part shall be cleaned before being installed in the motor, and the pump shall be free of foreign
substances. It is forbidden to dismantle the hydraulic pump with hammer or other hard tools or by
means of beating. It is better not to damage the parts or scrape the seal cooperating face during the
disassembly.
6.12 Structure and Maintenance of Slewing Motor

6.12.1 Structure, Working Principle and Common Malfunctions of Slewing Motor
The slewing motor of the crane of this series is the swash plate dosing plunger hydraulic motor.
1. Working Principle of Slewing Motor
Classified to be plunger motor, the slewing motor bears the similar Working principle as the winch
motor’s (refer to the chapter for winch motor). As for difference, since the slewing motor is of
swashplate type, while the winch motor is of the oblique shaft type, so their layouts are different.
2. Analysis on Common Malfunctions of Slewing Motor
The analysis on the common malfunctions of slewing motor is presented in Table 6-7 (1), which lists
the malfunctions possibly caused in relation to the slewing motor, and can be used for inspection as
reference. Many parts generate such malfunctions, but only the reasons related to the slewing motor
and irrelevant to the product quality and design are listed in the table. As for the troubleshooting of the
same malfunctions at other parts, please refer to other chapters. It is necessary to carefully analyze
on site whether it is caused by the motor itself or by installation, so as to conduct the purposeful
servicing.
Table 6-7(1) Common Malfunctions of Slewing Motor
Malfunction Causes Related to the Slewing Motor
Severe inside leakage, and much oil leaking from the oil drain tube:
The sliding cooperating face between the plunger and the cylinder hole is worn or
pulled into an axial through groove, so that the cooperating clearance between the
plunger and the cylinder hole is widened, and hence the pressure oil will leak into the
Slow slewing
inside empty chamber of motor through this clearance (drain out from the oil drain
speed or
tube).
no-slewing
The spring is overused, and the joint face of oil distribution disc and cylinder isn’t
close.
The bearing is worn, and the radial force generated by cylinder results in the
wedge-shaped clearance between the cylinder and the oil distribution disc.
The joint face isn’t close due to loose screws.
Oil leakage The sealing elements of joint face are broken.
The frame oil seal of output shaft is broken.
Shoe looseness: It refers to the looseness of sliding shoe from plunger head, which is
one of the common mechanical failures of axial plunger motor, and will intensify
Loud noise, and vibration and noise. The main reason is the wedging of pollutant grains in the oil, or
great vibration the long service time.
and pressure The clutches of motor’s output shaft is installed with different centers.
fluctuation The joint of pipeline adaptor is loose (esp. the oil inlet), so air enters the hydraulic
motor.
The journals of the bearings at two ends of output shaft are severely worn.
65
6.12.2 Replacement Steps of Slewing Motor
Step1. Make sure that the oil pump stops working, repeatedly turn the slewing control handle to
unload the winch circuit, and avoid the oil jetting when disassembly.
Step2. Dismantle the oil-in & oil-out tube and oil drain tube connecting with slewing motor. And seal
the tube orifice with clean plastic cover or plug in time, so as to prevent the hydraulic circuit from
pollutants.
Step3. Screw down the bolts connecting with slewing motor and slewing reducer, and pull out the
output shaft of slewing motor from the spline shaft of slewing reducer.
Step4. Coat the output shaft of new slewing motor with a little consistent grease, and insert it in the
spline shaft of slewing reducer. Coat the connecting bolt with fastening adhesive, and then install it on
the flange of slewing reducer.
Step5. Connect the oil-in & oil-out tube and the oil drain tube with the slewing motor.
Step6. Fill oil to check whether the winch motor is properly installed, whether the optional direction is
correct, and then formally put it into use.
6.12.3 Replacement of Parts of Slewing Motor
Step1. Screw down the screw fixing rear cover to take off the rear cover. And protect the oil
distribution disc and other parts.
Step2. Pull out the piston cylinder, and place it at proper site.
Step3. Clip out the spring clamp at the output shaft end with the external snap ring pincers, and
dismantle the end plate, bearing, and output shaft (with piston).
Step4. Dismount the ball pressure plate of plunger to take off the piston.
Step5. The assembly order is contrary to the disassembly order. However, it is required to align the oil
distribution disc when assembly (one axis pin for alignment).
1. Tools
Name Model Qty.
Ringent spanner 6~27 1
Copper bar Φ　　　
  1
2. Precautions
It is better not to directly disassemble the slewing motor, and please contact our after-sale service
personnel if the slewing motor generates any internal problem that will be solved by professional
manufacturer.
Remember the mounting position of each joint and part during the disassembly.
Any part shall be cleaned before being installed in the motor, and the pump shall be free of foreign
substances. It is forbidden to dismantle the hydraulic pump with hammer or other hard tools or by
means of beating. It is better not to damage the parts or scrape the seal cooperating face during the
disassembly.
66
7. Electrical System of Superstructure
7.1 SYML Torque Limiter
7.1.1 Composition and Functions of SYML Torque Limiter
SYML series torque limiter (in short: limiter) consists of a controller (SYMC), a touch screen display,
length/angle sensors, hydraulic pressure sensors and height limiter, etc.
Through its pressure, length and angle sensors and other status monitors, the system collects real-time
working status parameters about the truck crane, and after processing the data, it can precisely judge
whether the truck crane is working within safety ranges, and shows the actual working conditions of the
truck crane on the LED display visually & truthfully by means of Chinese characters/graphics, including:
arm length (L), working angle (A), working condition, ratio, maximum weight (MW), actual weight (AW),
swing (S), and torque percentage (P).
When the loaded torque of the truck crane exceeds 90% of the maximum torque, SYML will timely give out
