Preface: Study Manual (First and Second Half Edition) For The Heavy Duty Crane

前言
Preface
服务案例是将发生在车间、施工现场的疑难故障处理过程、分析思路以图文并
茂的方式再现出来的一种陈述，具有很强的指导性、借鉴性与启发性，是服务代表
在岗学习与技能提升的好材料、好帮手。
The Service Case is a kind of image-text representation of the
troubleshooting process and analysis thought in workshops and
construction sites, which provides useful guidance, reference and
inspiration, and can assist the service representatives in their on-the-job
learning and skill enhancement.
本手册的服务案例来源于全国各地服务代表、车间调试技术人员，并根据质量
部 TOP50 、 DMS 系统数据进行精心筛选；同时，经过技术、培训工程师的认真
审核与编制，具有高发性、典型性、时效性。
The service cases in the Manual come from service representatives and
staff responsible for workshop debugging technology from all parts of
China, which have been elaborately screened based on TOP50 and DMS
system data of the Quality Department. In addition, such cases have also
been carefully reviewed and prepared by the technical and training
engineers, which have high frequency, typicalness and timeliness.
2013 年我们将继续推出《服务案例学习手册》中小吨位下半年版，《服务案

例学习手册》大吨位上、下年版，请各位服务代表关注。
In 2013, we will successively issue the Service Case Study Manual (Second
Half Edition) for the medium and light duty cranes and the Service Case
Study Manual (First and Second Half Edition) for the heavy duty crane.
And, we draw all service representatives’ attention.
此外，请各位服务代表经常登入 DMS 系统学习服务案例 ( 电子档 ) 。注意每月

月底前提交当月服务案例。对于通过审核的服务案例，总部将给予编写者 100-300
元 / 篇不等的奖励。
In addition, we hope that all service representatives can frequently log in
the DMS system to study the service case (electronic document). Please
remember to submit the current service case before the end of each month.
For the approved service case, the headquarters will give the
corresponding reward (100-300 yuan for each) to the author.
上车目录
Superstructure Content
1 、 25T 变幅下沉 -I 5
1. 25T luffing sinking-I
变幅
Luffing 2 、 25T 变幅下沉 -II 7
2. 25T luffing sinking-II
3 、 25T 变幅下降无动作 10
3. 25T luffing has no descending action
1 、 25T 吊臂完全缩回后伸出 11
吊臂 1. 25T boom extends after full retraction
Boom
2 、 25T87 吊臂异常磨损 13
2. 25T 87 boom is worn out
1 、 50T 回转不顺畅
1. 50T has unsmooth slewing 15
回转 2 、 20T 回转时油门时有时无
Slewing 17
2. The throttle is spongy sometimes during 20T slewing
3 、 80T 回转向右速度慢 19
3. The 80T rightward speed is slow during slewing
1 、 25T 主卷扬下降抖动 20
1. 25T main winch jitters during descending
主卷扬 2 、 25T 吊重时起升小开口抖动 22
main winch 2. The 25T small lifting opening jitters during load hoisting
3 、 25T 主卷扬有时无动作 24
3. 25T main winch has no action sometimes
4 、 25T 主卷扬吊起重物时突然停顿 26
4. 25T main winch suddenly stops during load hoisting
5 、 25T 主卷扬无动作 29
5. 25T main winch has no action
副卷扬 1 、 25T 副卷扬溜钩
auxiliary winch
1. 25T auxiliary winch hook slides 31
2 、 50T 副卷扬下方抖动
2. The lower part of 50T auxiliary winch jitters 33
配重 1 、 80T 配重无动作
Counterweight 35
1. 80T counterweight has no action
上车目录
Superstructure Content
1 、 25T 电脑长度显示不准 37
电脑 1. The length displayed in 25T computer is inaccurate
Computer 2 、 25T 电脑长度等显示都是 XXX 39
2. The length displayed in 25T computer is always XXX
1 、 20T 主卷扬减速机漏油 42
减速机 1. 20T main winch reducer leaks oil
Reducer 2 、 20T 回转减速机透气帽漏油 44
2. 20T slewing reducer ventilating cap leaks oil
1 、 80T 上车空调烧保险 47
1. 80T superstructure A/C fuse is burnt
2 、 25T 上车空调效果差 49
空调 2. 25T superstructure A/C has poor effect
A/C 3 、 25T 上车暖风不工作 -I 51
3. 25T superstructure heater doesn't work-I
4 、 25T 上车暖风不工作 -II 53
4. 25T superstructure heater doesn't work-II
1 、 25T 上车动作发抖
56
1. 25T superstructure jitters
2 、 25T 变幅下，吊臂伸出等没有动作
2. 25T luffing has no downward action and the boom has no extension action 57
3 、 25T 主副卷扬，回转无动作
60
3. 25T main and auxiliary winches have no slewing action
4 、 20T 上车危险方向切不断
62
4. 20T superstructure dangerous action can’t be stopped
5 、 30T 无副勾起升，吊臂只有缩方向
综合 5. 30T auxiliary hook has no lifting action and the boom is only available for retracting 64
Comprehensive
6 、 25T 卷扬无法下放，吊臂无法缩回 66
6. 25T winch can't be descended and the boom can't be retracted
7 、 30T 不挂取力器上车常带电
7. 30T superstructure is always electrified without engagement of power take-off 68
8 、 50T 上车无动作 -I 71
8. 50T superstructure has no action-I
9 、 50T 上车无动作 -II 74
9. 50T superstructure has no action-II
10 、 25T 回转时上车偶尔无电 77
10. 25T superstructure is un-electrified occasionally during slewing
下车目录
Chassis Content
1 、 25T 取力器挂不上 80
取力器
1. 25T PTO can't be engaged
PTO 2 、 25T 行车后取力器挂不上 82
2. 25T PTO can't be engaged after traveling
1 、 80T 方向机在行驶时异响 84
1. 80T steering gear has abnormal sound during traveling
转向 2 、 25T 转向油箱翻油 87
Steering
2. Oil overflows from the QY25T steering oil tank
3 、 25T 转向沉重 89
3. 25T steering is heavy
1 、 16T 刹车温度高 91
制动 1. 16T brake temperature is high
Brake 2 、 25T 低气压报警 93
2. 25T has low air pressure alarm
3 、 50T 后轮刹车抱死 95
3. 50T rear wheel brake is locked
传动 1 、 25T 只有低档没有高档 97
Transmission 1. 25T is available for low gear only
2 、 25T 挂档困难 101
2. 25T has difficult gear engagement
1 、 25T 下车无法启动 103

1. 25T chassis can't be started
2 、 50T 发动机水温高 106
2. 50T engine has high water temperature
3 、 20T 发动机无法启动 109
3. 20T engine can't be started
发动机 111
4 、 50T 上车发动机油门不正常
Engine
4. 50T superstructure engine throttle is abnormal
5 、 16T 发动机无油门 114
5. 16T engine throttle is spongy
6 、 50T 发动机加不上油 116
6. 50T engine can’t be throttled up
7 、 25T 发动机异响 119
7. 25T engine has abnormal sound
Superstructure
变幅
Luffing
1 、 QY25T 变幅下沉 -I
1. QY25T luffing sinking-I
问题描述：在吊重物时停放一段时间（ 15 分钟左右），变幅下沉往前了，角度变
小，其他一切正常。
Fault descriptions: After stopping for some time (about 15 min.) during
load hoisting, the luffing sinking increases, the angle becomes smaller,
and other all are normal.
deskripsi kesalahan: (. Sekitar 15 menit) Setelah berhenti selama beberapa
waktu selama beban mengangkat, yang Luffing tenggelamnya meningkat, sudut
menjadi lebih kecil, dan lainnya semua adalah normal
处理过程：
Troubleshooting process:
Step 1:
根据客户反映的现象是变幅下沉，可能出现
的故障情况有：
According to the customer’s response, the
phenomenon is luffing sinking and
possible faults include:
Kemungkinan penyebabnya :
1 、变幅平衡阀内泄； 1. The luffing
balance valve has internal leakage;
Balance valve mengalami kebocoran
internal
2 、油缸密封件失效。 2. The oil cylinder
sealing element fails.
Silinder seal oil mengalami kerusakan
如图，上车熄火，拆开平衡阀控制铁管和无
杆腔油管，发现有油从无腔油管内流出，判
断是平衡阀问题。 As shown in the Figure,
when stopping the superstructure and
removing the balance valve control steel
tube and piston-side oil pipe, find out that
平衡阀 Balance
oil flows out from the piston-side oil pipe
and it judges that the balancevalve
valve has
fault.
Seperti ditunjukkan dalam Gambar, ketika
berhenti suprastruktur dan menghapus
katup keseimbangan tabung kontrol baja
dan pipa minyak piston-side, menemukan
bahwa minyak mengalir keluar dari pipa
minyak piston-sisi dan hakim bahwa katup 第 6 页
keseimbangan memiliki kesalahan.
变幅
Luffing
1 、 QY25T 变幅下沉 -I
1. QY25T luffing sinking-I
第二步 :
Step 2:
平衡阀的内部可能有异物卡死或密封件损坏，
拆开平衡阀发现阀芯内有赃物。
The balance valve inside may be stuck by

foreign matters or the sealing element is
damaged, remove the balance valve and find
out that the valve core has dirt.
Check apakah Balance valve terdapat kotoran

Bongkar valve dan bersihkan komponennya
第三步 :
Step 3:
用柴油清洗阀芯，装好阀芯，装好平衡阀，（如
果重新装好，试车还下沉就需更换平衡阀）。吊
重试车，问题解决。
Clean the valve core with diesel; install the
valve core and balance valve. (If sinking still
exists after re-installation and commissioning,
please replace the balance valve). After
commissioning with load, the troubleshooting
can be done.
Bersihkan balance valve dengan solar,jika

problem masih sama,ganti dengan valve yg
baru
第 7 页
变幅
Luffing
2 、 QY25T 变幅下沉 -II

2. QY25T luffing sinking-II
问题描述：上车工作时，在不动操纵手柄的情况下变幅下沉明显。
Fault descriptions: When the superstructure works, the luffing sinking
becomes obvious without moving the control handle.
原理分析：判断变幅下沉首先要了解变幅平衡阀的
工作原理，右图为我公司中小吨位所采用的变幅平
衡阀原理图。
Analysis on principles: To judge the luffing
sinking, please firstly know working principles
of the luffing balance valve. The right-side
Figure shows the basic diagram of the luffing
balance valve for our medium and light duty
cranes.
抬变幅：液压油经过上部操纵阀 A2 至变幅平衡阀 A
口，然后打开平衡阀内单向阀到变幅平衡阀无杆腔，
从而推动油缸伸出，油缸有杆腔的液压油从平衡阀
B2 口回油箱。
Lifting the luffing: The hydraulic oil will flow to the
port A of the luffing balance valve through the
upper control valve A2; after that, open the one-
way valve in the balance valve and move it to the
luffing balance valve piston-side, so as to extend
the oil cylinder. By this way, hydraulic oil in the rod-
side of the oil cylinder will return to the oil tank
through the port B2 of the balance valve.
落变幅：液压油从上部操纵阀 B2 口流入变幅油缸有
杆腔推动活塞杆缩回，此时平衡阀内的单向阀被有
杆腔的压力油打开，从而让变幅油缸无杆腔的油通
过 B 口回到 A 口，再经 A2 口回油箱。
Descending the luffing: The hydraulic oil will flow
into the luffing oil cylinder from the port B2 of the
upper control valve and the rod-side will retract the
piston rod. In such case, the one-way valve in the
balance valve will be opened by pressure oil in the
rod-side, thus making oil in the piston-side of the
luffing cylinder return to port A via port B, and then
to the oil tank via port A2. 第 8 页
变幅
Luffing

处理过程：
第一步：变幅油缸自动下降时的可能原因有：
Step 1: Possible causes of automatic
descending of luffing cylinder:
1 、变幅油缸内泄； 1. The luffing cylinder
has internal leakage;
2 、变幅平衡阀故障： 2. The luffing
balance valve has fault:
a 、由于平衡阀单向阀阀杆被异物卡死处于
常开位； a. The one-way valve stem of the
balance valve is stuck at the normally-open
position by foreign matters;
b 、端盖阻尼脱落导致平衡阀单向阀发卡不
能封锁无杆腔压力油。 b. The end cover
damping peels off, which results in that the
one-way valve of balance valve cannot
block the piston-side pressure oil due to
seizure.
判断是油缸故障还是平衡阀故障，最简单的
方法就是将变幅抬至合适高度，上车熄火，
拆开平衡阀 X 控制铁管和 A 口油管，看 A
口是否有油流出。如果有油不断流出则为平
衡阀失效，需维修或更换，否则为油缸内泄。
The simplest method to judge the oil
cylinder fault or the balance valve fault is
to lift the luffing to a proper height; stop the
superstructure; remove the X control steel
tube and port A oil pipe of the balance
valve, and see if oil flows out from the port
A. If oil constantly flows out, it means the
balance valve fails, which shall be repaired 拆开是否有油流出
or replaced; or else, it means that the oil 来
cylinder has internal leakage.
Remove it to第 see if9 页
oil flows out
变幅
Luffing