warning signals; when the loaded torque exceeds 100% of the maximum torque, warning signals is sent
out and through the truck crane control mechanism, the truck crane movement towards the dangerous
directions is cut off promptly to only allow it moves towards the safe directions; when the hook ascends to
its height limit, warning signals will be sent out, and the lifting ascending and boom dropping movements
are promptly cut off; when the truck crane rope is released to the position of only 3 layers left on the winch,
the rope release is promptly cut off; when the lifted object’s weight equals to or is bigger than 30% of the
maximum load, the boom telescopic movement is promptly cut off. All the safeguarding motions can be
turned off through the overload-relief switch, and some of the safeguarding motions can be turned off by
the enforce switch. However, the overload-relief switch should be utilized with discretion.
7.1.2 Basic Troubleshooting Methods
1 The display alarm Use a multimeter to check whether the controller has 5V power output (the
column potential of #19 pin of the controller A2 terminal (smaller terminal) should
indicates\Length be 5V+, while that of the #34 pin of the controller A1 terminal be 5V-).
sensor Use a multimeter to check the length sensor communications cable
communication (whether there is voltage output between #10 pin of the controller A2
failure terminal (smaller terminal) and #34 pin of the sensor grounding cable
(controller A1 terminal (bigger terminal)).
Check whether #10 pin of the length sensor communications cable (the
controller A2 terminal (smaller terminal)) is connected.
column potential of #19 pin of the controller A2 terminal (small terminal) should be
indicates\Angle 5V+, and that of #34 pin of the controller A1 terminal be 5V-).
sensor Use a multimeter to check whether there is voltage output between #11 pin
communications of the controller A2 terminal (small terminal) of the angle sensor
failure communications cable and #34 pin of the sensor grounding (the controller
A1 terminal(bigger terminal)).
Check whether #11 pin of the angle sensor communications cable (the
controller A2 terminal (smaller terminal) is connected.
column potential of #19 pin of the controller A2 terminal (small terminal) should be
indicates\Main 5V+, and that of the #34 pin of the controller # A1 terminal be 5V-).
chamber pressure Use a multimeter to check whether there is voltage output between #8 pin
sensor of the controller A2 terminal (smaller terminal) of the main chamber
communications pressure sensor communications cable and #34 pin of the sensor
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failure grounding (the controller A1 terminal(bigger terminal)).
Check whether #8 pin of the main chamber pressure sensor
communications cable (the controller A2 terminal (smaller terminal) is
connected.
4 The display alarm Use a multimeter to check whether the controller has 5V power output(the
column potential of #19 pin of the controller #A2 terminal (small terminal) should be
indicates\Small 5V+, and that of #34 pin of the controller # A1 terminal be 5V-)
chamber pressure Use a multimeter to check whether there is voltage output between #9 pin
sensor of the controller A2 terminal (smaller terminal) of the small chamber
communications pressure sensor communications cable and #34 pin of the sensor
failure. grounding (the controller A1 terminal(bigger terminal)).
Check whether #9 pin of the small chamber pressure sensor
communications cable (the controller A2 terminal (smaller terminal)) is
connected.
5 No overrelaxing When overrelaxing happens, check the display whether there is
protection overrelaxing protection indication on it; if not, check the overrelaxing signal
cable (see if the overrelaxing alarm is sending out signals, and whether the
overrelaxing signal cable is connected with #28 pin of the controller A1
terminal (smaller terminal)).
Check whether the terminal of the corresponding controlling
electromagnetic valve of the controller is connected to the electromagnetic
valve circuit (#2 pin of the A1 terminal).
Check whether there is 24V output from the terminals of the corresponding
controlling electromagnetic valve of the controller.
6 No overwinding When overwinding happens, check whether there is overrelaxing protection
protection indication on the display, if not, check the overwinding signal cable (see
whether the height limiter is sending out signals, and if the overwinding
signal cable is connected with #29 pin of the controller #A1 terminal
(smaller terminal).
Check whether the terminal of the corresponding controlling
electromagnetic valve of the controller is connected to the electromagnetic
valve circuit (#1 pin of the A1 terminal).
Check whether there is 24V output from the terminals of the corresponding
controlling electromagnetic valve of the controller.
7 The indicated Perform length calibration.
boom length on Adjust the length sensor potentiometer or gears before performing the
the touch screen length calibration.
does not change
along with the
changes of the
boom and
remains to be one
certain value,
normally 0, or the
indicated length is
not accurate.
68
8 While the load is Check whether the indicated working condition is correct and the indicated
empty the torque ratio is correct.
percentage alarm
is on or the
telescopic or
swing protection
is on.
9 The indicated The calibrated minimum angle is too small. The minimum calibrated angle
angle value should be above 1 degree.
doesn’t change The display version doesn't match with that of the controller, and so the
along with the program shall be re-downloaded.
boom swinging Check the resistance value of the angle sensors #2 & #3, they should
movements and change along with the left & right revolving motions.
remains to be a
certain value,
normally 0, or the
indicated angle is
not accurate.
10 Indicated weight Make sure if the working condition choice was correctly made.
not accurate Set the parameters following the stipulations in the manual.
Accurately calibrate the length & angle parameters.
11 Indicated Make sure if the working condition choice was correctly made.
swinging value Set the swinging value following the stipulations in the manual.
not accurate
12 Display functional Replace the display.
keys failure
7.2 Length/angle Sensor