第二步 :
Step 2:
检查发现平衡阀内泄，拆开变幅平衡阀
检查，发现节流阀阻尼脱落，阻尼丝牙
磨损打滑。
Find out that the balance valve has
internal leakage by check; remove and
check the luffing balance valve and
find out that the throttle valve damping
peels off and the damping thread
wears and skids.
阻尼丝牙打滑。
The damping thread
slips.
检查阀杆有无损伤，
若有则用油石研磨。
Check the valve
stem for damages; if
it is damaged, polish
it with the oilstone.
第三步：拆开平衡阀的单向阀杆，检查
是否发卡，检查完毕后涂抹黄油安装。
Step 3: Remove the one-way valve
stem of the balance valve and check it
for seizure. After check, coat it with
grease for installation.
第 10 页
变幅
Luffing
3 、 QY25T 变幅下降无动作
3. QY25T luffing has no descending action
问题描述：上车工作时，往下变幅发现没有
动作。
Fault descriptions: When the
superstructure works, the luffing has no
descending action.
处理过程：
第一步 : 检查系统压力是否正常，发现下放
时压力没有，其余动作时压力都正常。
Step 1: Check if the system pressure is
normal; find out that there is no pressure
during descending but the pressure is
normal during other actions.
第二步：可以推断不是电气问题引起，也大致可以判定由于变幅下放溢流阀卸荷
造成，拆开溢流阀，发现里面有杂物造成溢流阀卡滞卸荷，取出杂物重新装配，
装好后吊臂下放正常。
Step 2: It can be deduced that the fault is not caused by the electrical problem
and it can be roughly judged that the fault is caused by the luffing descending
and overloading of overflow valve. After that, remove the overflow valve, and it is
found that foreign matters inside cause seizure of the overflow valve. Re-
assemble the valve and take out foreign matters, and the boom descending
becomes normal consequently.
第 11 页
吊臂
Boom
1 、 QY25T 吊臂完全缩回后自动伸出
1. QY25T boom automatically extends after full retraction
问题描述：吊臂完全缩回后 , 等 30 秒左右，第二 , 三
节吊臂会自动伸出一点。
Fault descriptions: After full retracting the boom
and wait for about 30s, the second and third
sections of the boom will automatically extend a
bit.
故障处理：
Troubleshooting:
第一步：首先检查各部位的工作情况，仔细观察发
现第一、二节臂之间有间隙 , 第二、三节臂之间有间
隙 , 第三、四节臂无间隙 . 。
Step 1: Firstly check the working conditions of all
parts and perform careful observation and find out
the followings: clearance exists between the first
and second sections of the boom; clearance exists
between the second and third sections of the
boom; and no clearance exists between the third
and fourth sections of the boom.
第二步：通过调整基本臂上的回拉钢丝绳和第四节
臂上的回拉钢丝绳 , 调节好 , 试车发现无效果。
Step 2: After adjusting the pullback steel wire ropes
on the base boom and the fourth section of the
boom, find out that the adjustment is correct, but
there is no effect by the commissioning.
第四节臂上的回拉钢绳
基本臂上的回拉钢丝绳 Pullback steel wire rope on
Pullback steel wire rope on the base boom the fourth section of the boom
第 12 页
吊臂
Boom
1 、 QY25T 吊臂完全缩回后自动伸出
1. QY25T boom automatically extends after full retraction
第三步 : 通过吊臂尾部观察油缸发现油缸在完全缩回后，油缸会自动向前伸出一
点 , 怀疑油缸内有空气 . 让驾驶员全伸吊臂 , 全缩吊臂摒压几次 , 排出油缸内的空
气，重新缩回吊臂 , 但吊臂仍然会自动伸出一点。
Step 3: By observing the boom tail, find out that the oil cylinder will automatically
extend a bit after fully retracting. It is suspected that there is air in the oil cylinder.
Ask the driver to fully extend and retract the boom and hold the pressure for
several times; after that, exhaust the oil cylinder and retract the boom again;
however, the boom will still extend a bit automatically.
第四步：仔细观察吊臂之间的挡块 , 发
现第三、四节臂之间挡块过长 , 通过调
节各吊臂之间的挡块 , 重新缩回吊臂后 ,
吊臂不会伸出去，故障解决。
Step 4: Carefully observe the block
stop between booms, and find out that
the block stop between the third and
fourth sections of the boom is too long.
After adjusting the block stop between
booms and retracting the boom again,
the boom will not extend and the fault
is eliminated.
吊臂之间的挡快
Block stop between
booms
第 13 页
吊臂
Boom
2 、 QY25T87 吊臂异常磨损
2. QY25T 87 boom is worn abnormally
问题描述 : 服务员在做月度例检时发现，第四节臂伸出拉绳右导向轮安装固定销与
吊臂异常磨损。现场无法处理 , 通知用户把车开到保障中心修理厂。
Fault descriptions: When the service staff performs the monthly check, find
out that the mounting and fixing pin of the right guide wheel of the draw
cord of the fourth section of the boom and the boom are worn out. The fault
can’t be eliminated in site, notify the user to drive the crane to the repair
workshop of the guarantee center.
处理过程：
第一步 :
Step 1:
伸吊臂时，发现第四节臂伸拉绳左导向轮转动
正常，右导向轮卡死不转，导轮固定销跟转。
When extending the boom, find out that the
left guide wheel of the draw cord of the fourth
section of the boom normally rotate. The right
guide wheel is stuck and can’t rotate and the
guide wheel fixing pin rotates along with it.
导轮固定销
Guide wheel
fixing pin
第二步 :
Step 2:
导轮与销卡死后，伸吊臂过程中势必把固定
销锁板的螺丝带断 , 导致锁板脱落 , 导轮和销
子同时转动，以致吊臂异常磨损 .
After the guide wheel and pin are stuck, the
boom extension will inevitably fracture the
screw of the fixing pin locking plate, thus the
locking plate peels off; simultaneously
rotating the guide wheel and pin, and the
boom is worn abnormally.
第 14 页
吊臂
Boom
2 、 QY25T87 吊臂异常磨损
2. QY25T 87 boom is worn abnormally
第三步：拆吊臂，固定销与导轮已经发热烧结在一起，用工装无法拆出，用氧割割断固定
销，发现 87 臂臂头已磨损，导轮、衬套、套、销、档圈都已损坏，更换 87 臂焊接总成、
导轮、衬套、套、销、档圈、 88 臂伸出钢丝绳后，试车正常。
Step 3: Remove the boom and find out that the fixing pin and guide wheel become hot
and get sintered, which can be removed with tooling. In such case, cut off the fixing pin
with the oxygen cutting machine, and it is found that the 87 boom end is worn out; the
guide wheel, bushing, sleeve, pin and retainer ring are damaged. After replacing the 87
boom welding assembly, guide wheel, bushing, sleeve, pin, retainer ring and 88 boom
steel wire rope, it becomes normal during the commissioning.
第 15 页
回转
Slewing
1. 50T has unsmooth slewing
问题描述：根据客户反映和自己在现场试车发现，车辆在回转过程中不顺畅，一
抖一抖且压力有跳动。
Fault descriptions: By the customer’s response and the site commissioning,
find out that the crane jitters and works abnormally during slewing and the
pressure also fluctuates.
处理过程：
第一步 :
Step 1:
检查回转缓冲阀，清洗阀芯后试车，问题还是存
在。
After checking the slewing cushion valve;
cleaning the valve core and performing
commissioning, the fault still exists.
回转缓冲阀
Slewing
cushion valve
第二步 :
Step 2:
检查回转马达，拆下回转马达泄油口，发现泄油口只有少许液压油流出，判断马达
正常。
Check the slewing motor and remove its oil-drain outlet; it is found out that only
few hydraulic oil flows out from the oil-drain outlet, and it can be judged that the
motor is normal.
第 16 页
回转
Slewing
1. 50T has unsmooth slewing
第三步：检查下部操纵阀，拆下 15MPa 溢流阀，发现阀芯发卡且内部弹簧弹力不

足。增加垫片来增强弹簧弹力，但是没有效果，更换阀芯后正常。
Step 3: Check the lower control valve and remove the 15MPa overflow valve,
and find out that the valve core is stuck and the interior spring elasticity is
insufficient. Add the gasket to reinforce the spring elasticity; however, it doesn’t
work. In such case, replace the valve core and it becomes normal.
第 17 页
回转
Slewing
2 、 50T 车辆在回转时油门不稳定时有时无
2. 50T crane throttle is unstable sometimes during slewing
问题描述：车辆在回转时油门不稳定时有时无。
Fault descriptions: the crane throttle is unstable sometimes during slewing.
处理过程：
第一步 : 检查油门踏板电阻器是否正常，将上下车油门踏板
兑换，装到驾驶室时，油门踏板正常。
Step 1: Check if the throttle pedal resistor is normal and
exchange the superstructure throttle pedal with the
chassis throttle pedal. After installing it in the cab, the
throttle pedal becomes normal.
第二步：
Step 2:
1 、怀疑 GPS 天线信号有问题，接触不好导致锁机造成油
门时有时无，检测 GPS 天线，发现天线接触正常，车辆所
在地区不是偏远无信号覆盖的山区，排除此原因；
1. It is suspected that the GPS antenna signal has fault
and poor contact, which leads to locking and makes the
throttle become unstable sometimes. Test the GPS
antenna, and find out that the antenna contact is normal.
The crane-located area is not a remote mountainous
area, which is covered by signals; therefore, the cause
can be eliminated;
2 、怀疑油门踏板经过滑动连接器的线路有问题，将
油门线的插头拔掉，在回转的过程中用万用表测量 2
根电源线的电压，发现 1 根电源线波动较大，在 1.9
到 4.8V 之间波动，导致油门忽高忽低，由此可以确定
是滑动连接器内部划片磨损严重。
2. It is suspected that the circuit for the throttle pedal
passes on the sliding connector has fault; remove
the throttle line plug and measure the voltage of 2
power lines with the universal meter during slewing,
and find out that 1 power line has larger fluctuations
between 1.9-4.8V, which results in unstable throttle
fluctuations. And, it can be confirmed that the interior
scribing of the sliding connector is worn out.
第 18 页
回转
Slewing
2 、 50T 车辆在回转时油门不稳定时有时无
2. 50T crane throttle is unstable sometimes during slewing
第三步 : 将出现问题的线路更换到滑动连接器的备用
线路上，问题已将解决。
Step 3: Change the circuit with fault to the standby
circuit of the sliding connector, and the fault is
eliminated.
3 、 80T 回转向右速度慢
3. 80T rightward speed is slow during slewing
故障描述：向右回转时，回转速度慢，加油门，速度不变，向左回转正常。
Fault descriptions: During rightward slewing, the slewing speed is low;
when stepping down the throttle, the speed is unchanged and the leftward
slewing is normal.
处理过程：
第一步 : 先检查回转缓冲阀上的左右两个溢流阀，
并调换位置进行调试，故障仍存在，可排除溢流
阀故障。
Step 1: Firstly check left and right overflow
valves on the slewing cushion valve, and then
exchange them and perform commissioning; if
the fault still exists, it can be confirmed that the
overflow valve is normal.
回转缓冲阀上的溢流
阀
Overflow valve on the
slewing cushion valve
第 19 页
回转
Slewing
3 、 80T 回转向右速度慢
3. The 80T rightward speed is slow during slewing
第二步 :
Step 2:
再次调试发现回转向左正常，且加油门时回转速度明
显提升，说明主泵压力正常。将回转马达的两根进油
胶管调换顺序后，发现回转向左速度慢，向右正常，
说明减速机与制动缸正常。
After second commissioning, find out that the
leftward slewing is normal and the slewing speed
obviously increases when stepping down the throttle,
which shows that the main pump pressure is normal.
Exchange two oil inlet hoses of the slewing motor,
and find out that the leftward slewing speed is low
and the rightward slewing speed is normal, which
shows that the reducer and brake cylinder are
normal.
回转马达左右油管交换
Exchange left and right oil
pipes of the slewing motor
第三步 :
Step 3:
拆开回转缓冲阀的阀芯，发现阀杆与弹簧的连接
处有松动，将其拧紧，复原后故障解除，回转正
常工作。
Remove the slewing cushion valve core, and
find out that the connection between the valve
stem and the spring is loose. In such case,
screw it down, and the fault is eliminated and
the slewing becomes normal after recovery.
回转缓冲阀阀杆松动处
Loose valve stem of the slewing
cushion valve
第 20 页
主卷扬
Main Winch
1 、 QY25T 主卷扬下降抖动
1. QY25T main winch jitters during descending
问题描述：主卷扬吊重物下降抖动严重 , 吊轻物的时候抖动不太明显。
Fault descriptions: The main winch seriously jitters during load hoisting,
which has minor jittering during light object hoisting.
处理过程：
第一步 : 检查大、小钩的控制压力是否正常，
标准压力为 (3.5-5mpa). 做大小钩动作，查看
控制压力表，压力显示正常，排除控制压力低。
Step 1: Check if the control pressure of large
and small hooks is normal, and the standard
pressure is (3.5-5mpa). Perform large and
small hooks actions; read the control
pressure gauge; if the pressure display is
normal, it can be confirmed that the control
pressure is not low.
第二步：怀疑主阀上的主卷扬下降次级溢流阀设定压力低。调整主卷扬次级溢流
阀压力，故障仍然存在。把主卷扬跟副卷扬的次级溢流阀对调，故障仍然存在，
所以排除次级溢流阀的问题。
Step 2: It is suspected that the set pressure of secondary overflow valve
controlling the descending of main winch on the main valve is low. After adjusting
the secondary overflow valve pressure of the main winch, the fault still exists.
Exchange the secondary overflow valve of the main winch with that of the
auxiliary winch and the fault still exists, and it can be confirmed that the
secondary overflow valve is normal.
次级溢流阀
Secondary
overflow valve
第 21 页
主卷扬
Main Winch
1 、 QY25T 主卷扬下降抖动
1. QY25T main winch jitters during descending
第三步 :
Step 3:
分析可能是主卷扬平衡阀上端盖阻尼发堵导致平衡阀半开半不开，所以造成下降
抖动。拆开平衡阀端盖，拆出阻尼检查，发现阻尼孔处有一小点铁屑，但没有把
阻尼孔完全堵死，清洗端盖后装上，主卷扬下降正常，故障排除。
Through the analysis, it is judged that the balance valve is abnormally opened
due to end cover damping blocking on the main winch balance valve; therefore, it
jitters and descends. Remove the balance valve end cover and the damping for
checking, and find out that the damping hole has some slag; however, the
damping hole is not completely blocked. After cleaning and re-installing the end
cover, the main winch descending becomes normal, and it means that the fault is
eliminated.
阻尼孔
Damping
hole
第 22 页
主卷扬
Main Winch
2 、 QY25T 吊重时起升小开口抖动
2. QY25T small lifting opening jitters during load hoisting
问题描述：主卷扬吊重物时，动操作杆 , 小开口时起升发抖，空钩正常。
Fault descriptions: During load hoisting by the main winch, operate the
operating rod, the lifting jitters in case of small opening, which is normal in
case of empty hook.
处理过程：
第一步 : 首先判断系统压力是否正常，查看压力
表，压力在 20 至 24MP 之间，压力正常。
Step 1: Firstly judge if the system pressure is
normal and check the pressure gauge. If the
pressure is between 20 and 24MP, it means the
pressure is normal.
阀杆
Valve
stem
第二步：其次判断上部操作阀阀杆是否磨损，将
其阀杆拆下无磨损现象。
Step 2: Secondly, judge if the upper operation
valve stem wears. When removing the valve
stem, find out that the valve is normal.
第 23 页
主卷扬
Main Winch
2 、 QY25T 吊重时起升小开口抖动
2. QY25T small lifting opening jitters during load hoisting
第三步 : 卷扬平衡阀是否有问题，将卷扬平衡阀上的单向阀拆下，发现弹簧弹力
不足，在其弹簧上加个垫片后，试车正常。
Step 3: Check the winch balance valve to see if it is normal; when removing the
one-way valve on the winch balance valve, find out that the spring elasticity is
insufficient. When adding the gasket on the spring, it becomes normal during
commissioning.
第 24 页
主卷扬
Main Winch
3 、 QY25T 主卷扬有时无动作
3. QY25T main winch has no action sometimes
问题描述：用户反映大钩经常没动作，时有时无，特别冷车大钩无动作，需加一
会儿油门，动作才能恢复正常。
Fault description: The user reflects that the large hook often has no or
intermittent action, especially during the cold start, which will become
normal after stepping down the throttle for a while.
处理过程：
第一步 : 做主卷扬动作，发现没有主压力，先
导压力正常，说明主卷扬换向阀杆没打开 , 初
步判断可能控制油口的阻尼堵塞。
Step 1: Perform the main winch action, and
find out that there is no main pressure and
the pilot pressure is normal, which shows that
the steering valve stem of the main winch is
not opened, and it is preliminarily judged that
the control oil port damping may be blocked.
第二步 :
Step 2:
拆开控制油管，卸下两端阻尼，发现阻尼有堵
塞。
After removing the control oil pipe and
damping at both ends, find out that the
damping is blocked.
第 25 页
主卷扬
Main Winch
3 、 QY25T 主卷扬有时无动作
3. QY25T main winch has no action sometimes
第三步：清洗阻尼，装好阻尼后，试车主卷扬动作正常。
Step 3: Clean and install the damping, and the main winch normally acts during
commissioning.
第 26 页
主卷扬
Main Winch
4 、 QY25T 主卷扬吊重后缓缓下滑
4. QY25T main winch slowly descends after load hoisting
故障描述：起重机在正常工作状态下，主卷扬吊起重物在空中停顿时，操作杆已
回到中位，重物缓缓下滑，当起重机熄火时，重物停止下滑。
Fault descriptions: When the crane is under normal working state and the
main winch hoists the load and suspends it in the air, the operating rod
returns to center and the load slowly descends. When the crane stops, the
load stops descending.
处理过程：
第一步 : 因为重物是由卷扬制器制动的，故主卷扬制动器有故障。主卷扬制动是先
导压力打开，当起重机正常工作时，整车有液压动力，才有先导压力；熄火后整
车液压动力消失，制动器是靠弹簧力回位，从而刹住主卷扬的。
Step 1: As the load is braked by the winch brake, it means that the main winch
brake has fault. The main winch brake is activated by the pilot pressure; when
the crane normally works and the complete crane has hydraulic power, there will
exist the pilot pressure; after stop, the complete crane hydraulic power will
disappear and the brake will return with the spring force, thus it can brake the
main winch.
主卷扬制动阀
Brake valve of the
main winch
第 27 页
主卷扬
Main Winch
第二步：熄火检查操纵杆前后行程一致，拆开平衡阀到双联卷扬控制阀压力油管，
有压力喷出。
Step 2: After stop, check it and find out that the front and rear strokes of the
control lever are inconsistent. Remove the pressure oil pipe between the balance
valve and the double winch control valve, and pressure injects.
第三步 : 检查双联卷扬制动液控制阀的阀芯，
发现发卡，导致先导压力油直接进入制动器
打开制动器，可拆下双联液控制动阀到卷扬
制动器压力油管，有压力油喷出。
Step 3: Check the brake fluid control valve
core of the double winch, and find out that
the core is stuck, which makes the pilot
pressure oil directly enter into the brake and
activate brake. Remove the pressure oil
pipe between the double hydraulic control
brake valve and the winch brake, and
pressure oil injects.
第 28 页
主卷扬
Main Winch
第四步：清洗双联液压制动阀时，发现阀芯弹簧断了，阀芯不回位，先导压力油直
接进入制动器缸打开刹车，所以主卷扬吊重后缓缓下滑。
Step 4: When cleaning the double hydraulic brake valve, find out that the valve
core spring is broken, the valve core doesn’t return, and the pilot pressure oil
directly enters into the brake cylinder and activates brake. Therefore, the main
winch slowly descends in case of load hoisting.
第 29 页
主卷扬
Main Winch
5 、 QY25T 主卷扬无动作
5. QY25T main winch has no action
故障现象：取力器挂上后，主卷扬起降都没有反应，其余动作正常。
Fault phenomenon: After PTO engagement, the main winch has no
response to lifting and descending, but other actions are normal.
处理过程：
第一步 : 到达现场后，先排除电气报警。然后对各个动作进行调试，发现主卷扬单
独起降钩都没有反应，且无压力显示。但在组合动作（除回转）时，动作正常。
Step 1: After reaching the site, firstly remove the electrical alarm. After that,
perform commissioning to all actions, and find out that the main winch has no
independent hook lifting and descending responses and there is no pressure
display. However, in case of the combined action (except slewing), it has normal
action.
第二步 : 由于单独操作时，没有压力，而组合
动作时有压力且能动作 , 可以判断不是由于溢
流阀问题导致压力没有。且能大致判定为由于
没有反馈压力导致主压力起不来。
Step 2: As there is no pressure during
independent operation while there is pressure
and it acts during combined action, it can be
judged that the cause is not the overflow
valve fault. And, it can be roughly judged that
the pressure fault is caused by no feedback
pressure.
负载反馈阀
Load feedback
valve
第 30 页
主卷扬
Main Winch
5 、 QY25T 主卷扬无动作
5. QY25T main winch has no action
第三步 : 拆下主卷扬压力补偿阀，发现 2 个小阻尼全部脱落顶住钢球，导致液压油根本不能
通过小孔到达反馈油路；故而造成主压力起不来。在把小阻尼重新固定后，装好压力补偿
阀，故障排除。
Step 3: Remove the pressure compensation valve of the main winch, and find out that 2
small damping peels off completely and jacks up the steel ball, therefore, the hydraulic oil
can’t reach the feedback oil circuit through small holes and the main pressure can’t be
increased. After re-fixing the small damping, install the pressure compensation valve,
and the fault is eliminated.
第 31 页
副卷扬
Auxiliary Winch
1 、 QY25T 副卷扬溜钩
1. QY25T auxiliary winch hook slides
故障描述：副卷扬在吊载时发现有溜钩现象。
Fault descriptions: The auxiliary winch hook slides during load hoisting.
处理过程：
第一步 : 到现场试车，发现客户在吊载后熄火 ,
副卷扬仍然有溜钩现象，关掉使能键时，副卷
扬溜钩现象停止。
Step 1: When performing site commissioning,
find out that the crane stops after load
hoisting while the auxiliary winch still has
hook sliding; when turning off the enable key,
the auxiliary winch hook can stop sliding.
第二步：拆掉制动缸油管，打开使能键。发现制动缸油管有油喷出，此时可判断
副卷扬制动阀没锁死。
Step 2: Remove the brake cylinder oil pipe and turn on the enable key, find out
that oil injects from the brake cylinder oil pipe. In such case, it can be judged that
the auxiliary winch brake valve is not locked.
制动缸油管
Brake cylinder
oil pipe
第 32 页
副卷扬
Auxiliary Winch
1 、 QY25T 副卷扬溜钩
1. QY25T auxiliary winch hook slides
第三步 : 拆掉副卷扬制动阀，发现内部弹簧断裂，重新购买并安装，试车后恢复正
常。
Step 3: Remove the auxiliary winch brake valve, and find out that the interior
spring is broken. Buy another spring and install it, the hook becomes normal after
commissioning.
第 33 页
副卷扬
Auxiliary Winch
2 、 QY50T 副卷扬下放抖动
2. QY50T auxiliary winch jitters during descending
故障描述：副卷扬做下放动作时抖动厉害，在中长臂工况下吊重的时候抖动更严
重。
Fault descriptions: The auxiliary winch seriously jitters during descending,
which is even worse during load hoisting by medium and long booms.
处理过程：
第一步 :
Step 1:
先检查控制油路压力和副卷扬下放压力，检查结果发现控制压力和下放压力为正
常。
Firstly check the control oil circuit pressure and the descending pressure of the
auxiliary winch, and find out that both of them are normal.
第 34 页
副卷扬
Auxiliary Winch
2 、 QY50T 副卷扬下放抖动
2. QY50T auxiliary winch jitters during descending
第二步 : 考虑到可能是副卷扬下放压力和卷扬
平衡阀开启压力的匹配有问题，匹配副卷扬下
放次级溢流阀与平衡阀开启压力，发现副卷扬
做下放动作还是抖动。
Step 2: Consider that the descending
pressure of the auxiliary winch and the
startup pressure of the winch balance valve
may have matching fault. After matching the
secondary overflow valve for auxiliary winch
descending with the startup pressure of the
balance valve, find out that the auxiliary
winch still jitters during descending.
第三步 : 调整副卷扬马达起始摆角螺丝，不断进行吊重并调整摆角螺钉，直到副卷
扬做下放动作不抖动时停止。故障排除，车子恢复正常。
Step 3: Adjust the startup swing angle screw of the auxiliary winch motor and
constantly perform load hoisting and adjust it till the auxiliary winch doesn’t jitter
during descending. The fault is eliminated, and the crane becomes normal.
第 35 页
配重
Counterweight
1 、 QY80T 配重无动作
1. QY80T counterweight has no action
故障描述：操作配重油缸时没有动作，油泵失效。
Fault descriptions: When operating the counterweight oil cylinder, it has no
action and the oil pump fails.
80T
原理分析：采用一个 26ml/r 的齿轮泵为配重与空调提供压力源 ;
80T crane is equipped with one 26ml/r gear pump as the counterweight to
Analysis
provide on pressure
A/C with principles:
source;
1 、当空调与配重电磁阀不得电时， 26 泵的油经空调处直接回油箱；
1. When A/C and counterweight electromagnetic valve is no electrified, the 26
pump oil directly returns to the oil tank through A/C;
2 、当空调电液换向阀得电时空调工作；
2. When A/C electrohydraulic change valve is electrified, A/C works;
3 、当空调与配重电液换向阀得电，油路就切换到配重，此时配重电磁换向阀得电
就能实现配重上下操作了。
3. When A/C and the counterweight electrohydraulic change valve are electrified,
the oil circuit is switched to the counterweight. In such case, the counterweight
electromagnetic change valve is electrified and the counterweight is available for
lifting and descending operations.
第 36 页
配重
Counterweight
1 、 QY80T 配重无动作
1. QY80T counterweight has no action
处理过程：
第一步 : 此车在操作配重油缸时没有动作，怀
疑是电磁阀没电或线圈损坏。
Step 1: The crane has no action when
operating the counterweight oil cylinder, it is
suspected that the electromagnetic valve is
not electrified or the coil is damaged.
第二步 : 检查发现电路正常，线圈有磁力，阀芯无发卡现象，拆开进油口，发现没
有油源，怀疑为油泵失效。
Step 2: After check, find out that the circuit is normal, the coil is magnetic, and the
valve core is not stuck. Remove the oil inlet, and find out that there is no oil
source, and it is suspected that the oil pump fails.
第三步 : 将油泵拆解后，发现同轴断裂，导致此泵无法工作，更换新泵后正常。
Step 3: After disassembling the oil pump, find out that the pump can’t work as the
coaxial device is broken. The counterweight becomes normal after replacing a
new pump.
第 37 页
电脑
Computer
1 、 QY25T 电脑长度显示不准
1. The length displayed in QY25T computer is inaccurate
故障描述：吊臂长度在伸或缩到 15 米 -21 米左右，长度数据猛增或猛减。