7.2.1 Structure & Principle
The length & angle sensor is a measuring device used to measure the boom length and angle values, it
consists of a length sensor, an angle sensor and a central conductive ring (see figure below).
The working of the length sensor is that through pulling the cord it drives the gearing potentiometer to
change its resistance, and then the controller calculates lengths by picking up the potentiometer’s
feedback voltage values. The terminal #1 & #3 pins are connected to the positive and negative poles of the
length sensor power supply, and # 2 pin is connected to the signal cable. The voltage supplied to the
length sensor is 5V, the resistance is 0~5 k Ohms, and the practical measuring range is 0~52 m.
The working of the angle sensor is that through the changes of the main boom angle, it drives the angle
sensor to change its relative position which in turn changes the internal potentiometer’s resistance value,
and then the controller calculates angles by picking up the potentiometer’s feedback voltage values. The
terminal #7 & #9 pins are connected to the sensor power supply’s positive and negative poles, and #8 pin
is connected to the signal cable. The voltage supplied to the angle sensor is 5V, the resistance is 0~2.5 k
Ohms, and the measuring range is -10~90 degree.
The central conductive ring is used for transmitting signals. Currently in the cord switch it contains 3
communications cables, the white cable is used for transmitting the signals of height limiting switch, the
blue cable is used as power cord for boom top lamp, and the remaining one is not utilized at present. The
terminal #4 pin is connected to the signal cable of the height limiting switch, and #5 pin is connected to the
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power cord of the boom top lamp.
No power supply with the sensor, there is no voltage between the

Replace the
controller A2-19 & A1-34 pins (normally it should be 5V), or the
The display controller
output pins are damaged.
prompts that
No output voltage from the sensor signal cable indicates the sensor Replace the
the length or
is damaged. controller
angle sensor
Sort out the
signal is Open circuit with the sensor power cord or signal cable
circuit
interrupted
Replace the
The controller signal-collecting pins damaged.
controller
The sensor potentiometer drifts, the initial resistance of the length
sensor potentiometer is approximately 600 Ohms, and the initial Re-calibrate the
resistance of the angle sensor potentiometer is approximately 800 torque limiter
Ohms.
Irregular changes with the sensor potentiometer resistance indicate Replace the
the potentiometer gets damaged. sensor
Inaccurate Broken length sensor cord. Rewind the cord

display of
Inside the length detector the transmission gears skid with each Re-adjust the
length or
other engagement
angle
clearance of
gear.
Re-wind the cord,
The length sensor cord doesn’t return to its original place and adjust the
wire-frame
Interference with the sensor signal cord or poor grounding with the Sort out the
concealed cord circuit
7.3 Height Limiting Switch (Overwinding Prevention Switch)

7.3.1 Structure and Principle
When the lifting hook exceeds the specified height, it pulls up the counterweight, the cord switch then loses
the pulling force of the counterweight and leads to its internal contacts closure, and the control cable is
connected to the grounding terminal on the boom; consequently via the length & angle sensor central
sliding ring, the grounding signal is transmitted to A1-11 pin of the SYMC motion controller, through the
SYMC internal programming control, the output from A1-27 pin is a high potential of 27V, the
corresponding electromagnet is energized and the controlling pressure of the hydraulic system is
unloaded, thus such motions as hook lifting, boom extension and boom bending etc. are cut off to ensure
safety. At this time it is only allowable to operate the handles to control hook dropping, boom retraction and
boom lifting (viz. movements toward the safety directions), so as to remove constraints from the limiting
counterweight and then the operations can resume its normal state.
While STC75 series truck crane is performing its height limiting function, the grounding signal is
transmitted to A1-11 pin of the SYMC motion controller, and the output from several corresponding pins
changes from 24V to 0V, which cause their corresponding electromagnetic valve to de-energize, the
70
controlling pressure is unloaded and therefore the protective action is realized.
The inspection method for height limiting switch is: using a multimeter to check the overwinding switch
condition: while being pulled down it is disconnected, and while being propped up it is connected.

While the Inside the switch the contacts stick together and close for long
Replace the switch
counterweight time
is not propped Length & angle sensor central sliding ring abnormally damaged, Replace length &
up, the short-circuited, cord damaged, or grounding cord scratched angle sensor
display Wrong wiring, with grounding signal (low voltage signal)
Sort out the wiring
prompts: transmitted into A1-11 pin of the SYMC controller
height limiting Damaged SYMC controller output pins Replace the SYMC
The counterweight damaged, or with insufficient weight to trigger Replace qualified
the switch contacts closure counterweight.
Switch failure makes the contacts closure impossible Replace the switch
While the The length & angle sensor central sliding ring damaged, open Replace the length &
counterweight circuit, or cord partial open circuit angle sensor
is propped up Bad connection with the connectors, and bad connection with the
Re-connect it
the height SYMC AMP terminals
limiter doesn’t Wrong wiring, with the grounding signal unable to be transmitted
Sort out the wiring
function into A1-11 pin of the SYMC controller
properly Damaged SYMC controller output pin(s), so the received
Replace the SYMC
grounding signal cannot be properly exported
Replace or clean up
Electromagnet failure or seizure of the valve core
the electromagnet
7.4 Other Electrical System Malfunctions of Superstructure

1. Replace the switch
2. Re-connect the
Wiper switch failure, and loosened wiring connector, to make sure
No action of the wiper or good contact with the
slow motion with wiping inserts
arm(the 4-hole connector’s Replace the fuse with one
Wiper fuse melted.
red, yellow, green and blue of same spec.
wires control motor positive Malfunction of wiper motor Replace the motor
pole, reset, low speed and Find out the open-circuit
high speed respectively) Bad grounding or open circuit with the wiring point, and then re-connect
the wire
Wiper arm fixing screw over- tightened or Readjust the tightening or
motor failure replace the motor.
While the lifting is dropping,
the 3-layer protection
mechanism doesn’t The 3-layer protector’s cam position not Re-adjust the cam position
function properly adjusted when the rope lifting
reaches to 3-layer
71
remaining on the winch to
enable the jog switches
contacts closure.
Damaged jog switch with the 3- layer Replace the jog switch or
protector, the closure cannot be realized 3-layer protector.
Poor wiring or open circuit, with the grounding
Check the wiring and
signal generated by over-relaxing unable to be
circuit
transmitted into the controller
The controller output pins failure. Replace the controller.
Malfunction of over-releasing unloading
Clean up or replace the
electromagnetic valve or seizure of the valve
electromagnetic valve.
core
The lamp broken Replace it
Bad connection with the terminals, or open
Repair it
The turntable or base boom circuit with the wires
lamp doesn’t work The lamp relay contacts closure disabled Replace the relay
The fuse melted Replace it
The rocker switch failure Repair or replace it
Loosened ignition lock wiring Re-connect it
The start ignition of the cab Damaged ignition lock Replace the ignition lock
is workable, whereas the Check the wiring or
Bad contact with the conductive ring connector
superstructure ignition replace the conductive
or malfunction of the conductive ring
switch cannot start ring
Malfunction of the superstructure ignition relay Replace the relay
1. Replace the engine oil
After the ignition, alarm of engine oil pressure
pressure sensor
keeps being sent out and the generator center
2. Find out the wiring
voltage cannot be transmitted into the
break point and re-wiring.
controller
3. Replace the generator
The air conditioner doesn’t
Malfunction of the air conditioner control Replace the air conditioner
function
panel control panel
Bad connection of the connector between the
Re-connect it
electric cabinet and the control panel
Malfunction of the evaporator fan, the
Replace it
condenser fan or the harness
Bad connection with the controller B2-03
Re-connect it
The buzzer doesn’t work output pin
properly Damaged controller B2-03 output pin Replace the controller
Damaged buzzer Replace the buzzer
72
8. Maintenance
To guarantee the safety in operation and high efficiency, the truck crane shall be regularly checked each
week (if it is under bad weather, the check interval shall be shortened). If the abnormality is found, it shall
be timely repaired.
8.1 General Check

8.1.1 Check of Work Oil Liquid Level
z Liquid level of hydraulic oil tank;

z Lubricating oil level in transfer case;
z Engine oil level of chassis
8.1.2 Check whether all safety equipment are at proper locations and with complete functions
z Check whether each caution plate is intact.

z Check whether each auxiliary safety device is intact.
8.2 Check of Driving Device

1. Operating rod and switch
2. PTO
z Check whether it is loose or leaky.

z Check whether there are abnormal noise and heating.
8.3 Check of Hydraulic System

8.3.1 Hydraulic Oil Tank
z Check whether there is looseness or damage.

z Check whether there is crack or oil leakage.
z Check for the oil quantity, dustiness and viscosity.
z Check whether the filter is blocked and then clean it if necessary.
8.3.2 Hydraulic Pump

z Check whether it is loose or damaged.
z Check for the noise, vibration and heating.
z Check for oil leakage.
z Check whether the oil suction pipeline sucked air in.
z Check the oil supply pressure.
z Check whether the pipeline connector is loose or leaky.
8.3.3 Overflow Valve
z Adjust the pressure
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8.3.4 Control Valve
z Check for the action state.

z Check the bolt for looseness.
8.3.5 Luffing and Telescopic Cylinders
z Check for the action state.

z Check for the brake oil volume.
z Check the hose for aging, distortion or abrasion.
8.3.6 Pipeline
z Check whether the connecting position is loose.
z Check the clamp for looseness or crack.
z Check the hose for aging, distortion or damage.
8.4 Check of Slewing Mechanism

8.4.1 Brake
z Check for the braking performance.
z Check the connecting rod for distortion or abrasion.
z Check the lubrication.
8.4.2 Slewing Connector

z Check for abnormal noise, vibration or heating in slewing state.
8.4.3 Reductor and Slewing Mechanism

z Check for oil volume and dustiness.
z Check the reductor for crack, distortion and oil leakage.
z Check for abnormal noise and vibration.
z Check the mounting parts for looseness.
z Check whether the working pressure of hydraulic motor is normal.
z Check the oil pipe connector for looseness or oil leakage.
8.5 Check of Derrick Mechanism of Main Boom