Fault descriptions: When the boom extends and retracts to about 15m-21m
long, the displayed data sharply increases or decreases.
处理过程：
第一步 : 查看基本臂 AD 值是否正常，内置拉线盒 70 ，外置拉线盒 200 。
Step 1: Check if the base boom AD value is normal, and find out that the in-built
pull box is 70 and the exterior pull box is 200.
AD 标准值参考
AD standard value reference
最小 AD 值范围最大 AD 值范围
Minimum AD value range
Maximum AD value range
长度 1 （ L1 ） 60-200 900-
1100
Length 1 (L1) 60-200 900-
1100
长度 2 （ L2 ） 60-200 300-
500
Length 2 (L2) 60-200 300-500
角度（ A ） 100-200 900-
1000
Angle (A) 100-200 900-1000
压力（ P1 、 P2 ） 145 或者 168
1008
Pressure (P1, P2) 145 or 168
1008
压力分两种： 30M 或 25M 对应的最小值不
同，为 145 或 168 ，最大值相同为 1008.
The pressure is classified into two
categories: The corresponding minimum
value of 30M or 25M is different: 145 or
168; the maximum value is the same:
1008.
第 38 页
电脑
Computer
1 、 QY25T 电脑长度显示不准
1. The length displayed in QY25T computer is inaccurate
第二步 : 如若 AD 值偏高偏低均需调整拉线盒。
Step 2: If the AD value is higher or lower, please adjust the pull box.
第三步 : 此车 AD 值正常，检查拉线盒电位器是否正常，经检查发现调整锁紧螺丝
松动导致吊臂长度在伸或缩到 15 米 -21 米左右长度，数据猛增或猛减。
Step 3: The crane AD value is normal; check if the pull box potentiometer is
normal. After check, find out that the adjustment locking screw is loose, which
makes the boom extend or retract to about 15m-21m long and the displayed data
sharply increases or decreases.
【长度 1 】调整：
[Length 1] adjustment:
确认长度检测器是否安装固定好，在基本臂状态下调整
拉线盒电位器，使长度 AD 值保持 60-400 之间，按
【▲】、【▼】选择【长度 1 】栏进行调整；
Confirm if the length detector is properly installed and
fixed; adjust the pull box potentiometer under the base
boom state and keep the length AD value at 60-400,
and then press down [▲] and [▼] to select the [Length
1] bar for adjustment; Pull box
将吊臂全伸出，按【▲】、【▼】键选择【长度 1 】， potentiometer
右边「 L1 」 AD 值显示在 600-1008 之间方可调满。
Fully extend the boom and press down [▲] and [▼]
keys to select the [Length 1]; if the displayed rightward
[L1] AD value is between 600-1008, it can be fully
adjusted.
【长度 2 】调整：
[Length 2] adjustment:
确认长度检测器是否安装固定好，在基本臂状态下调整
拉线盒电位器，使长度 AD 值保持 60-200 之间，按
【▲】、【▼】选择【长度 2 】栏进行调整；
Confirm if the length detector is properly installed and
fixed; adjust the pull box potentiometer under the base
boom state and keep the length AD value at 60-200,
and then press down [▲] and [▼] to select the [Length
2] bar for adjustment;
将吊臂全伸出，按【 ▲】、【 ▼】键选择【长度 2 】，
右边「 L2 」 AD 值显示在 200-1008 之间方可调
满。 Fully extend the boom and press down [▲] and
[▼] keys to select the [Length 2]; if the displayed
rightward [L2] AD value is between 200-1008, it can be
fully adjusted.
第 39 页
电脑
Computer
2 、 QY25T 电脑长度，角度，幅度显示都是 XXXX

2. The length, angle and reach displayed in 25T computer is
always XXXX
故障描述：电脑长度，角度，幅度都是 XXXX ，没有实际吨位和额定重量显示。
Fault descriptions: The length, angle and reach displayed in the computer
is always XXXX , and no actual capacity and rated weight displayed.
处理过程：
第一步 : 现在还不知道是那根传感器的线断路或者接头处松动，将显示屏拆下并将
显示屏后面的角度、压力、长度传感器航空接头处共四根线拔掉，再将长度传感
器接上，重启显示屏再看其采样值（相当于华德电脑的 AD 值），电源电压值
（ 5V 为正常）和长度的电压值（ 0.4V-0.5V 正常）按照此步骤依次试一下。
Step 1: It is not yet known which sensor line has open circuit or which connector
is loose, remove the display screen and four lines at the aviation connectors of
the angle, pressure, length sensor at its back; after that, connect the length
sensor and restart the display screen to check its sampling value (equivalent to
the AD value of Huade computer), power voltage value (5V is normal) and length
voltage value (0.4V-0.5V is normal) in turn.
第 40 页
电脑
Computer

2. The length, angle and reach displayed in QY25T computer is
always XXXX
第二步 : 重新接一遍以后发现是长度传
感器出问题了，采样值只有 1-3 之间跳
动，电压值只有 0.004V ，电源电压只
有 0.045V 。
Step 2: After reconnection, find out that
only the length sensor has fault; the
sampling value bounces only between
1 and 3; the voltage value is only
0.004V, and the power voltage is only
0.045V.
正常参数显示
Normal
parameters
第三步：现在开始查长度传感器线路，用万
能表测量其红色线发现并不是电源线而黑色
是电源线。将其反过来，再重启显示器电源，
电源电压正常，长度传感器电源值也正常了。
但采样值是 2500 ，计算值也不太准确。
Step 3: Now, check the length sensor
circuit and measure its red line with the
universal meter, and find out that the black
line is the power line not the red line.
Exchange these two lines and restart the
displayer, find out that both the power
voltage is normal and the length sensor
power value is normal. However, the
sampling value is 2500 and the calculated
value is not very accurate.
第 41 页
电脑
Computer

2. The length, angle and reach displayed in QY25T computer is
always XXXX
第四步：现在调节拉线盒里的传感器将采样值调到 300-400 之间即可，再按照电
脑显示步骤开始重新标定最大值和最小值，在标定时，有时候电脑会超重报警切
断动作，此时可以打强制开关，进行强制标定。
Step 4: Now, adjust the sensor in the pull box and adjust the sampling value to
300-400. After that, re-calibrate the maximum and minimum values according to
steps displayed in the computer. During calibration, the computer gives overload
alarm and stops actions sometimes; in such case, please turn on the forced
switch and perform forced calibration.
拉线合电位器
Pull box
potentiometer
调节这里
Adjust
here
第 42 页
减速机
Reducer
故障描述：主卷扬从缝隙里漏液压油。
Fault descriptions: The main winch leaks hydraulic oil from the clearance.
处理过程：
第一步 : 客户报修主卷扬漏油，到现场，首先
检查漏的是齿轮油还是液压油。
Step 1: The customer reflects that the main
winch leaks oil; in such case, perform the site
check to determine the leakage is the gear oil
or hydraulic oil.
第二步：分析故障原因： 1 、如果漏的是
齿轮油则说明是卷扬减速机故障； 2 、如
果漏的是液压油则说明是卷扬马达故障。
经过检查发现漏的是液压油，那么需要检
修的应该是卷扬马达，故拆掉卷扬马达维
修。
Step 2: Analyze the fault cause: 1. In case
of the gear oil, it means that the winch
reducer has fault; 2. In case of the
hydraulic oil, it means that the winch motor
has fault. After check, find out that the
leakage is the hydraulic oil and confirm
that the winch motor shall be replaced,
remove the winch motor for repair.
漏油点
Oil
leakage
point
第 43 页
减速机
Reducer
第三步 : 拆下卷扬马达，并拆掉马达油封更
换，装好油封后再把马达装配好，并将减速
机装配到位。
Step 3: Remove the hoist motor; replace the
motor oil seal; install the oil seal; assemble
the motor, and properly assemble the
reducer.
马达油封
Motor oil
seal
第四步：更换减速机内部的齿轮油到规定值并把余油擦拭干净，试车，车辆未有新
油渍流出，故障排除。
Step 4: Replace the reducer gear oil till reaching the specified value, and then
wipe off residual oil and perform commissioning, and find out that the crane has
no new oil stain, and the fault is eliminated.
第 44 页
减速机
Reducer
2 、 QY20T 回转减速机透气帽漏油
2. QY20T slewing reducer ventilating cap leaks oil
故障描述：到达现场后，首先试车，经检查发现在做回转动作时，从回转减速机
透气帽处不断流出油液，仔细观察为液压油与齿轮油的混合体。
Fault descriptions: After reaching the site, perform commissioning firstly.
After check, find out that: When performing slewing, oil constantly flows
out from slewing reducer ventilating cap; after careful observation, confirm
that it is the mixture of the hydraulic oil and gear oil.
处理过程：
第一步 : 判断引起此故障的原因有二
Step 1: Judge that there are two fault causes
1 ，回转马达漏油；
1. The slewing motor leaks oil;
2 ，回转减速机制动缸油封磨损，密封不严导致漏油。
2. The oil seal of the slewing reducer brake cylinder is worn out and loose and
leads to oil leakage.
透气帽油封漏油
Oil leakage of the
ventilating cap oil
seal
第 45 页
减速机
Reducer
第二步 : 熄火停机后开始准备拆卸回转马达。
Step 2: After crane stop, begin to remove the slewing motor.
首先拆掉固定回转马达的四个螺丝，把回转马达拿下来，并小心收好马达输出轴的花键，用
铁钉堵死制动缸油管接头处。
然后发动车，动回转并观察回转马达输出轴骨架油封处是否漏油。反复操作几次，未发现漏
油，可以排除回转马达漏油的故障。
Firstly, remove four fixing screws of the slewing motor and take down the slewing motor,
and then properly put away the motor output shaft spline and block the oil pipe connector
of the brake cylinder with iron nails.
After that, start the crane; move the slewing, and observe if the output shaft framework oil
seal of the slewing motor has oil leakage. If no oil leakage after several repetitions,
confirm that the slewing motor has no oil leakage.
第三步：拆掉回转减速机制动缸，拿下活塞观察
油封，油封已经磨损严重，确定为回转减速机制
动缸油封失效导致漏油。
Step 3: Remove the slewing reducer brake
cylinder; take down the piston and observe the
oil seal; in such case, find out that the oil seal is
worn out and confirm that the oil leakage is
caused as the oil seal of the slewing reducer
brake cylinder fails.
制动缸油封
Brake
cylinder oil 拆下回转马达
seal Remove the
slewing motor
第 46 页
减速机
Reducer
第四步：现场取下制动缸油封，更换新的制动缸油封并在油封外表面薄涂些润滑
脂，便于安装。然后按照拆卸时的相反顺序安装，逐一紧固各固定螺丝后，取出
制动缸油管里的铁钉堵头后，安装好油管。试车正常，故障排除。
Step 4: Remove the brake cylinder oil seal and replace it with a new one in site;
and then coat the oil seal surface with some lubricating grease for convenient
installation. After that, install them in the reverse order of removing them; screw
down all fixing screws one by one; take out iron nail plug in the brake cylinder oil
pipe one by one, and install the oil pipe. It becomes normal during
commissioning, and the fault is eliminated.
第 47 页
空调暖风
A/C heater
1 、 QY80T 上车空调烧保险
1. QY80T superstructure A/C fuse is burnt
故障描述：刚开始时空调正常工作，几分钟后发现空调没有风吹出来，之后检查
发现保险烧了，换上新保险后一开空调又烧保险。
Fault descriptions: At the beginning, A/C works normally; however, several
minutes later, A/C doesn’t work anymore. After check, find out that the fuse
is burnt, and A/C fuse is burnt again after replacement.
处理过程：
第一步 : 开空调马上烧保险，说明电源线路有地方直接搭铁了。将空调的开关都恢
复到原位后换上新的保险。操纵室后面有一组连接到压缩机、风扇等空调的插头，
将此插头拔开后再去开空调，还是烧保险，那说明短路点出现在操作室内。
Step 1: If A/C fuse is burnt after startup, it means that the some parts in the
power line are directly ground. Recover all A/C switches and replace a new fuse.
A group of A/C plugs at the back of the control chamber are connected with the
compressor and fan; if the fuse is still burnt after removal, it means the short
circuit point is in the operating chamber.
鼓风机开关
Blower switch
制冷开关
Refrigeration
switch
第 48 页
空调暖风
A/C heater
1 、 QY80T 上车空调烧保险
1. QY80T superstructure A/C fuse is burnt
第二步：进入操作室内检查，将鼓风机的外盖
打开用一根线将电源直接送到制冷开关，不经
过蒸发器风扇开关。把开关打到制冷档，指示
灯亮、冷凝风扇工作、压缩机吸合，说明问题
出现在蒸发器风扇回路中。
Step 2: Perform check in the operating
chamber; open the blower cover and directly
connect the power supply to the refrigeration
switch with a line, without passing the
evaporator fan switch. Turn the switch to the
refrigeration gear, the indicator lamp is on; the
condenser fan works and the compressor
engages, it means that the evaporator fan
circuit has fault.
第三步 : 将蒸发器外盖打开检查发现风扇电机的电源线被盖板压破了造成短路搭
铁；将线包好，试用空调，空调正常工作。
Step 3: Open the evaporator cover and check it, find out that the fan motor power
line is damaged by the cover plate and leads to short circuit grounding; repair the
line and perform commissioning to A/C, and it normally works.
搭铁位置
Grounding
position
第 49 页
空调暖风
A/C Heater
2 、 QY25T 上车空调效果差
2. QY25T superstructure A/C has poor effect
故障描述：客户打开空调时，发现制冷效果相当的差。
Fault descriptions: The customer reflects that the refrigeration effect is very
poor when turning on A/C.
处理过程：
第一步 : 到现场试车，发现上车空调制冷效果极差，观察制冷剂又不缺。
Step 1: When performing commissioning in site, find out that the superstructure
A/C has very poor refrigeration effect while the refrigerant is sufficient.
观察窗
Observati
on
window
第 50 页
空调暖风
A/C Heater
2 、 QY25T 上车空调效果差
2. QY25T superstructure A/C has poor effect
第二步 : 观察空调齿轮马达，空转时转速还可以，一旦空调带载转速明显降了下来，
此时判断齿轮马达可能有问题。
Step 2: Observe A/C gear motor, which normally rotates during idle speed while
sharply decreases under load conditions. In such case, confirm that the gear
motor may have fault.
第三步 : 拆开马达尾部泄油管，有液压油喷出，于此可判断马达内泄，更换马达后
恢复正常。
Step 3: Remove the tail oil-drain tube of the motor and hydraulic oil injects from it;
confirm that the motor has internal leakage. It becomes normal after replacing the
motor.
第 51 页
空调暖风
A/C Heater
1 、 QY25T 上车暖风不工作 -I
1. QY25T superstructure heater doesn't work-I
故障描述：将上车暖风机打开，上车暖风机风机不转，上车无暖风。
Fault descriptions: When turning on the superstructure heater, its fan
doesn’t work and no warm wind in the superstructure.
处理过程：
第一步 :
Step 1:
1 、将上车暖风打开，暖风机不工作，先检查暖风机的保险，发现保险并无异常；
1. Turn on the superstructure heater, which doesn’t work. Firstly, check the
heater fuse, and find out that it is normal;
2 、再检查暖风机控制盒是否通电，发现通电为正常；
2. Secondly, check if the heater control box is electrified and find out that it is
normal;
3 、于是又检查与控制盒连接的插头是否有电，经检查并没有电流通过，说明控制
盒内部某位置损坏，需更换控制盒。
3. Thirdly, check if the plug connected with the control box is electrified, and find
out that it is not electrified, which shows that some position in the control box is
damaged, and the control box shall be replaced.
暖风控制盒
Heater control box
第 52 页
空调暖风
A/C Heater
1 、 QY25T 上车暖风不工作 -I
1. QY25T superstructure heater doesn't work-I
第二步：更换控制盒后，发现暖风机还是工作
不正常，于是开始观察暖风机，刚打开暖风机
开关时，先转一下，之后就不转了，这种现象
一般都是暖风主机有问题，于是更换暖风主机。
Step 2: After replacing the control box, the
heater still works abnormally; in such case,
observe the heater. At the beginning of
turning on the heater switch, the heater runs,
and then it stops, which means that its main
engine has fault, and then replace it.
第三步 :
Step 3:
更换完主机后，试车，暖风机工作正常。
（如果此时暖风机还不工作或工作异常时，可
检查火花塞是否完好，如果火花塞太脏或者烧
毁，就要更换火花塞。）
After replacing the main engine and
performing commissioning, the heater works
normally.
(If the heater doesn’t work yet or works
abnormally in such case, please check if the
spark plug is undamaged. If the spark plug is
too dirty or burnt, please replace it.)
火花塞
Spark plug
第 53 页
空调暖风
A/C Heater
2 、 QY25T 上车暖风不工作 -II

2. QY25T superstructure heater doesn't work-II
故障描述：将上车暖风机打开，上车暖风机不转，上车无暖风。
Fault descriptions: Turn on the superstructure heater, it doesn’t work and
there is no warm wind in the superstructure.
处理过程：
第一步 : 检查暖风，用万用能表测量线
路 300 号线通电正常。
Step 1: Check the heater and measure
if the 300# line of the circuit is normally
electrified with the universal meter.
第二步 : 检查暖风开关保险，发现烧
坏，更换新的保险之后，暖风还是不工
作，保险还是烧坏。推断控制盒或者电
机内部搭铁。
Step 2: After checking the heater
switch fuse, find out it is burnt; after
replacing it with a new fuse, the heater
doesn’t work yet and the fuse is still
burnt. Confirm that the control box or
the motor inside is grounded.
第 54 页
空调暖风
A/C Heater
2 、 QY25T 上车暖风不工作 -II

2. QY25T superstructure heater doesn't work-II
第四步：更换暖风电机后暖风正
第三步 : 更换新控制盒后暖风依然不工
常工作，整车工作正常。
作，确定是暖风电机故障。
Step 4: After replacing the
Step 3: After replacing the control box,
heater motor, it works normally,
the heater doesn’t work yet, confirm
and the complete crane also
that the heater motor has fault.
works normally.
暖风电机
Heater motor
控制盒
Control box
第 55 页
空调暖风
A/C Heater
1 、 QY25T 上车动作发抖
1. QY25T superstructure jitters
故障描述：做变幅、伸缩、卷扬动作时不顺畅、发抖，动作慢、加速动作一样
慢。
Fault descriptions: In case of luffing, extending and retracting and
winch, it acts abnormally, slowly and jitters. Its acceleration action is
slow too.
处理过程：
第一步 : 把变幅抬到 80° ，拼压，检查压力正

常（ 21mpa ）。
Step 1: Lift the luffing to 80° and assemble it,
and check if the pressure is normal (21mpa).
第二步 : 检查流量，把上部操纵阀的三通流量阀及每片阀的压力补偿阀进行清洗，
未发现有发卡及堵塞现象。
Step 2: Check the flow and clean the three-way flow valve of the upper control
valve and its pressure compensation valve, and it is not stuck and blocked.
第 56 页
综合
Comprehensive
1 、 QY25T 上车动作发抖
1. QY25T superstructure jitters
第三步 : 做动作时，中心回转压力油管在跳动。用手摸压力管，感觉压力一时大一
时小，有空气声音；检查进油管发现未破裂不漏油。
Step 3: During action, find out that the central slewing pressure oil tube bounces.
Touch the pressure pipe by hand and find out that the pressure fluctuates
frequently and hear the air sound. After checking the oil inlet pipe, find out that it
is has no fracture and oil leakage.
中心回转接头
Central slewing
connector
第四步：蹲在液压油箱下往上看，发现液压
油箱的截止阀阀柄与进油管不在一条直线，
朝车前身 45° ，液压油箱截止阀关闭了一
半，只有一半的流量，导致进油不够，做动
作发抖，把截止阀扳到与进油管一条直线
后，动作恢复正常。
Step 4: When standing under the hydraulic
oil tank and looking forward, find out that the
hydraulic oil tank cut-off valve handle and
the oil inlet pipe are not collinear. When
looking the front part of the crane by 45°, find
out that the hydraulic oil tank cut-off valve is
closed by half and there is only half flow,
thus resulting in insufficient oil-inlet and
jittered action. After making the cut-off valve
and the oil inlet pipe be collinear, the action
becomes normal.
油箱截止阀
Oil tank cut-off
valve
第 57 页
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2 、 QY25T 变幅下、吊臂伸出等没有动作
2. 25T luffing has no downward action and the boom has
no extension action
故障描述：主臂抬到 70 度以后突然下降没反应，变幅下等也没有动作。
Fault descriptions: When lifting the main boom to 70°, it suddenly
descends and then has no reaction, and the luffing doesn’t have
descending action.
处理过程：
第一步 : 到了现场以后，观察做主臂下降动作时压力只有 4Bar ：