8.5.1 Luffing Cylinder of Main Boom
z Check whether the locking plate bolt of pin-connected shaft is loose.
z Check for the vibration or noise.
z Check whether the cylinder can naturally retract in case of overweight operation.
z Check the hose for aging or distortion.
z Check the pin-connected shaft for abrasion or damage.
74
8.5.2 Balance Valve
z Check for the pulsation.
8.6 Check of Telescopic Mechanism of Main Boom

8.6.1 Main Boom
z Check for crack, bending or damage.
z Check the locking bolt of pin-connected shaft at the bottom of main boom for looseness.
z Check the sliding surface for scuffing.
z Check the pin-connected shaft sleeve for abrasion or damage.
z Check the lubrication of sliding surface.
z Check the main boom support for distortion or crack.
8.6.2 Telescopic Cylinder of Main Boom

z Check for the action state (pulsation and noise)
z Check whether the action order is normal.
z Check the functions of balanced valve.
z Check whether the oil pipe connector is loose.
8.6.3 Jib
z Check for the crack, bending or damage.
z Check the lubrication of connecting pin and pin sleeve.
8.6.4 Steel Wire

z Diameter
z Broken wire
z Kink
z Distortion
z Rust
z Lubrication
z Tension
8.7 Check of Lifting Mechanism

8.7.1 Reductor
z Check the mounting parts for looseness or crack.
z Check for noise.
z Check the gear box for crack, distortion or oil leakage.
z Check the abrasion of bearing.
z Check for lubrication.
75
8.7.2 Brake
z Check the abrasion of brake piece and liner.
z Check whether the spring is distorted.
8.7.3 Balance Valve

z Check for pulsation.
8.7.4 Winding Drum

z Check for crack.
z Check the steel rope for winding.
8.7.5 Jib
z Check for the crack, bending or damage.
z Check the connecting pin and pin sleeve for lubrication.
8.7.6 Lifting Hook and Sheave

z Check the slewing state of lifting hook.
z Check for distortion.
z Check whether the cross beam swings normally.
z Check for the connection between the cross beam and lifting hook.
z Check the retaining device for distortion.
z Check the slewing state of sheave (for abnormal noise).
z Check the sheave for crack or abrasion.
z Check the support and protective cover of sheave for bending or damage.
z Check lubrication.
8.7.7 Steel Rope

z Diameter
z Broken wire
z Kink
z Distortion
z Rust
z Check whether the wire sleeve and wedge are in the right place.
z Check for the connection between the steel rope and wire sleeve.
z Check the axis pin of wire sleeve and bushing for abrasion or crack.
z Check whether the steel rope gets through the sheave normally.
8.8 Check of Control System of Truck Crane

8.8.1 Start Switch
z Check the functions of start switch.
z Check for the mounting conditions.
z Check for the action of indicator lamp.
76
8.8.2 Wiper
z Check for action
z Check the blade for abrasion or damage.
8.8.3 Inner Lamp

z Check whether the inner lamp can be lighted up.
8.8.4 Buzzer
z Check the functions of buzzer.
8.8.5 Automatic Force Limiter

z Check for action state.
z Check for precision.
8.8.6 Overwinding Stop Device (altitude limiter)

z Check for action.
z Check whether the hammer sling is damaged.
z Check for action of electromagnetic valve.
8.8.7 Superstructure Cab

z Check whether the nut and bolt are loose.
z Check the switching function of window and door.
8.8.8 Pressure Gauge

z Check whether the meter needle is moving evenly.
z Check whether the connection is loose.
8.8.9 Control Handle and Pedal

z Check the functions.
z Check for the oil clearance.
8.8.10 Working Lamp

z Check whether the working lamp is lighted up.
z Check whether the working lamp is damaged.
8.8.11 Top Lamp of Boom
z Check whether the top lamp can be lighted up.
8.9 Check of Outrigger Mechanism

8.9.1 Vertical Cylinder of Outrigger
z Check whether the vertical cylinder can retract naturally during the lifting operation.
z Check whether the vertical cylinder falls naturally during the motion.
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z Check the function of hydraulic one-way valve.
z Check for noise or looseness.
z Check the outrigger plate for distortion or damage.
8.9.2 Fixed Outrigger Box, Movable Outrigger Box and Level Cylinder of Outrigger
z Check for distortion or damage.
z Check whether the fixing pin and pin sleeve of movable outrigger box are loose.
z Check whether there is crack or distortion on the bracket.
z Check for noise or vibration.
z Check whether the oil pipe and hose are connected loosely.
8.9.3 Control Valve of Outrigger

z Check for action.
z Check whether the bolt is loose.
8.9.4 Leveling Gauge

z Check whether there are scuffing and distortion on the appearance.
z Check for the bubble state.
8.9.5 5th Outrigger Cylinder

z Check for action.
z Check the brake oil volume.
z Check whether the hose is aged, distorted or damaged.
78
Caution
z In the regular monthly check, if the bolts for mounting the slewing bearing are found loose,
re-fasten them at the maintenance station.
z In addition, it is recommended to conduct a check each year and confirm the bolts for
mounting the slewing bearing in conformity with the stipulated fastening state. The frequent
check cycle depends on how heavy the work is and how rough the environment is, but it is
unable to be lower than once every month. The regular check cycle depends on how heavy
the work is and how rough the environment is, but it is unable to be shorter than once every
year.
z The crane under the following conditions shall be tested in line with the relevant standards:
(a) The test shall be carried out once per two years for the crane under normal operation;
(b) Before the handover of the truck crane after being overhauled, re-installed or modified;
(c) Before the re-use of the crane after leaving unused for more than 1 year;
(d) The crane possibly with the intensity, rigidity, stability of structural parts as well as
importance of mechanisms damaged after undergoing rainstorm, violent earthquake as
well as momentous accidents.
8.10 Lubrication of Superstructure