Step 1: After reaching the site, find out the pressure is only 4Bar when the main
boom descends:
1 、首先从压力和平衡阀入手，调节变幅二次溢流阀压力后，压力没有明显的变
化，还是无动作。
1. Firstly observe the pressure and balance valve; after adjusting the secondary
overflow valve pressure of the luffing, the pressure has no obvious change and
no action.
2 、分析是否为平衡阀卡死，在平衡阀上端盖打开后加一个比较厚的垫片后，做动
作还是没反应。
2. Analyze if the balance valve is stuck; after opening the end cover on the
balance valve and adding a thicker gasket, it acts while without reaction.
3 、第三个原因分析可能是二次溢流阀卡死导致压力建立不起来，把主臂伸缩和变
幅阀片上的两个二次溢流阀交换后问题依然存在。
3. The third cause is: The secondary overflow valve is stuck and the pressure
can’t be established. After exchanging two secondary overflow valves on the
telescopic and luffing valve plates on the main boom, the fault still exists.
第 58 页
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2. QY25T
QY25T luffing has no downward action and the boom has no
extension action
第二步 : 在试车的过程中发现，此车在小钩起升和变幅一起做复合动作时，主臂下
降有动作，而且压力可以建立起来，根据这种现象分析可能有两种原因：
Step 2: During commissioning, it is found that the main boom descends and the
pressure can be established when the crane acts together with the luffing in case
of small hook lifting. According such phenomena, judge there may exist two
causes:
1 、主阀阀片内部阻尼发卡。
1. The interior damping of the main valve plate is stuck.
2 、可能是组合控制阀上面单向阀发卡导致。
2. The fault may be caused by the stuck one-way valve on the combined control
valve.
3 、首先判断到底是主阀原因还是组合控制阀原因，主阀上面变幅和伸缩二次溢流
阀上面各有一根油管接到组合控制阀上面，组合控制阀各有一个单向阀之对应，
两根油管短接后试车，发现此时主臂可以下降，根据此现象判断主阀没有问题是
组合控制阀上面单向阀的问题。
3. Firstly judge the cause is the main valve or the combined control valve. One oil
pipe of the luffing on the main valve and one oil pipe on the secondary overflow
valve are connected with the combined control valve, and one one-way valve
corresponds with the combined control valve respectively. After short circuiting
two oil pipes, perform commissioning, and find out that the main boom can
descend. It can be judged that the main valve is normal while the one-way valve
on the combined control valve has fault.
组合控制阀上的单
向阀
One-way valve on
the combined
control valve
第 59 页
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2. QY25T luffing has no downward action and the boom has no
extension action
第三步 : 由于小勾和变幅一块做复合动作时，主臂下降才有反应，所以拆开小钩起
升和变幅所对应的单向阀，发现小勾起升单向阀发卡，清洗后，试车正常，问题
解决。
Step 3: As the main boom can descend when small hook and luffing perform
compound action together, remove the one-way valve corresponding to the small
hook lifting and luffing. Find out that the one-way valve for small hook lifting is
stuck; after cleaning, it becomes normal during commissioning and the
troubleshooting can be done.
第 60 页
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3 、 QY25T 主副卷扬、回转无动作
3. QY25T main and auxiliary winches have no slewing action
故障描述：用户打电话报修说主副卷扬和回转无动作，而且能听见液压油吱吱的
响。
Fault descriptions: The user calls to reflect that the main and auxiliary
winches have no slewing action, and the hydraulic oil makes squeaky
sound.
处理过程：
第一步 : 根据用户描述的故障现象，查看上车液压系统的控制压力是否正常 . 当时
控制压力值为 0.8Mpa 左右，与正常压力值 3.5Mpa 相差太多，所以卷扬减速机和
回转减速机的制动缸无法正常被开启。
Step 1: According to the fault phenomenon described by the user, check if the
control pressure of the superstructure hydraulic system is normal. Find out that
the control pressure value is about 0.8Mpa, which is largely different from the
normal pressure value of 3.5Mpa. Therefore, the brake cylinders of the winch
reducer and the slewing reducer can’t be normally started.
第 61 页
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3 、 QY25T 主副卷扬、回转无动作
3. QY25T main and auxiliary winches have no slewing action
第二步 : 控制压力过低，先进行压力调整，调
整压力后试车查看压力，发现压力表上的压力
值没有变化，试动作也还是没有。
Step 2: The control pressure is too low. Firstly
adjust the pressure, and then perform
commissioning to check the pressure, find out
that the pressure value of the pressure gauge
doesn’t change and the winches don’t act.
先导压力溢流阀
Pilot pressure
overflow valve
第三步：安装清洗后的控制溢流阀，然后试车，查看压力值是否正常。试车发现
清洗溢流阀后压力值可以达到 4Mpa ，此时，主副卷扬和回转的动作也恢复正常。
Step 3: Install the cleaned control overflow valve; perform commissioning, and
check if the pressure value is normal. During commissioning, find out that the
pressure value of the cleaned overflow valve can reach 4Mpa and the main and
auxiliary winches have normal slewing action.
第 62 页
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4 、 QY20T 上车危险方向不切断
4. QY20T superstructure dangerous action can’t be stopped
故障描述：用户打电话报修说，作业时，限位不起作用，危险动作不会切断。
fault descriptions: The user calls to reflect that the limit function doesn’t
work and the dangerous action can’t be stopped.
处理过程：
第一步 : 首先要检查线路，从最简单的入手。要明白动作不切断，主要原因是卸荷
阀不工作，检查卸荷线是否给电。
Step 1: Firstly, check the circuit, and try to solve the problem from the simplest
way. You need to know that the unstopped action is due to abnormal unloading
valve. Check if the unloading line is electrified.
卸荷电磁阀
Unloading
solenoid valve
第 63 页
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4 、 QY20T 上车危险方向不切断
4. QY20T superstructure dangerous action can’t be stopped
第二步 : 检查各个工作元件，卸荷阀电磁线圈
是否正常，可以发现电磁线圈一针脚被碰断，
导致断电，卸荷阀不能正常工作。
Step 2: Check all working elements to see if
the solenoid coil of the unloading valve is
normal, find out that one pin of the solenoid
coil is broken, which leads to un-electrification
and abnormal unloading valve.
第四步：更换新的电磁线圈后试车。发现当卷
扬快速缩到限位处时动作会切断，但是做慢动
作时，动作就不能切断；此问题看似无从下
手，其实只要我们搞清楚原理即可。慢动作不
能切断动作，也就是不能给电到泄荷阀，操纵
杆不够灵敏。调节操纵杆的螺杆挡杆，使行程
开关到最灵敏位置，试车后限位动作正常。
Step 4: After replacing it with a new solenoid
coil, perform commissioning, and find out that
the action will be stopped when the winch
quickly retracts to the limit position. However,
in case of slow action, it can’t be stopped.
Such fault seems very difficult, which can be
solved if we know its principles. The cause
why the slow action can’t be stopped is that
the unloading valve can’t be electrified and the
control lever is not sensitive enough. Regulate
the stop lever of the threaded lever of the
control lever to make the stroke switch be the
most sensitive. During commissioning, the limit
action becomes normal.
第 64 页
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5 、 QY30T 无副勾起升，吊臂只有缩方向
5. QY30T auxiliary hook has no lifting action and the boom is only
available for retracting
故障描述：此车在进行吊臂伸缩操作时，吊臂缩方向正常，但伸方向是副钩下放，
同时副钩没有起升动作。
Fault descriptions: The boom has normal retracting direction in case of
extension and retracting; however, the auxiliary hook descends in case of
extension and the auxiliary has no lifting action.
处理过程：
第一步 : 伸缩与副卷扬是通过电磁切换阀实现，正常情况下为伸缩动作，如需副卷
扬操作，须经过操纵室旋钮开关切换；
Step 1: The extension and retracting and the auxiliary winch lifting are hit through
the solenoid switch valve, and it performs extension and retracting under normal
conditions. If auxiliary winch operation is needed, please use the knob switch in
the control chamber;
吊臂伸与副卷扬起切换
电磁阀 Solenoid valve
for boom extension
and auxiliary winch
lifting
第 65 页
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5 、 QY30T 无副钩起升，吊臂只有缩方向
5. QY30T auxiliary hook has no lifting action and the boom
is only available for retracting
第二步 : 经分析，出现此故障的原因为组合控
制阀上的伸缩与副钩切换电磁阀失效或单方向
卡死。
Step 2: After the analysis, find out that the
solenoid valve for extension and retracting
and auxiliary hook switching on the combined
control valve fails or it is stuck in one
direction.
吊臂伸与副卷扬起切
换电磁阀
Solenoid valve for
boom extension and
auxiliary winch lifting
switching
第三步 : 检查电磁线圈通电，发现有磁力，证
明线圈没有问题。将两个电磁阀分别拆解，并
用油品清洗，重新安装后，动作恢复正常。
Step 3: After check, find out that the solenoid
coil is electrified and it is magnetic, which
shows that the coil is normal. Disassemble
two solenoid valves; clean them with oil, and
then re-install them, and their action becomes
normal.
第 66 页
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6 、 QY25T 卷扬无法下放，吊臂无法缩回
6. QY25T winch can't descend and the boom can't be retracted
故障描述：车主在立塔吊时突然性的出现此现象，且无法恢复。拧住强制开关
后，动作恢复。
Fault descriptions: The crane owner reflects that such phenomenon occurs
suddenly in case of tower crane erection, which can’t be recovered. After
screwing down the forced switch, the action becomes normal.
处理过程：
第一步 : 此故障现象为过放电路问题，过放报警，首先检查操纵室过放电磁阀 A5
的保险是否烧坏。检查后发现保险熔断，换上新保险后，故障未解除，过放依旧报
警，但保险未被熔断。
Step 1: The fault phenomena include the overrelaxing circuit fault and
overrelaxing alarm. Firstly, check if the overrelaxing solenoid valve A5 fuse of the
control chamber is burnt. After check, find out that the fuse is burnt, and replace it
with a new fuse; however, the fault is not eliminated: The overrelaxing still alarms
but the fuse is not burnt.
过放电磁阀
Overrelaxing
solenoid valve
第 67 页
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Comprehensive
6 、 QY25T 卷扬无法下放，吊臂无法缩回
6. QY25T winch can't descend and the boom can't be retracted
第二步 : 将故障往后推到过放电磁阀，用电压表量取过放电磁阀电压，发现无电压，用尖角物体将电

磁阀阀芯抵住，变幅等动作恢复正常；将此电磁阀拔出与过卷电磁阀对调，发现过卷等动作正常，说
明电磁阀正常。由此得出为过放线路问题。
Step 2: Consider that the fault may arise from the overrelaxing solenoid valve: Measure the
overrelaxing solenoid valve voltage with the voltmeter and find out that there is no voltage. When
resisting the solenoid valve core with sharp-angled object, the luffing and other actions become
normal. After exchanging the pullout and overwinding solenoid valves of the solenoid valve, find out
that the overwinding and other actions are normal, which shows that the solenoid valve is normal
and the overrelaxing circuit has fault.
过放电磁阀
Overrelaxing
solenoid valve
第三步 : 将三圈过放保护装置拆开后，发现
客体内存在积水且生锈严重，动卷扬手柄，此
装置短路而无法工作，将过放装置断接，过放
报警解除，所有动作恢复正常。
Step 3: After removing the three-layer
overrelaxing protection device, find out that
there is accumulated water and serious rust.
When operating the winch handle, the device
is short-circuited and can’t work. When
disconnecting the overrelaxing device, the
overrelaxing alarm is released and all actions
become normal.
过放开关
Overrelaxin
g switch
第 68 页
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7 、 QY30T 不挂取力器上车常带电
7. QY30T superstructure is always electrified without engagement
of power take-off
故障描述：客户报修，上车没有油门。
Fault descriptions: The customer reflects that the superstructure throttle is
spongy.
处理过程：
第一步 :
Step 1:
上车没有油门，有以下几种情况会导致：
Following conditions will result in spongy throttle of the superstructure:
1 、取力器信号异常；
1. Abnormal PTO signal;
2 、 GPS 系统故障；
2. GPS system fault;
3 、油门踏板损坏；
3. Throttle pedal damage;
4 、油门踏板相关线路故障。
4. Fault of relevant throttle pedal circuit.
到达现场后挂上取力器，取力信号灯不亮，未听到发动机加载声（转速提高），观察发现油泵已工
作，初步判断取力信号不正常。但到上车却意外发现上车有电。摘掉取力器，发现上车仍然有电。以
下几种情况会出现此种现状：上车电源继电器 K3 损坏常闭合；线路短路。
After reaching the site, engage PTO, but the PTO signal lamp is off and there is no engine load
sound (increasing rotation speed). After observation, find out that the oil pump works, thus
preliminarily judging that the PTO signal is abnormal. When observing the superstructure, find out
that it is electrified accidentally. When removing PTO, find out that the superstructure is still
electrified. Following conditions may result in such phenomenon: The superstructure power relay K3
is damaged and normally-closed and the circuit is short-circuited.
拔下上车电源继电器 K3 ，用万用表量得 30# 脚和 87# 脚通路，判断为 K3 失效。更换新继电器后挂
上取力器上车没电，取力器信号灯仍然不亮。
Remove the superstructure power relay K3 and measure 30# pin and 87# pin with the universal
meter, and find out that they have open circuit, thus judging K3 fails. Replace it with a new relay and
engage PTO, and the superstructure is not electrified and the PTO signal lamp is still off.
第 69 页
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of power take-off
第二步 : 挂上取力器后上车没电，电脑不显示。上车没电故障点一般为： 19# 上车电源保

险烧坏；取力器传感器损坏；取力器传感器插头松动；中心导电环接触不良；上车电源继
电器 K3 失效等。
Step 2: After engaging PTO, the superstructure is not electrified and the computer has no
display. The un-electrified superstructure is usually caused by: Burt power fuse of the
19# superstructure; damaged PTO sensor; loose PTO sensor plug; poor contact of the
central conducting ring; abnormal superstructure power relay K3, etc.
检查 19# 保险正常， K3 继电器刚更换后正常。到取力器传感器量得传感器良好， 0# 搭铁
线正常，但是 017# 线没有 24V 电源，判断取力器传感器信号线路有断路现场。
Check the 19# fuse, and find out that it is normal. After replacing it with a new K3 relay,
find out that it becomes normal. After measurement, find out that both the PTO sensor
and the 0# grounding are normal. However, find out that the 017# circuit has no 24V
power supply, thus judging that PTO sensor signal circuit has open circuit.
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of power take-off
第三步 : 用万用表测量得 K3 继电器的插座 86# 脚有

24V 电源， K3 继电器是好的，可以判断 85# 脚到传感
器信号线路有断路，挂取力后无法构成回路。依线路寻
找，发现驾驶室保险盒出来的排插中 017# 线松动接触
不良，导致取力信号异常。拔下插头，挑出 017# 线，
紧固后重新安装插好插头，试车恢复正常。
Step 3: After measurement with the universal meter,
find out that the 86# pin of the K3 relay socket has 24V
power supply and the K3 relay is normal, thus judging
that the circuit between the 85# pin and the sensor
signal circuit has open circuit and the circuit can’t be
formed after PTO engagement. Try to find out the
cause along the circuit, and find out that the 017# line
of the extension socket of the cab fuse box is loose
and has poor contact, which results in abnormal PTO
signal. Remove the plug and pick out the 017# line,
and then re-install the plug after fastening, and it
becomes normal during the commissioning.
第 71 页
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Comprehensive
8 、 QY50T 上车无动作 -I
8. QY50T superstructure has no action-I
故障描述：从总部开至保障中心的车辆，进行首次开机检查时发现一按上车右边
手柄的使能开关， F5 保险就烧坏，导致上车无动作。
Fault descriptions: When the crane is driven to the guarantee center for
first startup check from the headquarters, the F5 fuse is burnt after
pressing down the enable switch of the right handle of the superstructure,
which leads to the superstructure has no action.
处理过程：
第一步：根据此故障，一按右边手柄使能开关就烧保险，说明在电气上出故障，
于是按左边手柄发现，并未有保险烧坏的现象，说明右边手柄控制有问题
Step 1: The fault phenomenon is that the fuse is burnt after pressing down the
enable switch of the right handle, which shows that the crane has electrical fault.
After pressing down the left handle, find out that the fuse is not burnt, thus
judging that the right handle control has fault.
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第二步：将右边手柄拆开，到手柄处有两个插头，一个是四插的，一个是两插的，
先拔掉两插插头（ 150 号线与 131 号线），按右边手柄使能开关，发现保险未烧
坏，说明故障点在 150 号线与 131 号线处。
Step 2: Remove the right handle, and there are two plugs at the handle: One has
four-socket and one has two-socket. Firstly, remove the two-socket plug (150#
line and 131# line) and press down the enable switch of the right handle, and find
out that the fuse is not burnt, thus judging that the 150# and 131# lines have
fault.
第 73 页
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第三步：将进入左边手柄的控制线路开关两插头调至
右边手柄，动右边手柄使能开关，发现未烧保险，说
明从操纵室配电处到手柄下方的两插的插头处线路是
好的，由此得出两插插头到手柄使能键连接处线路出
问题所致。
Step 3: Adjust two plugs of the control circuit switch
of the left handle to the right handle and move its
enable switch, and the fuse is not burnt, which
shows that two plugs between the part from the
power distribution of the control chamber and the
lower part of the handle are normal, thus judging that
the circuit at the connection between two-pin plug
and the handle enable switch has fault.
第四步：将手柄完全拆开，检查线路，发现线路进入手柄缝隙处被压破，重新接线
并布线后，试使能开关，发现未烧保险，动作恢复正常。
Step 4: Completely remove the handle and check the circuit, find out that the
circuit access handle gap is damaged. After re-connection and wiring and test the
enable switch, and find out that the fuse is not burnt and the action is normal.
搭铁处
Groundin
g position
第 74 页
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Comprehensive
9 、 QY50T 上车无动作 -II

9. QY50T superstructure has no action-II
故障描述：上车无动作，只有支腿可以做动作。
Fault descriptions: The superstructure has no action, and only the
outrigger can act.
处理过程：
第一步：首先从上车启动检查先导压力，发现先导压力为零；可以确定是先导控制
部分的问题导致的整车无动作。
Step 1: Firstly start the superstructure and check the pilot pressure, and find out
that it is zero and confirm that the complete crane has no action because of the
pilot control part fault.
先导压力表
Pilot pressure
gauge
第 75 页
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第二步 :
Step 2:
1 、检查组合控制阀，发现上车启动之后，电磁阀均不得电，然后检查控制 103 号
线的保险发现其烧断。
1. Check the combined control valve and find out that the solenoid valve is not
electrified after starting the solenoid valve. After that, check the fuse of the control
103# line and find out that it is burnt.
2 、更换新的保险 , 启动时仍然烧坏。推断某处有短路现象，检查时发现，再换上
新的保险启动上车时 Y3 电磁阀有烧焦的味道并伴有烟冒出。
2. After replacing it with a new fuse, it is still burnt after start, thus judging that
some part has short circuit. When replacing it with a new fuse and starting the
superstructure, find out that the Y3 solenoid valve is burnt and discharges smoke.
第 76 页
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Comprehensive

第三步 : 将 Y3 电磁线圈的连接插头拔掉，然后再换上新保险并启动上车，先导压
力恢复正常值 3.7MPa 左右，更换新的电磁线圈之后上车的动作恢复正常。
Step 3: After removing the connecting plug of the Y3 solenoid coil; replacing a
new fuse and starting the superstructure, the pilot pressure becomes normal
(about 3.7MPa). After replacing a new solenoid coil, the superstructure acts
normally.
第 77 页
综合
Comprehensive
10 、 QY25T 回转时上车偶尔无电
10. QY25T superstructure is un-electrified occasionally during
slewing
故障描述：客户刚施工时动回转，有时出现上车没电。
Fault descriptions: The customer reflects that the superstructure is un-
electrified when performing slewing action during construction.
处理过程：
第一步 : 首先我到达现场时，要客户动回转发现有时上车突然没电，做别的动作都
正常，我判断可能是中心导电滑环出问题，客户说导电滑环是换的新的，测量导
电环出来的电源线都有电过来。
Step 1: After reaching the site, find out that: When the customer performs slewing
action, the superstructure is suddenly powered off sometimes, but other actions
are normal, thus judging that the central conducting slip ring may have fault. The
customer reflects that the conducting slip ring is new and all power lines are
electrified.
第 78 页
综合
Comprehensive
10 、 QY25T 回转时上车偶尔无电
10. QY25T superstructure is un-electrified occasionally during slewing
第二步 : 这时客户说每次出现这种情况都在早上刚干活的时候，其余时间都正常，这时我联
想到是不是因为这段时间东北这里气温低，上车的回转齿轮那里黄油被冻住，导致打铁线
电路没有与下车车架形成回路，而当在起重机干活一段时间后，黄油逐渐的变稀，从而不
会出现这种现象。
Step 2: The customer reflects that such phenomenon often occurs when starting to work
in the morning and it is normal at other times, thus judging that the phenomenon may be
related to low temperature in the northeast region. The grease of the slewing gear of the
superstructure may be frozen, which results in no circuit between the grounding line
circuit and the chassis frame. And, after the crane operating for some time, the grease
becomes thinner, and such phenomenon disappears.
第三步 :
我把导电滑环的备用线，上面的接一根线搭
在电喇叭那里打铁，导电环下面那根备用线
搭在车架上，让它直接这样形成一个回路，
后面再动回转，此故障排除。
Step 3:
After that, connect one upper standby wire
of the conducting slip ring with the electric
horn and connect one lower standby wire
with the frame to form a circuit directly.
When performing slewing action again, the
troubleshooting can be done.
第 79 页
Chassis
第 80 页
取力器
PTO
1 、 QY25T 取力器挂不上
1. QY25T PTO can't be engaged
问题描述：车辆启动后无法挂上取力，还伴有轻微的磨齿声，偶尔挂上取力后，
无法摘下取力。
Fault descriptions: After starting the crane, PTO can’t be engaged and
there is also slight gear grinding sound. Sometimes, PTO can be engaged,
which can’t be removed.
处理过程：
第一步 :
Step 1:
检查气压在 5.5bar
Check if the air pressure is 5.5bar.
将取力传感器上的线路短接，指示灯亮，电路正常。
Short circuit the circuit on the PTO sensor, the indicator lamp is on and the circuit
is normal.
将取力传感器拆下，用手按动传感器底部，取力器指示灯亮，传感器正常。
Remove the PTO sensor and press down its bottom by hand, the PTO indicator
lamp is on and the sensor is normal.
取力器感应开关
PTO induction switch
第 81 页
取力器
PTO
1 、 QY25T 取力器挂不上
1. QY25T PTO can't be engaged
第二步 : 考虑机械故障
Step 2: Consider that the cause is the mechanical fault
将取力器上气路管拆下，没有堵塞漏气现象。
Remove the gas circuit pipe of PTO, and there is no blocking and air leakage.
拆开取力器气缸，发现气缸内和活塞上有锈迹，并用手按动，发现活塞和气缸间隙变小有阻力，判断
此处为故障点。
After removing the PTO cylinder, find out that the cylinder and piston have rust; press them by hand,
and find out that the clearance between the piston and cylinder becomes small and there is
resistance, thus judging that it is the fault cause.
将气缸内和活塞圆弧面用细砂纸研磨，更换活塞上的 O 型圈，涂抹润滑油安装好。试车一切正常，故
障排除。
Grind the arc surface of the cylinder and piston with a piece of find sandpaper; replace the O-ring on
the piston with a new one, and install it after coating lubricating oil. During the commissioning, all
become normal and the troubleshooting can be done.
第 82 页
取力器
PTO
2 、 QY25T 行车后取力器挂不上
2. QY25T PTO can't be engaged after traveling
问题描述：每次行车后取力挂不上。
Fault descriptions: PTO can’t be engaged after traveling.
处理过程：
第一步 : 客户反映取力挂不上，经检查气路的管路，管路一切正常，所有问题都聚
集在气控截止阀上，（因为每次挂不上取力器，将其气管松开会有气排出）所以
我怀疑气控截止阀有故障，更换新的气控截止阀，故障还是存在。
Step 1: The customer reflects that the PTO can’t be engaged; after check, find
out that the gas circuit pipelines are normal and the fault may be the pneumatic
control cut-off valve (as PTO can’t be engaged, residual air may be exhausted
when loosening its air pipe). Accordingly, judge that the pneumatic control cut-off
valve has fault, and the fault still exists after replacing it with a new pneumatic
control cut-off valve.
第 83 页
取力器
PTO
2 、 QY25T 行车后取力器挂不上
2. QY25T PTO can't be engaged after traveling
第二步 : 经过以上的检查可以断定不是
气控截止阀毛病，我对手刹制动阀进行
检查，检查时发现手刹制动阀没有拉到
位，用手强制手刹制动阀还能听到有排
气声。
Step 2: After check, judge the
pneumatic control cut-off valve is
normal. After checking the brake valve
of the hand brake, find out that it is not
properly engaged; in addition, when
forcedly applying the brake valve of the
hand brake by hand, exhaust sound
can be heard.
第三步 : 通过上面的观查，可以断定是
手刹阀的问题，气路排气不干净导致取
力挂不上，更换手刹制动阀后试车正常。
Step 3: After above check, judge that
the hand brake valve has fault and the
gas circuit is not completely exhausted
and PTO can’t be engaged. After
replacing the brake valve of the hand
brake, it becomes normal during the
commissioning.
手刹
Hand
brake
第 84 页
转向
Steering
1 、 QY80T 方向机行驶时异响
1. QY80T steering gear has abnormal sound during
traveling
问题描述：用户车辆在路上行驶时方向机突然发出异常的响声。
Fault descriptions: The user reflects that the steering gear suddenly sends out
abnormal sound when traveling on the road.
处理过程：
第一步 : 现场和用户交流，用户反映车辆在 50 公里行驶时方向发出齿轮打齿的声
音，原地起动发动机，没有明显听见方向异常的响声，用手打动方向比较轻力度
也正常，但使方向保持在一个位置上，感觉方向比平常车辆方向声音响一点，但
也没有用户说的很响的声音。打开油箱检查方向机油量正常，油品目测也正常。
Step 1: After site communication, the user reflects that the steering gear
suddenly sends out gear knocking sound when traveling mileage reaches 50km;
when starting the engine in site, there is no obvious abnormal sound. The
steering gear can be normally operated by hand; when keeping it at one position,
its sound is louder than that of other cranes; however, no user reflects that the
sound is very large. When opening the oil tank and checking the oil volume of
steering gear is normal; after the visual inspection, the oil quality is also normal.
转向油箱
Steering oil
tank
第 85 页
转向
Steering
1. QY80T steering gear has abnormal sound during traveling
第二步：检查方向机油路各处油管（动态和静态状态下）没有发现有明显拆弯、
漏油、变形、振动和进空气现象，也不像是外部引起的。怀疑是否是转向油泵内
部损坏引起这种现象，在方向机上接入压力表，检测压力能达到 12MPa, 而且压力
很稳定，近距离听油泵的声音也正常。检查方向机在行驶和静态下方向都正常。
Step 2: After checking all oil pipes of the oil circuit of the steering gear (dynamic
and static conditions), find out there are no obvious bending, oil leakage,
deformation, vibration and air intake; however, such phenomena are not caused
by external factors. It is suspected that the phenomenon is caused by interior
damages of the steering oil pump. Connect the steering gear with the pressure
gauge and test the pressure, find out that it can reach 12MPa and it is stable.
After short-distance hearing, the oil pump sound is normal. After check, find out
that the direction is normal under traveling and static conditions.
压力表接头
Pressure gauge
connector
第 86 页
转向
Steering
1. QY80T steering gear has abnormal sound during traveling
第三步：检查方向助力油缸正常。
Step 3: Check if the steering booster oil
cylinder is normal.
第四步：怀疑是否是油箱里面有异物堵
塞了进油口。用手在里面检查时发现并
没有异物，但是吸油滤芯掉下来了，重
新装上，试车工作正常。
Step 4: It is suspected that if the oil
inlet of the oil tank is blocked due to
foreign matters. When checking the oil
tank inside by hand, find out that there
are no foreign matters but the oil
suction filter core falls down. After re-
installation, it becomes normal during
commissioning.
第 87 页
转向
Steering
2 、 QY25T 转向油箱翻油
问题描述：打方向时转向油箱有大量气泡。
Fault descriptions: There is a lot of bubbles in the steering oil tank during
steering.
处理过程：
第一步 : 试车，把支腿支起来，让前轮悬空，发动车子来回打方向盘，发现不断
有气泡冒出。
Step 1: Perform commissioning; support the outriggers; suspend front wheels;
start the crane and turn the steering wheel, find out that bubbles appear
constantly.
转向油箱
Steering
oil tank
第 88 页
转向
Steering
2 、 QY25T 转向油箱翻油
第二步 : 来回打方向盘，然后把放气螺栓松
开，待气排尽后，把螺栓拧紧，再继续来回打
方向盘，如此反复几次，发现气泡几乎没什么
变化。
Step 2: Turn the steering wheel repeatedly
and then loosen the air-bleed blot; after
complete exhaust, screw down the bolt. After
that, continue turning the steering wheel for
several times, and find out that bubbles have
no changes almost.
第三步 : 气泡一直排不尽，说明一定有外界空
气进入，把整个转向系统检查一遍，发现没有
漏油部位，各管接头也没有松动，可以排除转
向系统进入空气。最有可能就是转向助力油泵
密封性不严，与机油串到一起，空气通过发动
机进入到转向系统，导致转向系统一直翻油，
更换新的转向助力油泵后，故障解除。
Step 3: The bubbles can’t be completely
exhausted, which shows that external air
comes in. Check the whole steering system,
find out there is no oil leakage part and no
pipe connector becomes loose, thus judging
that no air comes into the steering system.
The most possible cause is that the steering
booster pump sealing is loose and the engine
oil comes in it; after that, air enters into the
steering system through the engine, thus
resulting in oil overflows in the steering
system. After replacing it with a new steering
booster pump, the troubleshooting can be
done.
第 89 页
转向
Steering
3 、 QY25T 转向沉重
3. QY25T steering is heavy
问题描述：车辆行驶过程中转向比较沉重 , 特别是在转急弯时，方向转向非常吃
力，方向沉重相当明显。
Fault descriptions: The crane steering is heavier during traveling;
especially during the sharp turning, the steering is very heavy and the
heaviness is very obvious.
处理过程：
第一步 : 试车，车辆在行车过程中转向确实沉重 , 转大弯时方向沉重相当明显；检
查方向机油罐油量足够 , 油质也非常干净 , 滤芯也无堵塞现象。
Step 1: Perform commissioning, the crane steering is heavy during traveling,
which is very heavy during sharp turning. After checking the steering gear, find
out that its oil tank has sufficient oil, the oil is very clean, and the filter core is not
blocked.
转向油箱
Steering oil
tank
第 90 页
转向
Steering
3 、 QY25T 转向沉重
3. QY25T steering is heavy
第二步 : 将方向打死，检测方向机压力达到
10~12MPA 压力正常；检查方向机间隙也正
常 , 将方向机排空气口螺栓扭松发现有气泡
冒出 , 说明方向机内有空气。
Step 2: Turn the steering wheel to the limit
and check it, find out that the steering gear
pressure is normal (10~12MPA) and its
clearance is normal. After loosening
exhaust port bolt of the steering gear, find
out that bubbles come out from it, which
shows that there is air in the steering gear.
第三步 : 排完空气后试车正常，用了 5 天后 , 又出现转向沉重的现象 .

Step 3: After exhaust and perform commissioning, find out that it becomes normal.
However, after 5 days’ operation, the steering becomes heavy again.
再一次将方向机排气口螺栓松开，发现又有气泡冒出 , 拆掉转向助力泵油管，发现助力泵内
部不断有油从泵泄油口滴出来 , 说明助力泵内泄 . 更换助力泵后，加油排完空气后试车正常
。
Loosen the exhaust port bolt of the steering gear again, find out that bubbles come out
from it gains. After removing the steering booster pump oil pipe, find out that oil drips
from the oil-drain port, which shows that the booster pump has internal leakage. After
replacing the booster pump; filling oil and performing complete exhaust, it becomes
normal during commissioning.
转向助力泵
Steering
booster pump
第 91 页
制动
Brake
1 、 QY16T 刹车温度高
1. QY16T brake temperature is high
问题描述：当客户在野外把手刹拉上一段时间之后，把手刹放下之后不起作用，
一直处于抱死状态，但当客户每天在车库出来时是正常的。
Fault descriptions: The customer reflects that: When engaging the hand
brake for some time in the field and disengaging it, it can’t work and be
locked; however, it is normal when being driven out from the garage
everyday.
处理过程：
第一步 : 首先，在出现故障时看气压表的压力是否正常，经检查确定压力正常，将
发动机熄火，放下手刹听或摸气管是否有气传到后侧继动阀。经检查发现有气传
过去，但制动片还是处于抱死状态，确定问题出在继动阀上。
Step 1: Firstly, when the fault appears, check if the pressure of the air pressure
gauge is normal. After check, find out that it is normal. Stop the engine;
disengage the hand brake or touch the air pipe, try to find out that if air is
transmitted to the rear relay valve. After check, find out that air is transmitted but
the brake plate is locked, thus judging the cause is the relay valve.
第 92 页
制动
Brake
1 、 QY16T 刹车温度高
1. QY16T brake temperature is high
第二步：由于客户说在车库时一切正常，出去干活就会出现这个问题，所以猜测是气路进
水导致，所以我们将继动阀进行解体，发现继动阀内有水和被水解的黄油，这时可以判断
是水和黄油在零下 30 度时结冰和凝固导致活塞运动困难。
Step 2: As the customer reflects that the crane is normal in the garage and becomes
abnormal during operation, guess that the fault cause may be water entry into the gas
circuit. Accordingly, disassemble the relay valve and find out that there is water and
hydrolysed grease in the relay valve, thus judging that the piston movement becomes
difficult as water and grease are frozen and condensed under -30℃ 。
活塞
Piston
第三步：对继动阀进行除水和更换黄油，
复装后恢复正常，故障排除。
Step 3: Dewater the relay valve,
replace the grease and re-assemble it,
it becomes normal and troubleshooting
can be done.
第 93 页
制动
Brake
2 、 QY25T 低气压报警
2. QY25T has low air pressure alarm
问题描述：用户反映机器在气压达到 7bar 仍然低气压报警。