The lubrication of superstructure part is a key factor of extending the service life of truck crane, please
make sufficient lubrication regularly according to the lubricating map and
chart.
79
Cycle and Method of Lubricating Maintenance
Lubricating
No. Lubricated Location Cycle of Lubrication Lubricating Oil Grease
Method
Sheave group of the main Inject oil with oil General lithium-based
1 Every week
lifting hook gun grease
Lifting sheave group of the Inject oil with oil General lithium-based
2 Every week
main boom gun grease
Slide blocks of every section Coat with oil, inject General lithium-based
3 Every week
of the main boom oil with oil gun grease
Surface of slide blocks of the
General lithium-based
4 every section of the main Every week Coat with oil
grease
boom
Upper and lower
Inject oil with oil General lithium-based
5 pin-connected shafts of luffing Every week
gun grease
cylinder
6 Sheave of jib Before the Use
gun grease
Rear pin-connected shaft of Coat with oil, inject General lithium-based
7 Every week
the main boom oil with oil gun grease
According to the Inject oil with oil Extreme pressure
8 Slewing bearing
requirement of 5.2 gun lithium-based grease
9 Pinion of slewing mechanism Every week Coat with oil
grease
10 Auxiliary lifting hook Before the Use Coat with oil
grease
11 Steel rope Every week Coat with oil
grease
Steel rope (for the retraction of General lithium-based
12 Every week Coat with oil
the main boom) grease
13 Outrigger plate Every week
gun grease
14 Lifting bearing seat Every month
gun grease
Notes
Before filling oil, clean the grease nipple and surface to be coated.
The slide surface unlisted in the table shall also be coated with lubricating oil regularly.
When the main boom retracts on the frame of the main boom, if the piston rod of the luffing oil
cylinder of the main boom is exposed partly, the exposed part shall be coated with lubricating
grease monthly.
Main and Auxiliary Winch reducers
After the new machine works for 100 hours, the lubricating oil in the reducer shall be replaced once, and
after it works for another 500 hours, the oil shall be changed another time, later on, the oil shall be
changed once after it works for 1000 hours or at least once per year. The specific grade shall be based on
80
the lubrication chart.
Slewing Reducer
Check the height of the lubricating oil each day through the transparent glass of the slewing mechanism,
and timely fill it when it is insufficient. After the new machine works for 150 hours, the lubricating oil shall be
changed once, and later on, after it works for 1500 hours, the oil shall be changed once or at least once
per year.
Notes
If the gear oil is found contaminated seriously, change it even the cycle of changing oil is undue.
Regularly check the oil level, fill oil if the oil level is lower than the value stipulated.
Lifting mechanism: the 220 (40℃) L-CKD220 Great Wall gear oil of 1.5L shall be filled. After
dismounting the oil injection faucet on the hydraulic motor, fill the sufficient oil.
Slewing mechanism: the 220 (40℃) L-CKD220 Great Wall gear oil of 4.5L shall be filled. After
dismounting the oil injection faucet on the slewing reducer, fill the sufficient oil.
81
9. Common Malfunctions and Troubleshooting of Superstructure
9.1 Overview
The truck crane is a kind of machinery which can lift the weight vertically and move the weight horizontally
at the same time. The malfunctions of the truck crane shall affect the construction progress of users, bring
negative influences on the economic and social benefits of both sides, even result in casualties of
personnel, so the malfunctions shall be timely found and then eliminated to redeem the economic loss of
users and maintain the enterprise image of both sides. The following precautions shall be mastered when
eliminating the malfunctions:
(I) Acquaint and get to know the performance of the truck crane and the structural fundamental of parts;
(II) Master the operation essentials and carry out the proper operation in strict accordance with the User’s
Guide;
(III) Search malfunctions following the principles from the exterior to the interior, the outside to the inside,
and the simple to the complicated;
(IV) Find the abnormalities by touching, seeing, listening and smelling;
(V) Accumulate experiences, and master the rule of malfunctions occurrence.
To make users find out malfunctions and then eliminate them as soon as possible, the chapter will
describe the common malfunctions and the corresponding troubleshooting from the mechanical,
hydraulic and electrical systems.
9.2 Diagnosis of Common Malfunctions and Troubleshooting on Mechanical