Fault descriptions: The user reflects that the low air pressure alarm still
exists though the air pressure reaches 7bar.
处理过程：
第一步 : 先把气压打到 7bar ，踩下离合器，发现离合器特别紧，打到 8bar 气压，
离合器踩下正常，低气压报警解除，初步判断气压确实低，低气压报警开关没坏。
Step 1: Firstly, turn the air pressure to 7bar and step down the clutch, find out that
the clutch is very tight. When turning to 8bar, the clutch can be normally stepped
down and the low air pressure alarm can be released, thus preliminarily judging
that the air pressure is really low and the low air pressure alarm switch is normal.
低气压开关
Low air
pressure
switch
第 94 页
制动
Brake
2 、 QY25T 低气压报警
2. QY25T has low air pressure alarm
第二步：分别拉下 3 个储气罐的拉环，发现其中一个主管离合器手刹的储气罐气
压特别低。
Step 2: Pull down the suspension link of 3 gas receivers, and find out that the air
pressure of the gas receiver of one main pipe clutch hand brake is very low.
第三步 : 拆下这个储气罐到四回路保护阀的接头，发车打气，发现接头没排气，判
断四回路保护阀损坏，换上新的四回路保护阀，故障解除。
Step 3: Remove the connector between the gas receiver and the four-circuit
protection valve and start and charge the crane, find out that the connector is not
exhausted, thus judging that the four-circuit protection valve is damaged. After
replacing it with a new four-circuit protection valve, the troubleshooting can be
done.
四回路保护阀
Four-circuit
protection valve
第 95 页
制动
Brake
3 、 QY50T 后轮刹车抱死
3. QY50T rear wheel brake is locked
问题描述：驾驶员在休息两天后，动车子发现车子跑不动，后轮抱死。
Fault descriptions: The driver reflects that the crane can’t be started and
rear wheels are locked during start after two days’ rest.
处理过程：
第一步 : 观察中后桥各顶杆回位情况，通过观察发现左边中后桥两个刹车顶杆回位
不畅。
Step 1: Observe return conditions of the crown bars of the intermediate and rear
axles, and find out that two brake crown bars of the left intermediate and rear
axles have unsmooth return.
第 96 页
制动
Brake
3 、 QY50T 后轮刹车抱死
3. QY50T rear wheel brake is locked
第二步 : 将制动气室顶杆拆掉，晃动调
整臂，发现制动凸轮轴卡死，判断是制
动凸轮轴锈蚀卡死，需拆卸打磨并加注
润滑油。
Step 2: Remove the crown bar of the
brake chamber and shake the
adjusting boom, and find out that the
brake camshaft is locked, thus judging
that brake camshaft is rusty and
locked, which shall be removed,
ground and filled with lubricating oil.
第三步 : 将左中后两个轮毂解体检查，
发现的确是因为制动凸轮轴锈蚀卡死导
致。将制动凸轮轴进行打磨，加注润滑
油，重新装上试车正常。
Step 3: Disassemble and check two
left, middle and right wheel hubs, and
find out that the cause is the rusty and
locked brake camshaft. Grind the
brake camshaft; fill it with lubricating oil
and re-install it, and it becomes normal
during commissioning.
第 97 页
传动
Transmission
1 、 QY25T 只有低档没有高档
1. QY25T is available for low gear only
问题描述：车辆行驶中没有高档，即从低档切换为高档后仍为低档。
Fault descriptions: The crane is unavailable for high gear during traveling,
namely it is still available for low gear when being switched to high gear
from low gear.
处理过程：
第一步 : 现场试车发现情况属实，停车检查发现原地切换高低档时，变速器操作杆
上切换手柄切换时虽有明显过气的声音，但变速器副箱内无高低档拨叉滑动的明
显声响，初步判定高低档切换阀内部发卡；
Step 1: After site commissioning, find out that the fault is true. After parking and
check, find out that: During site high-low gear switching, the switch handle on the
transmission operating rod has obvious sound during switching; however, the
high-low gear shift fork in the auxiliary tank of the transmission has no obvious
sliding sound, thus judging that the high-low gear switch valve is stuck inside;
第 98 页
传动
Transmission
第二步 : 打开高低档切换阀，发现切换阀内部阀芯存在卡滞现象，重新清理装复后，
进行高低档切换时，在变速器高低档气缸处有明显的高低档同步器滑套滑动的声
音，此时起动车子，待气压达到 8bar 时，踩下离合器，将变速器挂入低档区 1 档
位置，松开手制动，同时松开离合器踏板，但车子并不走；
Step 2: After turning the high-low gear switch valve, find out that the interior valve
core of the switch valve is stuck; when performing high-low gear switching after
cleaning and re-assembling, the high-low gear air cylinder of the transmission
has obvious high-low gear synchronizer sliding sleeve sound. In such case, start
the crane; when the air pressure reaches 8bar, step down the clutch; turn the
transmission to the first gear; loosen the hand brake and the clutch pedal, but the
crane can’t be started;
第 99 页
传动
Transmission
第三步 : 因为刚到现场时曾试车行驶，所以继续拆检高低档换挡气缸，发现气缸内
部并无卡滞现象，重新装复后再次试车，情况跟之前一样，挂档不走车，此时打
开取力器开关，挂入 4 档，然而取力器传动轴不转，那么此时有两种可能；第一、
变速器副箱同步器出现问题（不在低档区也不在高档区），第二、离合器出现问
题（动力不能往后传递）；
Step 3: As commissioning is immediately done after reaching the site, continue
removing and disassemble the high-low gear switch cylinder for checking, and
find out that the cylinder is not stuck inside. After re-assembling and performing
commissioning, the condition is as before: The crane can’t be driven after gear
engagement. In such case, turn on the PTO switch and turn it to the fourth gear;
however, the PTO drive shaft doesn’t run. In such case, there are two
possibilities: Firstly, the auxiliary tank synchronizer of the transmission has fault
(not in the low gear area or the high gear area); secondly, the clutch has fault
(power can’t be transmitted backwards);
第 100 页
传动
Transmission
第四步；仔细检查发现离合器总泵的自由行程间隙过小，连续踩踏离合器踏板
后，造成制动液不能够很好的回油，即离合器不分离。重新调整离合器自由行程
后，试车正常，高低档切换也能正常工作了。
Step 4: After careful check, find out that the free play clearance of the clutch
master cylinder is too small; after continuously stepping down the clutch pedal,
the brake fluid can’t properly return, thus the clutch can’t be released. After re-
adjusting the free play of the clutch, it becomes normal during commissioning,
and the high-low gear shifting becomes normal too.
离合器总泵
Clutch master
cylinder
第 101 页
传动
Transmission
2 、 QY25T 挂档困难
2. QY25T has difficult gear engagement
问题描述：用户在行驶过程中发现分离离合器时，离合器踏板踩不动或踩不到
位，导致挂不上档，无法正常行驶。
Fault descriptions: The user reflects that the clutch pedal can’t be stepped
down or properly stepped down when the clutch is released during
traveling, which results in gear engagement failure and abnormal driving.
处理过程：
第一步 : 检查时发现踩踏离合器踏板，动作有时正常，有时踏板踩不到位，或者踏
板很硬踩不下去；初步断定离合器总泵损坏的故障率比较大。
Step 1: During check, find out that: When stepping down the clutch pedal,
sometimes the action is normal; sometimes the pedal can’t be properly stepped
down, or sometimes the pedal can be stepped down forcedly only, thus
preliminarily judging that the clutch master cylinder may be damaged most
probably.
第 102 页
传动
Transmission
2 、 QY25T 挂档困难
2. QY25T has difficult gear engagement
第二步 : 离合器总泵内部有皮碗，可能是皮碗破裂导致总泵在动作时有空气进入，
导致离合器踏板踩不到位或踩不动；解体溢流阀发现有小铁片卡住了溢流阀阀芯。
Step 2: The leather cup in the clutch master cylinder may be broken and lead to
air in the master cylinder during action; therefore, the clutch pedal can’t be
stepped down or properly stepped down. When disassembling the overflow
valve, find out that the small iron plate gets the overflow valve core stuck.
第三步 : 更换新的离合器总泵后解决问题。
Step 3: After replacing it with a new clutch master
cylinder, the troubleshooting can be done. 离合器总泵
Clutch master
cylinder
第 103 页
发动机
Engine
1 、 QY25T 下车无法启动
1. QY25T chassis can't be started
问题描述：启动马达能正常工作，但是车辆无法正常启动。
Fault descriptions: The startup motor can normally work, but the crane
can’t be normally started.
处理过程：
第一步 : 检查柴油管路，供油正常；
Step 1: Check the diesel pipeline, and find out that the oil supply is normal;
手油泵
Hand oil
pump
第 104 页
发动机
Engine
第二步 : 因为启动马达工作正常，证明发动机 ECU 电源正常。检查 ECU 上钥匙开
关信号线，线号 305 是否有 24V 电压。
Step 2: The startup motor works normally, which proves that the engine ECU has
normal power supply. Check the key switch signal line on ECU to see if the 305#
line has 24V voltage.
第三步 : 经测量 305 号线没有 24V 电压，检查

保险 F23 是否烧坏，经检查保险正常；
Step 3: After measurement, find out that the
305# line has no 24V voltage. Check if the
fuse F23 is burnt; after check, find out that
the fuse is normal;
第 105 页
发动机
Engine
第四步：
Step 4:
1 、检查熄火 K18 继电器常闭触点通断是否正常；
1. Check if the normally-closed point of the extinction K18 relay has normal connecting
and disconnection;
2 、测量熄火 K18 继电器 85 、 86 号脚是否有 24V 电压，如果不按熄火开关，熄火 K18 继
电器 85 、 86 号脚是不应该有 24V 电压的；
2. Measure the 85# and 86# pins of the extinction K18 relay have 24V voltage; if the exti
nction switch is not pressed down, the 85# and 86# pins of the extinction K18 relay shall
have no 24V voltage;
3 、经检查 85 、 86 号脚没有 24V 电压，那么 008 号线就会经过 K18 号继电器的常闭触点
到 305 号线；
3. After check, find out that the 85# and 86# pins have no 24V voltage, and the 008# line
will reach the 305# line through the normally-closed contact of the K18 relay;
4 、结果检查是熄火 K18 继电器出来到发动机 ECU305 号线路断路，重新处理好 305 号线
启动功能恢复正常。
4. The check result shows that circuit between the extinction K18 relay and the 305# line
of the engine ECU has open circuit; after retreatment, the starting function of the 305#
line becomes normal.
第 106 页
发动机
Engine
2 、 QY50T 发动机水温高
2. QY50T engine has high water temperature
问题描述：在行驶时尤其是开空调，发动机水温很容易到 105 度以上，故障灯常

亮。
Fault descriptions: During traveling especially when turning on A/C, the
engine water temperature rises to above 105℃ easily and the fault lamp is
normally on.
处理过程：
第一步 : 连接诊断仪试车查看水温实际温度，确定是到仪表的水温传感器或者仪表
失效引起的读数不准还是发动机实际水温真高。结果发现发动机一直报发动机水
温传感器温度过高这个故障，实际测量的水温跟仪表读数差别在 5 度左右，行驶
过程中水温很快上到 105 度左右。
Step 1: Connect the diagnostic tester and perform commissioning to check the
actual water temperature to determine if the water temperature sensor or
instrument fails and leads to inaccurate reading or the actual water temperature
of the engine is high. The result shows that the engine always reports that the
water temperature sensor of the engine is too high; the difference between the
actual water temperature and the instrument reading is about 5°, and the water
temperature quickly rises to about 105℃ during traveling.
节温器
Thermo
stat
第 107 页
发动机
Engine
第二步 : 更换给 ECU 信号的水温传感器，再试车（与之前试车为同一路段），测
的的水温与仪表读数依然相差在 5 度以内，发动机不再报故障码，所以排除了水
温传感器的影响，发动机水温高。
Step 2: After replacing the water temperature sensor sending signals to ECU,
perform commissioning (road section is same as that for the previous
commissioning), and the difference between the measured water temperature
and the instrument reading is still within 5°; the engine doesn’t report the fault
code anymore (confirming that the cause is not the water temperature sensor)
and the engine water temperature is high.
第三步：检查外围件能引起水温高的地方：
检查带动水泵的皮带松紧度，风扇叶转速都
正常，用水枪冲洗水箱外表面，并拆开水箱
进水管出水管，用清水冲洗内部，并装上加
水试车，仍然水温高。
Step 3: Check the part of the peripheral
parts leading to high water temperature
and the tightness of the belt driving the
water pump, and find out that the fan and
blade have normal rotation speed. Wash
the external surface of the water tank with
the water nozzle; remove the inlet and
outlet pipes of the water tank; clean the
water tank inside, and fill water for
commissioning; however, the water
temperature is still high.
水温传感器插头
Water temperature
sensor plug
第 108 页
发动机
Engine
第四步：
Step 4:
怀疑是节温器未开启，发动机冷却水没有进入大循
环，更换节温器，再试车，发动机依然水温高。
It is suspected that the thermostat is not activated
and the engine cooling water doesn’t flow into big
circulation. After replacing the thermostat, perform
commissioning, and the engine water temperature
is still high.
第五步：观察发动机汽缸盖与机体之间结合处，并没有发现有漏水漏气等外观现象。根据目前单一的
故障现象，可以排除气缸垫损坏的可能，把问题锁定在水箱上。拆下水箱仔细检查，发现水箱外表面
通过清洗确实已经清洗得相对干净，但是在散热栅格里，却有很多油泥堵住散热栅格，仔细观察油泥
多的位置刚好朝向转向油罐的位置，原来水箱进水管处有渗漏现象，换新水箱，再与用户试车，在任
何工况下，水温最高都不会高于 95 度。
Step 5: Observe the junction between the engine cylinder cover and the engine body, and find out
that there is no water and air leakage. According to the current single fault phenomenon, confirm that
the cylinder gasket is undamaged, and confirm that the fault cause is the water tank. Remove the
water tank for careful check, and find out that its external surface has been cleaned; however, there
are lots of sludge in the radiation grille and lead to blockage. After careful observation, find out that
the part with much sludge is towards the steering oil tank. And, find out that the inlet pipe of the water
tank has leakage; replace a new water tank and perform commissioning with the user, and the
highest water temperature is not higher than 95° under all working conditions.
水箱外表面散热栅格
External surface radiation

grille of the water tank
第 109 页
发动机
Engine
3 、 QY20T 发动机无法启动
3. QY20T engine can't be started
问题描述：车辆的驾驶员反应其吊车突然无法启动，启动时起动机有反应，但是
飞轮不动，并且起动机有打齿的声音。
Fault descriptions: The crane driver reflects that the crane can’t be started
suddenly; during start, the engine has response but the flywheel can’t be
started; in addition, the engine also has gear grinding sound.
处理过程：
第一步 :
Step 1:
1 、到现场试车发现上下车启动时故障相同，启动时起动机有反应但是飞轮不动，
并且有打齿的声音。用万用表测量起动机的线路正常，所以判断是起动机故障。
1. After reaching the site and performing commissioning, find out that the fault is
the same in case of superstructure and chassis starting. During start, the engine
has response but the flywheel can’t be started; in addition, the engine also has
gear grinding sound. After measurement, find out that the engine line is normal
with the universal meter, thus judging the cause is the engine fault.
2 、将起动机拆下后，并没发现起动机的齿轮有打齿的现象，更换新的起动机后故
障仍然一样，起动机没有问题。
2. After removing the engine, find out that it has no gear grinding; after replacing
it with a new engine, the fault still exists, but the engine is normal.
第 110 页
发动机
Engine
3 、 QY20T 发动机无法启动
3. QY20T engine can't be started
第二步 : 再检查发现启动时仪表板上电压表显示
的电压急剧下降且很不稳定，再量电瓶的电压很
稳定，从而判断是电路上出现问题。启动时出现
虚压，所以从电瓶处开始检查线路，当检查到大
梁搭铁线时发现固定螺丝有松动的现象。
Step 2: After check, find out that the voltage
displayed on the voltmeter sharply reduces and
becomes unstable during start; after measuring
the battery voltage, find out that it is normal,
thus judging the circuit has fault. During start,
virtual voltage occurs; therefore check the line
from the battery. When checking the main beam
grounding wire, find out that the fixing screw is
loose.
第三步 : 紧固搭铁线后，重新启动，启动成
功，车辆工作正常，问题解决。
Step 3: After fastening the grounding wire,
restart it, and the crane is normally operated
and the troubleshooting can be done.
第 111 页
发动机
Engine
4 、 QY50T 上车发动机油门不正常
4. QY50T superstructure engine throttle is abnormal
问题描述：客户反映在早晨出车准备干活时，挂上取力器以后油门特别大无法做
慢动作，耗油大无法施工。
Fault descriptions: The customer reflects that before working after starting
in the morning, the throttle has large opening and is unavailable for slow
action after PTO engagement; in addition, the oil consumption is large and
construction can’t be carried out.
处理过程：
第一步 :
Step 1:
1 、到了现场检查发现挂上取力器以后发动机怠速立刻提到 1800 转，而且保持这
个怠速不动，摘掉取力器以后下车油门正常。
1. After reaching the site and engaging PTO, find out that the engine idle speed
immediately rises to 1800rpm and keeps in the idle state. After removing PTO,
the chassis throttle becomes normal.
2 、此现象一般可能有三个故障：上车操纵室内电路问题；中心导电环以下及支腿
油门电路问题； ECU 信号问题导致。
2. Generally, there are three faults generally: The superstructure control chamber
circuit has fault; the part below the central conducting ring and the outrigger
throttle circuit has fault; ECU signal has fault.
3 、首先进行排除看看是否是上车油门踏板的问题，拔掉油门踏板连接插件，此现
象依然存在。
3. Firstly do troubleshooting to see if the fault cause is the superstructure throttle
pedal. After removing the throttle pedal connection inserter, the phenomenon still
exists.
油门插头
Throttle plug
第 112 页
发动机
Engine
第二步 :
Step 2:
1 、拔掉中心导电环上端和上车操纵室连接的油门线插件以后试车故障依然存在，排除上车
操纵室内的电路故障导致的油门过高现象。
1. After removing the throttle line inserter between the upper end of the central
conducting ring and the superstructure control chamber and performing commissioning,
the fault still exists, and confirm the fault cause is not the circuit fault of the
superstructure control chamber.
2 、再拔掉中心导电环下端连接整车电路的油门线插件，试车故障依然存在，排除中心导电
环故障。检查下车支腿油门的开关，拆下支腿油门开关线断开支腿油门线，试车故障依然
存在，排除由于支腿油门电路导致的发动机怠速过高问题。
2. After that, remove the throttle line inserter between the lower end of the central
conducting ring and the throttle line of the complete crane circuit and perform
commissioning, and the fault still exists, thus confirming that the central conducting ring
is normal. Check the chassis outrigger throttle switch; remove its switch wire; disconnect
the outrigger throttle line and perform commissioning, and the fault still exists, thus
confirming there is no too high idle speed of the engine due to the outrigger throttle
circuit.
第 113 页
发动机
Engine
第三步 :
Step 3:
1 、最后检查是否为 ECU 信号问题。拔掉 ECU 模块上连接的发动机油门线插件，试车发
现故障依然存在，分析可能是 ECU 信号问题，或者 ECU 接受到错误信号。
1. Finally check if the ECU signal is the fault cause. Remove the engine throttle line
inserter on the ECU module and perform commissioning, and find out the fault still exists,
thus analyzing the cause is the ECU signal fault or wrong signal received by ECU.
2 、检查 GPS 发现，此车 GPS 绿灯不亮，设备不在线状态，打电话到总部查此吊车的信
号状态为不在线导致锁车状态。
2. After checking GPS, find out that the GPS green lamp is off and the equipment is off-
line. After calling the headquarters, find out that the crane is locked owing to that the
crane signal is off-line.
3 、由于此车已过保 GPS 卡没有及时更换，换上新的 5 元卡后试车问题解决。
3. As the crane warranty has expired and the GPS card is not timely replaced, after
replacing it with a new 5-yuan card and performing commissioning, the troubleshooting
can be done.
第 114 页
发动机
Engine
5 、 QY16T 发动机无油门
5. QY16T engine throttle is spongy
问题描述：用户反映下车无油门，发动机故障灯常亮。
Fault descriptions: The user reflects that the chassis throttle is spongy and
the engine fault lamp is normally on.
处理过程：
第一步 :
Step 1:
根据用户描述的故障：
According to the fault described by the user:
1 、现场检查下车无油门，发动机故障灯常亮，上车油门能加到 1500 转；
1. After site check, find out that the chassis throttle is spongy; the engine fault
lamp is normally on, and the superstructure throttle rises to 1500rpm;
2 、检查下车电子油门踏板线路，用万用表测 510 号线和 512 号有 5V 电， 520 号
线和 522 号线有 3.7V 电，没达到 5V 电，无法满足电子油门需求电量；
2. Check the electronic throttle pedal line of the chassis; measure the 510# and
512# lines with the universal meter and find out they have 5V power supply;
however, the 520# and 522# lines have 3.7V power supply, which can’t meet the
power demand of the electronic throttle;
第 115 页
发动机
Engine
5 、 QY16T 发动机无油门
5. QY16T engine throttle is spongy
第二步 :
Step 2:
1 、检查 ECU 漏出来的电子油门踏板线路，发
现线路插头松动并有些水珠，清理线路插头；
1. After checking the electronic throttle pedal
line from ECU, find out that the line plug is loose
and there is some water drop. Clean the line
plug;
2 、检查 510 和 512 号线路有 5V 电， 520 和
522 号线路有 5V 电，正常。但下车还是无油门，
更换新的电子油门踏板以后也无改善。 2. Check
and find out that the 510#, 512#, 520# and 522#
lines have 5V power supply, and all of them are
normal. However, the chassis throttle is spongy,
which is not improved after replacing it with a
new electronic throttle pedal.
第三步 :
Step 3:
1 、因发动机故障灯常亮，上车电子油门踏板能
加到 1500 转，把上车油门踏板线路插头拔掉；
1. As the engine fault lamp is normally on, the
electronic throttle pedal of the superstructure
can be increased to 1500rpm, and then
remove the superstructure throttle pedal line
plug;
2 、试车，下车电子油门踏板能加到 2500 转，
正常，判断为上车电子油门踏板损坏，更换上
车电子油门踏板后试车正常。
2. After performing commissioning, the
electronic throttle pedal of the chassis can be
increased to 2500rpm, which is normal, thus
judging that the electronic throttle pedal of the
superstructure is damaged. After replacing the
electronic throttle pedal of the superstructure
and performing commissioning, it becomes
normal.
第 116 页
发动机
Engine
6 、 QY50T 发动机加不上油
6. QY50T engine can't be throttled up
问题描述：车子有时候出现加不上油，转速只能达到怠速左右。
Fault descriptions: The crane can’t be throttled up sometimes, and the
rotation speed can only be kept at the idle speed.
处理过程：
第一步 :
Step 1:
根据故障现象：
According to the fault phenomenon:
1 、车子有时候加不上油只能加到怠速左右，询问用户，用户反映在上车干活时有
同样的问题，可以把问题确定在发动机上或者相关电气电路上，暂时不用考虑下
车油门踏板引起的相关问题。
1. The crane can’t be throttled up sometimes, and the rotation speed can only be
kept at the idle speed. Ask the customer, and he/she reflects that superstructure
has the same fault during operating, thus ensuring the fault cause is the engine
or relevant electrical circuit. Ignore relevant faults due to the chassis throttle
pedal temporarily.
2 、进行试车，发现有时候故障灯出现点亮或者长亮的情况下加不上油门，有时候
故障灯没有亮也加不上。
2. Perform commissioning, find out that the crane can’t be throttled up when the
fault lamp is on, normally on or off sometimes.
发动机诊断仪
Engine diagnostic
tester
第 117 页
发动机
Engine
第二步 :
Step 2:
根据试车看到的故障现象，估计出现了电控方面的故障，读取故障代码显示为（ 229 上车
油门踏板错误， 242 冷却水温过高报警， 225 油门与制动可信检测错误）。用诊断仪消除
历史故障码，都能消除，从新试车，再次出现 242 冷却水温过高报警，怀疑是水温传感器
失效引起，
According to the fault phenomenon during commissioning, estimate that the electrical
control has fault, and the displayed fault reading codes are: wrong 229 superstructure
throttle pedal, too high 242 cooling water temperature alarm and wrong 225 throttle and
brake confidence test. When clearing the historic fault codes with the diagnostic tester,
and all of them can be cleared. Perform commissioning again and the too high 242
cooling water temperature alarm reoccurs, and it is suspected that the cause is the water
temperature sensor failure.
第三步 : 为了方便确定问题所在，临时拔掉水温传
感器，（拔掉后， ECU 会接受一个默认的正常水
温值）试车，发现仍然出现加不起油门的现象，不
过没有之前频繁，但是故障指示灯不再出现常亮或
者点亮，用诊断仪诊断发现没有报之前的水温方面
的故障，怀疑还有另外一个地方引起在行驶时偶尔
加不上油的状况。并且更换水温传感器。
Step 3: To confirm the fault cause conveniently,
temporarily remove the water temperature sensor,
(after removal, ECU will receive a default normal
water temperature value) and perform
commissioning, and find out that the engine can’t
be throttled up, but it is not as frequently as
before. However, the fault indicator lamp is not
normally on or on. When testing with the
diagnostic tester, no water temperature fault is
reported. It is suspected that another part makes
the engine can’t be throttled up occasionally
during traveling. And, replace the water
temperature sensor as well.
第 118 页
发动机
Engine
第四步：根据之前读取的历史故障码（ 225 油门与制动可信检测错误）以及司机反映有时候不踩刹车
也会出现刹车灯亮，推断，另外一个故障点的起因是因为错误输入给 ECU 刹车信号，造成发动机在
接受信号后将转速回归到怠速状态，加不起有门。
Step 4: According to the historic fault code (225 throttle and brake confidence testing error) and the
phenomenon that the brake lamp is on even thought not stepping down the brake reflected by the
driver, judge that another fault point is caused as the brake signal is inputted to ECU wrongly, thus
the engine returns the rotation speed to idle speed after receiving signals and the engine can’t be
throttled up.
第五步：排查造成制动信号错误输入给 ECU 的原因，查找

线路，发现脚刹制动开关的一个接线柱松动，引起脚刹开关
内部偶尔对地短路，接触不良，造成电源线 078# 对地短
路，直接控制 K19 继电器，输入给 ECU 错误的脚刹开关信
号，造成发动机回归到怠速，表现为加不起油门。重新接牢
接线柱，试车，故障排除。
Step 5: After investigation, find the cause is that the brake
signal is inputted to ECU wrongly. After checking the
circuit, find out that one terminal of the brake switch of the
foot brake is loose, which brings short circuit to ground and
poor contact occasionally. In addition, the power line 078#
is short circuited to ground, the K19 relay is directly
controlled, the foot brake switch signals is inputted to ECU
wrongly, thus making the engine return to idle speed and
can’t be throttled up. Firmly connect the terminal again and
perform commissioning, and the troubleshooting can be
done.
脚刹开关
Foot brake
switch
第 119 页
发动机
Engine
7 、 QY25T 发动机异响
7. QY25T engine has abnormal sound
问题描述：发动机在怠速时异响严重，发出“嗒嗒”的异响，转速到 1800 左右异

响声就不那么明显，发动机提速加油、烟度、功率都正常。没有其他异常现象，
发动机不报任何故障码。
Fault descriptions: The engine has serious abnormal sound and sends out
“click” sound at idle speed; however, such sound becomes smaller when
the rotation speed reaches about 1800; the engine can be normally
throttled up, and it also has normal smoke limit and power. In addition,
there is no other abnormal phenomenon, and the engine doesn’t report any
fault code.
处理过程：
第一步 : 根据用户描述的故障现象，试车，发现怠速的时候“噌噌”的异响声比较
大，打开发动机罩仔细听，首先确定异响声是从上部发出，但无法确定具体是那
一个地方，首先通过目测，听觉检查外围件，皮带涨紧轮、打气泵、空调压缩机
有没有异常，检查一切正常。
Step 1: According to the fault phenomenon described by the user, perform
commissioning and find out that the “jingle” abnormal sound is louder at idle
speed. After carefully hear by opening the engine hood, firstly confirm that the
abnormal sound comes from the upper part, but the specific position can’t be
determined. Firstly perform visual inspection and hearing to check peripheral
parts, belt tensioner pulley, inflating pump and A/C compressor for abnormality,
and find out that all of them are normal.
第 120 页
发动机
Engine
第二步 : 由于声音不是从中部发出，并且发动机提速，功率、烟度都是正常，可以排除
曲轴连杆瓦、活塞环、活塞、活塞销的异响，（一般活塞敲缸在怠速时明显为“当
当”的声音，活塞环敲击一般是比较钝哑的“啪啪”声）所以都可以排除，从顶部用空
心铁管听上部各缸响声，二四五缸声响比较大，像气门间隙调整不当引起。
Step 2: As the sound doesn’t come from the middle part; the engine can be normally
throttled up, and it also has normal smoke limit and power, confirm that the crankshaft
connecting rod bearing shell, piston ring, piston and piston pin have no abnormal
sound (generally, at idle speed, the cylinder knocking has obvious “clanking” sound
and the piston ring knocking has “rumble” sound). When hearing the sound of all upper
cylinders with the hollow steel tube from the top, find out that the second, fourth and
fifth cylinders have louder sound, which may be caused by improper valve clearance
adjustment.
第三步 :
Step 3:
按 1 ， 5 ， 3 ， 6 ， 2 ， 4 缸的爆发顺序调整气门间隙及 WEVB 间隙，试车，异响声仍然
存在。因为主要在缸盖一块发出来，可以排除以下几点原因：气门烧蚀不太可能，单缸气
门烧蚀该缸气压下降会影响功率；气门座圈脱落会发出较大“嚓嚓”破碎声；气门积碳胶
结，一般在温度高到一定程度会发出“嗲嗲”的异响；但是活塞顶进排气也不能完全排
除，考虑到是新车，不能再在其他问题没排除就抬缸盖检查势必会造成恶劣影响，所以要
先排除单缸喷油器是否存在工作异常引起工作粗暴产生异响。 Based on the explosion
sequence of the first, fifth, third, sixth, second and fourth cylinders, adjust the valve
clearance and WEVB clearance and perform commissioning, but the abnormal sound
still exists. As the sound mainly comes from the cylinder cover, following causes can be
eliminated: The valve ablation is improbable; the cylinder air pressure decreases due to
single-cylinder valve ablation and affects the power; the valve seat retainer peels off and
sends out louder “crack” crushing sound; the valve has carbon accumulation and
cementation, and it sends out “soft” abnormal sound when the temperature reaches a
certain extent. However, the piston top air intake and exhaust may also be the cause;
considering it is a new crane, if lifting the cylinder cover for check if other causes are not
eliminated, adverse impact will be caused inevitably. On this account, firstly try to ensure
that if the single-cylinder fuel injector works abnormally and leads to rude operation and
abnormal sound.
第 121 页
发动机
Engine
第四步：用空心管听各缸声音，发现 2 缸的声音爆发相对
粗暴，断开 2 缸喷油器线束试车，发现异响减弱，并
且“塔塔”异响声没那么连续均匀，更换 2 缸喷油器试车
异响相对减弱，没那么连续，但仍然有异响。
Step 4: Listen to the sound of all cylinders with the
hollow pipe, and find out that the sound of the second
cylinder is very rude. After disconnecting the second
cylinder fuel injector harness and performing
commissioning, find out that the abnormal sound
becomes small and the “tata” abnormal sound is not so
continuous and uniform. After replacing the second
cylinder fuel injector and performing commissioning, find
out that the abnormal sound becomes small and not so
continuous; however, the abnormal sound still exists.
第五步：再次通过用空心管听声音，无法明显听出各缸工作声响，通过各缸断线束的方法也无法听出
异响来自其他哪一缸，于是更换其他五缸喷油器，试车，故障依旧，但是异响声跟只换 2 缸喷油器一
样，于是重新拆掉 6 个缸的喷油器，换回原来喷油器，再重新找故障点，通过听觉各个缸摇臂罩发现
3 ， 4 ， 5 缸摇臂罩震动较大，估计是 WEVB 质量问题或者是六个缸在发动机运行时 WEVB 出现不
一致或者是装配不当引起。
Step 5: Listen to the sound with the hollow pipe again, and no abnormal sound can be heard. As
unable to judge which cylinder sends out the abnormal sound by disconnecting the harness of all
cylinders, replace the fuel injectors of other five cylinders and perform commissioning; however, the
fault still exists and the abnormal sound is same as the result after replacing the second cylinder fuel
injector only. On this account, remove the fuel injectors of six cylinders and install the original one to
find out the fault point again. By hearing, find out that the rocker arm covers of the third, fourth and
fifth cylinders have larger vibration, thus estimating that WEVB has quality problem; WEVB of six
cylinders is inconsistent in case of engine running, or improper assembling.
喷油器
Fuel
injector
第 122 页
发动机
Engine
第六步：全部松掉 WEVB 间隙调整螺钉到极限位置，使得 WEVB 内部小活塞不受
弹簧压力，再试车，异响声基本消除，不过发动机怠速比较难听，有些粗暴，怀
疑 2 缸喷油器有问题。
Step 6: Completely loosen the WEVB clearance adjustment screw to the limit
position to make the interior small pistons of WEVB are not pressurized by the
spring anymore. After that, perform commissioning, the abnormal sound is
eliminated almost. However, the engine idle speed sound is unpleasant and it
also runs rudely, and it is suspected that the second cylinder fuel injector has
fault.
第七步：更换 2 缸喷油器，试车，问题解决不
再有异响声。
Step 7: After replacing the second cylinder
fuel injector and performing commissioning,
the troubleshooting can be done and the
abnormal sound disappears.
第 123 页

Preface: Study Manual (First and Second Half Edition) For The Heavy Duty Crane

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前言

2013 年我们将继续推出《服务案例学习手册》中小吨位下半年版， 《服务案

此外，请各位服务代表经常登入 DMS 系统学习服务案例 ( 电子档 ) 。注意每月

1 、 25T 下车无法启动 103

The balance valve inside may be stuck by

Check apakah Balance valve terdapat kotoran

Bersihkan balance valve dengan solar,jika

2 、 QY25T 变幅下沉 -II

2 、 QY25T 变幅下沉 -II

2 、 QY25T 变幅下沉 -II

第三步：检查下部操纵阀，拆下 15MPa 溢流阀，发现阀芯发卡且内部弹簧弹力不

故障描述：吊臂长度在伸或缩到 15 米 -21 米左右，长度数据猛增或猛减。

2 、 QY25T 电脑长度，角度，幅度显示都是 XXXX

2 、 QY25T 电脑长度，角度，幅度显示都是 XXXX

2 、 QY25T 电脑长度，角度，幅度显示都是 XXXX

2 、 QY25T 上车暖风不工作 -II

2 、 QY25T 上车暖风不工作 -II

第一步 : 把变幅抬到 80° ，拼压，检查压力正

第一步 : 到了现场以后，观察做主臂下降动作时压力只有 4Bar ：

第二步 : 将故障往后推到过放电磁阀 ，用电压表量取过放电磁阀电压，发现无电压，用尖角物体将电

第二步 : 挂上取力器后上车没电，电脑不显示。上车没电故障点一般为： 19# 上车电源保

第三步 : 用万用表测量得 K3 继电器的插座 86# 脚有

9 、 QY50T 上车无动作 -II

9 、 QY50T 上车无动作 -II

9 、 QY50T 上车无动作 -II

第三步 : 排完空气后试车正常，用了 5 天后 , 又出现转向沉重的现象 .

问题描述：用户反映机器在气压达到 7bar 仍然低气压报警。

第三步 : 经测量 305 号线没有 24V 电压，检查

问题描述：在行驶时尤其是开空调，发动机水温很容易到 105 度以上，故障灯常

External surface radiation

第五步：排查造成制动信号错误输入给 ECU 的原因，查找

问题描述：发动机在怠速时异响严重，发出“嗒嗒”的异响，转速到 1800 左右异

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2013 年我们将继续推出《服务案例学习手册》中小吨位下半年版，《服务案

第二步 : 将故障往后推到过放电磁阀，用电压表量取过放电磁阀电压，发现无电压，用尖角物体将电