System of Superstructure
Diagnosis of Common Malfunctions and Troubleshooting on Mechanical System of Superstructure are
shown in Table 9.1:
Table 9.1 Diagnosis of Common Malfunctions and Troubleshooting
on Mechanical System of Superstructure
No. Malfunction Cause Troubleshooting
Inappropriate adjustment of the clearance
Adjust it
between the slide blocks of the boom
The retraction shake of
1 Coat it with lubricating
main boom The slide block in short of lubricating grease
grease
The telescopic boom rope loosened Adjust it
The linkage shaft abraded or in short of Repair it and fill the
The luffing shake of lubricating grease lubricating grease
2
main boom The pin-connected bearing on the oil cylinder
Replace with new parts
damaged
The big boom deformed Check and repair it
The main boom not Malfunction of the telescopic mechanism,
3
retracting such as the retraction boom rope damaged, Check and repair it
trip over the groove or the sheave damaged
The outrigger Adjust the clearance
4 stretching out The fixed outrigger box deformed between the free outrigger
asynchronously and the fixed outrigger
The Extension and
Adjust the clearance
retraction of the
5 The fixed outrigger box deformed between the free outrigger
outrigger with abnormal
and the fixed outrigger
noise
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9.3 Diagnosis of Common Malfunctions and Troubleshooting on Hydraulic System
The Diagnosis of Common Malfunctions and Troubleshooting on Hydraulic System of the main parts of the
truck crane are shown in Table 9.2:
Table 9.2 Diagnosis of Common Malfunctions and
Troubleshooting on Hydraulic System of Main Parts
No. Location Malfunction Cause Troubleshooting
Insufficient oil Fill oil
Air in the oil suction pipeline Repair and exhaust air
Hydraulic Mounting bolt loosened Screw down it
1 Abnormal noise
pump Hydraulic oil polluted Change oil or filtrate
Transmission shaft vibrating Repair it
Abrasion of the universal joint Replace it
Excessively low pressure of the
Adjust it to 20MPa
overflow valve in undercarriage
Overflow valve core blocked by Disassemble it for
No action
contamination washing
Failure of the multi-way valve in
Repair it
undercarriage
Dismount and wash the
Improper stroke of multi-way valve of
valve core, and adjust
2 Outrigger undercarriage
Slow action the tie rod mechanism
Excessively low adjusting pressure of
Adjust it
the overflow valve
The vertical oil Failure of the bi-directional hydraulic
WASH OR REPLACE IT
cylinder auto lock
retracted or extended Replace the relevant
in the lifting or travel Inner or outer leakage of the oil cylinder sealing parts or replace
state it.
3 Slewing Hydraulic motor damaged Repair or replace it
mechanism Malfunction of slewing mechanism
REPAIR IT
reducer or brake
No slewing Too low pressure of overflow valve of
Wash or adjust it
undercarriage
Malfunction of slewing control
Wash or replace it
electromagnetic valve
Too low pressure of overflow valve of
Wash or adjust it
undercarriage
Slow slewing Serious leakage of hydraulic motor Repair or replace it
Serious inner leakage of valve or Check and replace the
inappropriate slewing sealing
Heavy slewing impact Adjust it and check the
Malfunction of slewing balanced valve
and unstable damping in valve
Check the damping and
Malfunction of one-way throttle valve the accumulator
pressure in valve
83
Malfunction of slewing brake Check and repair it
Serious abrasion of slewing mechanism Check and repair it
Free slide electromagnetic valve
blocked without steering or malfunction Check and repair it
No free slide of the
of the electromagnetic valve circuit
slewing mechanism --
Adjust the pressure of
lockdown change Insufficient pressure in oil-in circuit of
low-pressure oil supply
brake
for main valve
Excessively low pressure of the
overflow valve in the superstructure Adjust it
No upward luffing multi-way valve
Serious inner leakage of oil cylinder Check and repair it
Serious inner leakage of main pump Check and repair it
Same as Item 1, 2 and 3 for “No upward
Check and repair it
luffing”
Derrick
4 No downward luffing Balanced valve core locked Wash or replace it
mechanism
Blockage of control oil circuit of
Wash it
balanced valve
Malfunction of balanced valve Wash and adjust it
Boom shaking in case
Too high secondary overflow pressure
of luffing downward Adjust it
when luffing downward
Auto retraction of Inner leakage of oil cylinder Repair or replace it
telescopic cylinder Inner leakage of balanced valve Wash or replace it
Too low pressure of secondary overflow
Wash and adjust it
valve for boom extension
Check and adjust it
No extension action luffing”
Check the relevant
Malfunction of telescopic control valve circuit, and repair the
control valve
Too low pressure of secondary overflow
Wash and adjust it
Telescopic valve for boom retraction
5
mechanism Balanced valve core locked Repair or replace it
Check and adjust it
No retraction action luffing”
Check the relevant
Malfunction of telescopic control valve circuit, and repair the
control valve
Inner malfunction of balanced valve and
Auto retraction in Repair it
failure of locking
working
Inner leakage of oil cylinder Repair it
No action of Excessively low pressure of the
Lifting
6 lifting/descending overflow valve in the superstructure Adjust it
mechanism
hook multi-way valve
Malfunction of the hydraulic motor Repair it
Serious leakage of the main pump Repair it
84
Blockage in the control oil circuit of the
Wash it.
balanced valve
Malfunction of the display signal of the
Repair it
force limiter
Malfunction of the brake oil circuit of the
Repair it
main valve
Malfunction of the overflow valve Wash and adjust it
Oil pump damaged Repair it
System pressure not
Malfunction of the central slewing joint Repair it
established
Malfunction of main control Repair the circuit and
7 Others electromagnetic valve electromagnetic valve
Overheating of the Serious inner leakage of the main pump Repair it
hydraulic oil and slow Serious leakage of lifting motor Repair it
motion of executive
Malfunction of the radiator Repair it
mechanism
9.4 Diagnosis of Common Malfunctions and Troubleshooting on Electrical System

The Diagnosis of Common Malfunctions and Troubleshooting on Electrical System are shown in Table 9.3:
Table 9.3 Diagnosis of Main Malfunctions and Troubleshooting on Electrical System
No. Malfunction Cause Troubleshooting
Bulb damaged Replace it
Failure of the working lamp, Fuse burned Replace it
1 main boom lamp and inner Poor earthing Repair it
lamp Break of conductor Repair it
Failure of switch Repair or replace it
Fuse burned Replace it
Failure of switch Replace it
2 No action of the wiper Motor damaged Replace it
Poor earthing Repair it
Break of conductor Repair it
Get in touch with the service
3 No sound of the buzzer Bad force limiter
station of the our company
Fuse burned or loosened Repair or replace it
No operation of the crane in
4 Break of conductor and failure of
the cab Repair or replace it
switch
Fuse burned Replace it
Bad action of the force Failure of relay Replace it
5
limiter Get in touch with our
Bad force limiter
company
6 Failure of altitude limiter Fuse burned Replace it
Malfunction of the coil box Repair or replace it
Break of conductor Repair it
Failure of limit switch Replace it
Break of hammer rope Replace it
Poor earthing of limit switch Repair it
85
Get in touch with our
Bad moment limiter
company
Check the 4-core plug of the
The guy of the length tester broken
cable and replace the guy
Inappropriate adjustment of the
Re-adjust it
potentiometer of the length tester
Malfunction of the length The transmission gear of the length Adjust the meshing
7
sensor tester sliding clearance of gear
Short circuit or break of the cables
Repair or replace it
and adaptor
Inappropriate setup of the length Get in touch with our
parameters company
Short circuit or earthing of the length
tester guy cable core wire and the Repair or replace it
8 Mistaken overwinding alarm shield wire
Earthing malfunction of the
Repair or replace it
overwinding switch
Short circuit or break of the cables Repair or replace the P1
Malfunction of the display
and adaptor cable adaptor
9 signal of the pressure
Malfunction of the P1 pressure Replace the pressure
sensor (P1)
sensor sensor
86

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STC75 Truck Crane

Hunan SANY Auto Hoisting Machinery Co., Ltd.

Hunan SANY Auto Hoisting Machinery Co., Ltd.

Hunan SANY Auto Hoisting Machinery Co., Ltd.

It is used to give the directive instructions to some specific information.

2. General Safety Requirements

Fig. 1 Example of Safety Words

Fig. 2 Example of Safety Signs

2) Make use of supporting columns or blocks;

2. Boom system ......................................................................................................................................... 3

7. Electrical System of Superstructure ...................................................................................................... 67

9. Common Malfunctions and Troubleshooting of Superstructure ............................................................ 82

1.2 Fundamental Structure

1-Boom system 2-Chassis 3.Electrical system

1.2.1 Composition of Superstructure

1.3 Overall Dimensions and Working Principles

Fig 1.2 Overall Dimensions

2.1 Composition of Main Boom

Fig. 2-1 Composition of Main Boom

2.2 Composition of Jib

2.3 Schematic Diagram of Telescopic Mechanism

2.3.2 Working Principle of Synchronous Retraction

2.4 Replacement of Base Boom

Fig 2-4(1) Outline Diagram of Base Boom

1. When the base boom bends, breaks, or distorts

1-Axis pin 2-Shaft baffle 3-Bolt 4-Big boom articulating shaft

12-Bolt 13-Nut 14-Supporting block 15-Axis pin

Fig. 2-4(3) Disassembly Fig. 2-4(4) Disassembly Details of base boom

The method of assembling base boom is in the reverse order of disassembling.

Fig. 2-5(1) Outline Diagram of 2nd Section of Boom

12-Bolt 13-Nut 14-Support block 15-Axis pin 16-Slide block ㈠

2.6. Replacement of 3rd Section of Boom

Fig. 2-6(1) Outline Diagram of 3rd Section of Boom

3rd section of boom

9-Nut 10-Pin 11-Support block 12-Bolt 13-Slide block

2.7 Replacement of 4th Boom

Fig. 2-7(1) Outline Diagram of 4th Section of Boom

5th section of 4th section

12-Nut 13-Pin 14-Support block 15-Bolt 16-Slide block17-Bolt 18-Shaft baffle

2.8 Replacement of 5th Section of Boom

Fig. 2-8(1) Outline Diagram of 5th Section of Boom

Fig 2-8(2) Disassembly Details of 5th Section of Boom

2.8.3 Assembly Method

2.9 Replacement of Jib

Fig. 2-9 Disassembly and Assembly Details for Jib

2.10 Replacement of Telescopic Mechanism

Fig. 2-10(1) Configuration for Telescopic Mechanism (I)

2.11 Replacement of Components of Boom Top Sheave

1- Turntable 2- Balance weight 3-Slewing reducer 4-Slewing bearing

3.1 Disassembly and Assembly of Balance Weight

3.2 Replacement of Slewing Reducer

3.3 Replacement of Turntable

Fig. 3-3(1) Structure of Turntable

1-Turnable 2-Nut 3-Slewing support

1-Slewing bearer 2-Chassis washer 3-Bolt 4-Slewing reductor

3.5 Replacement of Rope Guard

1-Rope guard 2-Bolt 3-Washer 4-Nut

3.6 Necessary Tools

4.1 Replacement of Main Grab Hook

1-Axis Pin 2-Clamp pin 3-Wedge sleeve

4.2 Replacement of Auxiliary Grab Hook

1-Rope clamp 2-Wedge 3-Wedge sleeve

4.4 Replacement of Main and Auxiliary Winch Reducers